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BACKGROUND OF THE INVENTION
The present invention relates to a device and a method for monitoring a thread wound on a bobbin during operation in a sewing machine.
It is known from various investigations that a bobbin on a sewing machine runs in a very uncontrolled manner during the sewing process. For example, a marking-off of the rotary movement takes place after the beginning of each sewing process, the time of the marking-off and the strength of the incipient rotary movement and the acceleration of the bobbin depending, among other things, on the degree of filling of the bobbin, on the material of the thread and the wear of the mechanical elements in the area of the bobbin, to mention just a few of the possible influential factors. The movement of the bobbin thus cannot substantially be predicted and as a consequence, cannot be described mathematically even when considered from the start of the sewing process.
These general statements apply both to the upper thread and to the lower thread of a sewing machine. However, since any type of monitoring and control in the area of the lower thread poses a major technical challenge because of the very confined spatial proportion, without restricting the invention to this particular case, only monitoring of the lower thread during operation of a sewing machine will be discussed hereinafter.
Various proposed solutions for monitoring a lower thread of a sewing machine for thread breaks or broken threads are known from the prior art. Starting from devices for residual thread monitoring in a lower bobbin, an optical device is known from DE 30 14 753 C2, for example, comprising a light-emitting diode and a photodetector which passes light through holes directed parallel to the axis of rotation of the lower bobbin when the lower thread on the lower bobbin is largely used up. Monitoring of the filling level of the bobbin is therefore performed using the dark/light transition.
In a further development according to DE 34 47 138 C2, a reflecting surface on the bobbin is used to arrange a transmitter and detector substantially as a compact unit only on one side of the lower bobbin on the sewing machine. Incident radiation is strongly absorbed by the thread through holes whilst webs between the holes and a metal rear wall of the bobbin reflect strongly. In this case, a constant continuous signal from the receiver unit is assessed as an indicator that the bobbin is at a standstill which can also occur as a consequence of a thread break.
In order to increase the reliability in this environment exposed to dust and thread abrasion, DE 41 15 520, for example, proposes a special guidance of the lower thread in the course of unwinding the lower bobbin. By this means falsifying impairments of the reflection caused by contaminant accumulations on the reflecting surfaces should be continuously cleaned by quasi-permanent wiping of these surfaces by the running-off thread.
For further monitoring tasks in the area of the lower bobbin, reference is made to the teaching of DE 35 40 126 A1 as an example. In this teaching, in order to achieve more extensive monitoring tasks, three optical sensor cells must cooperate in interplay with two different annular markings or marking units to be applied to a front side of the bobbin.
It is thus the object of the present invention to further develop a method and a device of the type specified initially whilst reducing the expenditure on apparatus and production technology with increased monitoring reliability.
This object is achieved by the features of the independent claims. Advantageous further developments are the subject matter of the dependent claims.
BRIEF SUMMARY OF THE INVENTION
The present invention is based on the finding that the proposed solutions according to the prior art are always based on a binary decision between two marking states. Thus, either more than 70% of the incident radiation is reflected by a white or silver or mirrored surface or more than 90% of the radiation is absorbed by threads or a blackened surface. In practice, this principle is comparatively prone to error despite the widely spaced threshold values of the logical decisions to be made. In addition, it has been found that a device according to this principle can only be extended at very high expenditure.
In contrast, in order to reduce the complexity of a monitoring device and substantially simplify a corresponding method, the invention proposes a device for monitoring a thread wound on a bobbin during operation in a sewing machine, wherein at least two different marking states are provided in the area of the bobbin and are coupled to an optical device in such a manner that movement of the bobbin produces a change in marking, which change can be detected in the optical device which can be evaluated in a logic unit connected to the optical device, the marking comprising more than two states in the area of the bobbin and at least one state being defined by at least one colour or a mixture of primary colours.
When considered from the physical viewpoint, the markings used according to the prior art in white/silver or mirrored on the one hand and black or very dark on the other hand, are not colours. By constructing a marking which additionally also has a colour or a colour panel compared to the marking known from the prior art, the hitherto only binary recognition space has been expanded to a state space comprising three states which can be clearly distinguished from one another. In particular, beside stoppage it is hereby possible using one optical device only to reliably and correctly detect a respective direction of rotation of the bobbin.
In addition, in the event of a thread break or broken thread in the area of the lower bobbin, it is now possible to detect the very common defect that the lower bobbin does not come to a standstill after the thread break but decays into a type of jitter or oscillating motion during the sewing process. This type of oscillating motion can be incorrectly interpreted as rotary motion by known detector devices. However, since oscillating motion usually only represents a change between two neighbouring marking states, a device according to the invention lacks a third state value so that this case of error is reliably detected by the method according to the invention in the course of a deviation from the defined pre-determined change in colour or marking state.
Since a device according to the invention and a corresponding method can be used both for a lower thread and for an upper thread, all possible versions of mock sewing can be reliably eliminated within the scope of the present invention. In this context, the person skilled in the art understands by mock sewing the result of sewing in which the seam only comprises one thread and is not secure on account of the complete absence of the second thread. The case is usually encountered in practice where the sewing by the upper thread becomes mock sewing as a result of the absence of the securing lower thread. Such defective seams can only be detected in the course of quality control. However, testing carried out subsequently can effect nothing other than finding in this additional work step the errors of the preceding work phases or work steps. A device according to the invention can effectively avoid errors already in the working phase in the sense of the Poka yoke approach.
Furthermore, an output signal of a corresponding device determined by a method according to the invention can be used for switching off and fault indication. In addition, the passes through the defined pattern change can be used for a very reliable counter for revolutions of the relevant bobbin for an estimate of the residual thread length frequently provided in sewing machines.
Finally, the two directions of rotation can be clearly distinguished from one another as a result of the sequence of the marking states. Thus, as a result of the possibility of distinguishing in the direction of rotation, it can be ensured that a bobbin has always been correctly inserted, what means having the correct winding direction. The winding direction is very important when unwinding thread or yarn from a bobbin. The seam construction diagram and tendency to tearing of the lower thread, which is usually relatively thin, differ substantially as a result of the different unwinding resistance depending on the winding direction. Winding directions which are the same in practice are therefore predefined differently when supplying thread to an automatic sewing machine. Consequently, a lower bobbin inserted in the inverted direction would be identified as a source of production error by a device according to the invention in the sense of the Poka yoke approach before this resulted in defects in the following sewing process. As a continuation of this idea, a change of a lower bobbin is preferably monitored and optionally also logged by at least one sensor. In particular, the circumstance that at least one light/dark transition can be detected in the course of a bobbin change at an axial sensor or a sensor which senses perpendicular to the axis of rotation, when the machine is at a standstill is used for this purpose. Alternatively or additionally, in one exemplary embodiment of the invention, the colour sensor is tested for reliability by withdrawing thread when the machine is at a standstill until all defined states have been passed through at least once and have been notified as recognised. After this test, the machine is released and a sewing process can be carried out in the usual manner.
In a preferred embodiment of the invention, a marking consists of one panel each in white or silver, black and a true colour or mixture of the primary colours. In this case, the colours yellow, red, blue and/or green are preferably used. In this embodiment, the binary state 1 is represented by the white or silver-coloured highly reflecting panel and the state 0 is represented by the black panel, as it is already the case according to the prior art. A third state is introduced by the specific recognition of an additionally introduced colour which now defines a sequence of different signal or marking states. A corresponding device for implementing a method according to the invention can be achieved by expanding known lower thread monitoring systems by a colour sensor which can be provided with its own light source and corresponding incorporation of an allocated colour state in a known marking. A design comprising one light source and two sensors would therefore be technically possible as an example and shows the low expenditure with increased performance of the device according to the invention. However, it is particularly preferable to use a marking having only coloured or differently coloured states since the previously described triggers of binary switching states can also occur in the course of error states caused in particular by contamination or detector defects.
The thread monitored in a device according to the invention is preferably a lower thread and the corresponding bobbin is a lower bobbin. In this context, the marking is preferably provided on at least one of the two outer front sides of the bobbin. In a particularly preferred embodiment of the invention, the marking is provided identically on both outer front sides of the bobbin with the same colour sequence of markings. This has the effect that the bobbin can be used universally. The correct insertion of the bobbin is then only dependent on the pre-determined winding direction.
The markings are preferably provided in the form of colour segments or annular sections radially to an axis of rotation of the bobbin. In this case, an arrangement, for example, in electro discharge machinings on the body of the bobbin is preferred among other things to protect the marking from mechanical influences. Webs between the individual machinings can then form boundaries of the colour surfaces, which simplifies production whilst providing a sharp separation between states.
In a preferred embodiment of the invention, an active multi-colour radiation source and a detector matched to this are provided as the optical device, which cooperate with corresponding markings and in particular, with markings in the colours red, green and blue. Reliably operating, very compact assemblies are available on the market for this purpose, including those designated as rgb sensors. These can be individually calibrated once to the respective colour states for initialisation.
In a particularly preferred embodiment of the invention, a nozzle for producing a contamination-repelling excess pressure area is disposed on the optical device. For this purpose, purified compressed air metered and triggered by a solenoid valve is blown into the optical region between the marking of a bobbin on the one hand and the optical device on the other hand, which is usually sensitive to contamination. Thus, as a result of the prevailing excess pressure, no dust, thread abrasion or oil mist can accumulate here.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
An exemplary embodiment of the invention will now be explained in detail hereinafter to illustrate further advantages and properties with reference to the diagrams in the drawings. In the drawings:
FIG. 1 : is a perspective exploded view of a device according to the invention;
FIG. 2 : is a sectional view of a lower bobbin configured according to the invention;
FIG. 3 : is a plan view of a front outer surface of the bobbin from FIG. 2 ;
FIG. 4 : is a time profile diagram of four signals with the needle sensor signal as a trigger for the individual signals of an rgb colour sensor and
FIGS. 5 a and 5 b : are time diagrams to show a length of a sensing phase as well as an inactive time before processing of loose exceed thread after a cutting process before response of a sensor depending on the respective colour scale division.
DETAILED DESCRIPTION OF THE INVENTION
The same designations and reference numerals are used as standard over the various diagrams for the same parts.
FIG. 1 shows an exploded view of a section of a known sewing machine 1 in which a bobbin 3 is held in a rotary gripper 4 under a sewing table 2 and is covered with a bobbin casing 5 . The bobbin casing 5 has a recess 6 through which radiation from an optical device 8 comprising an active multi-colour radiation source 9 passes along a radiation axis S onto a marking 10 on an outer front side 12 of the bobbin 3 comprising a plurality of marking states, is reflected there and is reflected to a detector device arranged in a manner not shown in further detail in the region of the active multicolour radiation source 9 . A so-called digital rgb sensor with integrated optics and triggering and evaluation electronics is used as the optical device 8 in a compact design. The operating mode is discussed in detail hereinafter with reference to the diagrams in FIGS. 2 and 3 , where these figures show that both outer front sides A, B are marked the same way.
In addition to the first optical device 8 described hereinbefore, a second optical device 14 which is binary or which operates using black-white contrast, is provided in a mounting position of the bobbin 3 . This second optical device 14 is aligned substantially onto an axis of rotation D of the bobbin 3 in the operating state. This forms a residual thread monitor since it can only distinguish in a known fashion between the states “thread present” and “reflecting bobbin base”. In addition to infrared radiation, other radiation in and outside the visible light can also be used.
FIG. 2 shows the bobbin 3 in a side sectional view from which it can be seen that the bobbin 3 has electro discharge machinings 15 in the area of one outer front side 12 in which the markings 10 are arranged in a protected manner by recessing by a value “a” before mechanical stressing by brake springs etc. which in particular are components of the bobbin casing 5 .
FIG. 3 shows a plan view of the outer front side 12 of the bobbin from FIG. 2 . It can be clearly seen from FIG. 3 that the markings 10 are arranged concentrically around the axis of rotation D of the bobbin 3 in the form of three annular segments 16 , with intermediate spaces z formed by webs, in the colours green g, red r and blue b. An average diameter d of the annular segments 16 is selected to correspond to the position of the recess 6 on the bobbin casing 5 . The optical device thus detects a pattern sequence in the colours green, red, blue in one direction of rotation of the bobbin but a colour sequence green, blue, red in the opposite direction of rotation. These colour sequences are clearly distinguishable from one another so that the two directions of rotation of the bobbin 3 can be clearly distinguished from one another in a logic unit connected to the optical device 8 and not shown in further detail.
Two outer front sides 12 of the bobbin 3 are coded in a manner not shown further in FIG. 2 so that such a bobbin 3 can be universally used. A distinction merely needs to be made with regard to the winding direction when inserting the bobbin 3 . However, since each of the possible directions of rotation of the bobbin 3 can be detected by means of a colour change in the manner described hereinbefore, a bobbin 3 which has been wrongly inserted with regard to its winding direction can be recognised immediately. In this case, a sewing process would be interrupted immediately, giving a suitably specific error message in the sense of the Poka yoke approach.
If the bobbin 3 comes to a standstill, only one of the colour signals g, r, b would be detected permanently. If the bobbin undergoes jitter, only a change between the markings b and r would be detected, for example. In both cases, a subsequent logic circuit would immediately detect a fault in the operation.
When a sewing machine 1 is started up again in a known fashion, a so-called follow-up quantity of thread on the lower bobbin 3 shown here must first be used up before the lower bobbin 3 can turn again. Thus, a turning of the bobbin 3 by incipient pattern changes is only detected by means of the optical device 6 with a time delay with respect to the beginning of sewing. In the present exemplary embodiment, this bobbin follow-up is taken into account by a stitch counter in this example waiting for seven stitches from restarting the sewing process before indicating a probable thread break of the lower thread when no turning of the bobbin 3 is detected. Thus, an error message with a forced switch-off of the sewing machine 1 is only brought about after making the seventh sewing stitch. From starting a new sewing process or changing a sewing movement, a measure of about 5 to about 19 stitches without detecting a turning of the bobbin 3 is to be awaited before outputting an error message.
This measure is set once by the person skilled in the art depending on the geometry or thickness and material stiffness of the sewing material and stitch length of a certain form of seam, as is specified hereinafter with reference to a specific example.
A nozzle 17 exposed to purified compressed air is provided to keep the optical device 8 clean, as is indicated in the diagram in FIG. 1 . The purified compressed air, being triggered by a solenoid valve with a relevant control circuit not shown in further detail, creates an excess pressure region between the optical device 8 and the marking 10 on the outer front side 12 of the bobbin. This largely eliminate accumulations of dust and thread abrasion but also deposition of oil or coolant and lubricant mist in this sensitive area for optical recognition. Consequently, such a device operates in a substantially more trouble-free manner compared to known devices.
Such a nozzle 17 can naturally also be used in the area of the second optical device 14 . However, this second optical device 14 using a binary decision based on a strong light/dark contrast is merely used for residual thread monitoring on the bobbin 3 , as is already known per se from the prior art.
In an exemplary embodiment of the invention not presented in further detail, as a modification of the diagram in FIG. 3 , a multiple of the previously described pattern sequence of the colour signals g, r, b is arranged on the outer front side 12 of the bobbin 3 . A lower bobbin 3 configured in such a manner is used in cases or applications where only a few seam stitches and then only with a short stitch length in each case need to be passed through per sewing process. The sensitivity is significantly enhanced by the arrangement of two successive colour sequences g, r, b. The start-up of the lower bobbin 3 is detected even earlier by arranging three successive colour signal sequences g, r, b at a time. As a result of the geometry being fixedly predefined within wide ranges, the interaction with mechanical components under severe ambient conditions and the normal vibrations of a sewing machine 1 , more extensive refinements are only appropriate in exceptional cases. In practical use, bobbins 3 with one, two or three successive colour signal sequences g, r, b are preferably used.
FIG. 4 shows a time diagram of a profile of four signals from a system test under real conditions as a printed screen shot. This comprises the individual output signals S 2 , S 3 , S 4 of an rgb colour sensor, i.e. detected colour change, with a needle sensor signal S 1 as the trigger. These measurement curves clearly show the discontinuous running of the bobbin 3 which is caused, among other things, by the nonuniform profile of the needle sensor signal S 1 or the associated change in a stitch frequency. On closer examination of the starting sequence, it is noticeable that at the very beginning, a number of stitches is executed without a colour change being detected. During this time interval, hereinafter designated as inactive time T i , a follow-up quantity of thread present in each case is consumed, this having already been withdrawn from the thread roll in the course of a preceding cutting process. This follow-up quantity of thread and an associated inactive time T i depends on the design of a sewing head used in each case, a thread thickness and a thread length consumed per stitch and not only on a respective stitch length.
At the end of the sewing process, a disproportionate thread consumption occurs in the oval region bordered by the dotted line in FIG. 4 , which can be attributed to the thread cutting. The follow-up quantity of thread is formed. In this case, the bobbin 3 continues to turn whilst the sewing signal is stationary. It should be noted in this context that the inactive time T i which occurs in principle or the excess thread length can be additionally shortened appreciably by using a hot cutter compared with an equivalent arrangement using a conventional thread cutter. A total response time of the monitoring system is give by adding the inactive time T i and the time for one complete colour change. Thus, at the start of a sewing process using a 2*3 coded bobbin 3 and 1 mm thread consumption per stitch, inactive periods of 12*2*2=26 stitches have been sensed whereas with 5 mm thread consumption, only 2*2+2=6 stitches have been sensed before sensing a first complete code change r,g,b. In a basic safety setting in the present process, at 5 mm tread consumption a tolerance range of about 10 stitches and an additional inactive time T i of about 10-15 stitches before detecting a first complete colour change is therefore provided before a thread break etc. is detected. Depending on the application, this value can be reduced to about 5 stitches or increased to more than 15 stitches, as already specified.
The time sequence of the colour sensor signals S 2 , S 3 , S 4 at the corresponding outputs of the rgb colour sensor also has various time widths during correct sensing but a uniform direction of rotation is always detected from the sequence of the respective signals S 2 , S 3 , S 4 .
FIGS. 5 a and 5 b each show time diagrams as a function of a respective colour scale division on a lower bobbin 3 . FIG. 5 a shows a length of each colour in process, FIG. 5 b shows a length of an inactive time T i before processing a loose excess thread after a cutting process before a sensor responds. It can be seen from FIG. 5 b that the response time of a colour sensor with 2*3=6 markings, i.e., using two sequences of rgb codings over a circumferential rotation of the bobbin, is about 1.1 s at 2000 revolutions per minute and 1 mm thread consumption. When the thread consumption is 5 mm, the inactive time T i of the monitoring system is less than 0.5 s. Whereas each of the codings shown operates reliably at higher thread consumption, for lower thread consumption per stitch a coding with 2*3=6 markings should be recommended for a sufficiently short response time and 3*3=9 markings for receiving a very short response time.
In the course of a change of application with altered requirements, this can be flexibly taken into account simply by changing the lower bobbin 3 . In one embodiment of the invention, default values for the monitoring system described hereinbefore are read in centrally via an electronic evaluation and control unit without being further represented by drawings, and a bobbin coding and direction of rotation are also monitored centrally.
LIST OF REFERENCE NUMERALS
1 sewing machine
2 sewing table
3 bobbin
4 rotary gripper
5 bobbin casing
6 recess
7
8 optical device
9 active multi-colour radiation source
10 marking
11
12 outer front side
13
14 second optical device
15 electro discharge machining
16 annular segment
17 nozzle
g Colour green
r Colour red
b Colour blue
D axis of rotation
S radiation axis S
a value of recessing received via electro discharge machining
z intermediate space formed by a web
d average diameter of the annular segments 16
S 1 needle sensor signal
S 2 individual output signal of an rgb colour sensor
S 3 individual output signal of an rgb colour sensor
S 4 individual output signal of an rgb colour sensor
T i inactive time
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The present invention relates to a device and a method for monitoring a thread wound on a bobbin during operation in a sewing machine that reduces the expenditure on apparatus and production technology with increased monitoring reliability wherein at least three different marking states are provided in the area of the bobbin ( 3 ) and are coupled to an optical device ( 8 ) in such a manner that movement of the bobbin ( 3 ) produces a change in marking which can be detected in the optical device ( 8 ) which can be evaluated in a logic unit connected to the optical device ( 8 ), that the marking ( 10 ) in the area of the bobbin ( 3 ) comprises more than two states, wherein at least one state is defined by at least one true color (g, r, b) or a mixture of the primary colors.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of reserving burst band-widths or band-widths in an ATM network.
DESCRIPTION OF THE RELATED ART
Heretofore, a congestion control method has been employed to detect a congestion in a network so as to prevent deterioration of the quality of network operation. For example, in "A Study on Congestion Control for Bit Rate Free ATM Network Resource Management", 1992 IEICE (Japan) Conference, SSE92-21, there has been described a technology in which an exchanger or a switching apparatus in a network detects a cell loss probability to decide a congested state of the network so as to control traffic therein according to the state of congestion. Namely, when the congestion is at a low level, the pertinent path is changed over to another path free of congestion; whereas, when the congestion is at a high level or heavy, the UPC (User Parameter Control) of each switching facility disposed at an entrance of the network is restricted to limit the traffic of the network, thereby improving the cell loss probability in the network.
In the congestion control method of the prior art, a switching device detects a cell loss probability to determine a congested state in the network. Consequently, the device is required to include means to detect the cell loss probability: moreover, there is necessitated means to decide one of the switching devices and to restrict the UPC thereof, thereby controlling the pertinent device.
Furthermore, in order to restore the cell loss probability to the original appropriate value in the network, it is required to restrict the UPC of the pertinent switching apparatus at an entry of the network. In consequence, data resultant from the UPC restriction is not returned to the pertinent terminal and the traffic through the terminal is lost at the entry point of the network.
Moreover, a conventional method of allocating bandwidths for each burst has been described, for example, in the "Fast Band-width Reservation Scheme with Multi-path & Multilink Routing in ATM Networks", Suzuki et al., 1991 IEICE (JAPAN) Conference, SSE91-112. According to this technology, to allocate a band-width to each burst level, a terminal notifies, before transmitting a burst, only a maximum bandwidth (peak rate) necessary for the burst transmission to the system. If the maximum band-width can be reserved for all links on a path, the burst is transmitted: otherwise, the burst transmission is blocked or inhibited.
That is, as shown in FIG. 1, immediately before a burst transmission, the terminal reports a maximum band-width therefor. If the maximum band-width is reserved in all links of the path, the burst is transmitted. If the band-width reservation is impossible, the burst is prevented from being transmitted. In this connection, reference numerals 210, 220, 230, and 240 respectively designate nodes of the network in FIG. 1.
However, the conventional method of allocating a burst band-width is attended with a problem when the load imposed on the ATM network becomes greater. Namely, when a request is issued with a high peak rate in such a situation, the probability of blockage thereof is increased and hence throughput of the ATM network is limited.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a congestion control method capable of removing the problems.
Moreover, another object of the present invention is to provide a flexible method of reserving a band-width for a burst capable of flexibly reserving a band-width according to a maximum band-width and a minimum band-width requested for reservation and a remaining band-width of each link, thereby solving the problem.
In accordance with the present invention, there is provided a burst band-width reservation method for use with an ATM network. The method includes the steps of connecting a source terminal via a plurality of nodes to a destination terminal, setting a path between an initiating node and a terminating node in a call set-up phase, reserving for each link on the path, prior to transmission of a burst from the source terminal, band-widths to send the burst therethrough, thereby transferring the the burst, releasing the reserved band-widths after the burst is completely transmitted, repeatedly conducting by the source terminal, at a failure of the band-width reservation on the path, a band-width re-reservation until band-widths are successfully reserved, and counting by the source terminal the number of successively failed attempts of the band-width reservation, thereby minimizing a request band-width at the band-width re-allocation for the burst transmission in accordance with the number of successively failed attempts.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention will become more apparent from the consideration of the following detailed description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic diagram showing a conventional method of reserving a band-width according to a burst level:
FIG. 2 is a diagram showing a network configuration to which the present invention is to be applied;
FIG. 3 is a diagram for explaining congestion control operations in a band-width reservation and a re-reservation of a band-width in a first embodiment in accordance with the present invention;
FIG. 4 is a diagram showing an example of status transition of the peak rate in a second embodiment according to the present invention:
FIG. 5 is a diagram showing another example of status transition of the peak rate in a second embodiment in accordance with the present invention:
FIG. 6 is a diagram useful to explain congestion control operations in a band-width reservation and a re-reservation of a band-width in a third embodiment according to the present invention:
FIG. 7 is a diagram showing a congestion control operation in a fourth embodiment in accordance with the present invention:
FIG. 8 is a diagram showing an ATM network to which the present invention is to be applied;
FIG. 9 is a diagram for explaining a burst-level band-width reservation in a fifth embodiment according to the present invention:
FIG. 10 is a diagram useful to explain a burst-level band-width reservation in a sixth embodiment in accordance with the present invention;
FIG. 11 is a diagram useful to explain a burst-level band-width reservation in a seventh embodiment in accordance with the present invention;
FIG. 12 is a network diagram for explaining an eighth embodiment according to the present invention;
FIG. 13 is a diagram useful to explain an example of the burst-level band-width reservation in the eighth embodiment in accordance with the present invention; and
FIG. 14 is a diagram useful to explain another example of the burst-level band-width reservation in the eighth embodiment according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows an example of an ATM network to which the present invention is to be applied. In this diagram, there is shown a virtual channel (VC) to transfer a burst from a source terminal 80 to a destination terminal 90. Reference numerals 10 to 70 respectively denote nodes of the ATM network. Between the respective adjacent nodes 10 and 20, 20 and 30, 80 and 40, 10 and 70, 60 and 70, and 40 and 60, there are established links 1 to 6, respectively. In this regard, the virtual channel comprises a chain of nodes 10-20-30-40 (i.e., a route passing the nodes 10 to 40 in this order) and links 1, 2, and 3 therebetween.
FIG. 3 shows an example of congestion control operations accomplished to reserve band-widths for each burst transmission and to reserve again band-widths in the first embodiment according to the present invention. Prior to transmission of a burst, a reservation request cell is sent from the node 10 to the node 40 to reserve a band-width. The bandwidth requested is a maximum band-width P, i.e., peak rate. When there exist only insufficient band-widths remaining in the links of the virtual channel VC; and hence the reservation is rejected, a rejection signal NACK is sent to the transmission source terminal. In addition, to prevent occurrence of a deadlock in the system, the band-width reserved on any link by a node associated therewith reserved is released. When a back-off period of time is elapsed thereafter, the source terminal 80 again sends a reservation request cell. Like operation may be repeated. In the present embodiment, however, to reduce the blockage probability of reservation, when NACK is received N times (N is a predetermined number), the terminal 80 lowers the request band-width from P to P/k, where k is an adequate denominator such as an integer 2. This operation is repeatedly accomplished until a band-width is successfully reserved. In FIG. 3, there is shown a case where N is set to one. Namely, each time when the NACK is received, the terminal 80 lowers the peak rate in proportion of P to P/k for subsequent reservation. The value of k is predetermined in the system. When the reservation is successfully completed, an acknowledge signal ACE is transmitted to the source terminal. In response thereto, the source terminal sends a burst of cells at a variable rate not exceeding the reserved band-widths to the destination terminal. After the burst transmission is successfully terminated, a cell indicating the termination is sent to release the reserved band-widths respective associated links.
FIG. 4 shows an example of state transition of peak rate alteration according to a second embodiment of the present invention. As shown in FIG. 4, the request peak rate takes two different values P1 and P2. N1 is the number of successive NACK's and N2, that of successive ACKS. N1 and N2 are assumed to be one and five, respectively.
Before sending a burst, to reserve a band-width, a reservation cell is transmitted from the node 10 to the node 40. The initially requested band-width is set to the maximum band-width (peak rate) P1. If the remaining band-widths are insufficient and hence the request for reservation is blocked, NACK is returned to the transmission side. Moreover, to prevent system deadlock, any reserved band-widths are released. After NACK is once received, the terminal lowers the peak rate from P1 to P2. Thereafter, the value P2 is held as the peak rate for the source terminal to issue a reservation request for the transmission burst. This also applies to the subsequent retries for reservation of band-width. When ACK is successively received five times, the peak rate is restored from P2 to P1. When NACK is received after three consecutive ACKs, the count value of ACKs is cleared to zero. Therefore, an ACK subsequent thereto is counted as the first only when ACKs are successively received five times, the peak rate is restored to P1.
FIG. 5 shows a modification in which the peak rate takes multiple values. In this case, after the peak rate is altered from P1 to P2 in response to N1 NACK receptions, when NACKs are consecutively received N1 times again, the peak rate is changed from P2 to P3. Unless ACKs are successively received N2 times, a similar operation will be repeated until the peak rate steps down to a preset value Pn that may be the minimum peak rate for the source terminal.
In FIG. 5, letting i be an arbitrary integer such the 1<i<n, any stepped down request peak rate Pi is varied to the next larger peak rate Pn-1 when ACKs are consecutively received N2 times, and the peak rate Pn is altered to the next smaller peak rate Pn+1 when NACKs are successively received N1 times. There may also be considered a method in which each of the values N1 and N2 is variable in accordance with the peak rate Pi. Namely, these values are determined as follows for the respective changes, for example, N1 as will be seen by comparison with FIG. 5 is set to ten for transition from P1 to P2, whereas N2 is equal to five for alteration from P2 to P3.
FIG. 6 shows an example of the congestion control operation in the band-width reservation and re-reservation for a burst transmission in a third embodiment according to the present invention. Like in the first embodiment, it is also assumed in the third embodiment that the remaining bandwidths are insufficient such that the reservation is blocked and NACK is returned to the requesting side. Thereafter, when a back-off period of time T is elapsed, the requesting terminal again tries or attempts the band-width reservation. If such a trial is unsuccessfully repeated so that NACKs are received N times (N is a predetermined value), the back-off time is elongated to T×K, where K is an adequate value such as an integer 2. This operation is repetitiously accomplished until the band-width reservation is successfully completed.
In FIG. 6, there is shown a case where the value of N is set to one. Namely, when NACK is once received after a failure of the first re-reservation, the back-off time is changed to T×K (K is a predetermined value).
When the reservation is successfully terminated, ACK is transmitted to the requesting terminal. In response thereto, the terminal sends a burst to a destination terminal. After the burst is completely transmitted, a cell reporting the termination of burst transmission is sent to release the reserved band-widths.
FIG. 7 shows an example of operation to control congestion in a fourth embodiment in accordance with the present invention. According to this method of the present invention, the peak rate is altered in a manner similar to the second embodiment in a network in which the band-width reservation is not conducted for each burst, i.e. a number of bursts in any call are sequentially transmitted at predetermined intervals, in a cell mode directly after establishment of call-level VC. In the fourth embodiment, when a cell is lost during a burst transmission and hence the transmission is failed, NACK is returned to the source terminal. In contrast thereto, when there does not occur such a cell loss and hence the burst transmission is successfully achieved, ACK is sent to the terminal. When NACKs are consecutively received N1 times, an interval between transmission cells is increased to minimize the peak rate. When ACKs are successively received N2 times, the interval between cell transmissions is decreased to set a greater value as the peak rate.
FIG. 7 shows a case where the values of N1 and N2 are set to one and two, respectively. When NACK is once received, the interval between cells transmitted from the terminal is multiplied by k to decrease the peak rate to P/k. Thereafter, when ACK is received twice, the interval is again reduced, namely, the value thereof is divided by k to restore the peak rate to P.
Also in the fourth embodiment, like in the second embodiment, the peak rate may take multiple values and the values respectively of N1 and N2 may be varied for each peak rate.
In the embodiments described, each terminal includes a detection means for detecting a band-width reservation cell which means may detect the loss of a cell or packet to thereby detect the congested state of a network, whereby the terminal is permitted to control a peak rate associated with itself. Namely, the terminal can achieve a congestion control independent of operation of the network in communication with another terminal. In other words, the network is not required to have a congestion control function for this purpose.
FIG. 8 shows an alternative example of an ATM network to which a burst band-width reservation method is applied in accordance with the present invention. The network includes a transmission source terminal 180, a destination terminal 190 and, a first path 17 and a second path 18 respectively established between the terminals 180 and 190. The first path 17 comprises nodes 110, 120, 130 and 140 and links 11 to 13. The second path 18 comprises nodes 110, 160, 150 and 140 links 14 to 16. Each node includes an ATM switching device, a processor for controlling transfer of cells, and the like (details of the configuration are not shown). Since each of the links 11 to 16 is in a single-link structure in this case, one virtual channel is formed in each of the paths 17 and 18. In this regard, even if each of the paths and links is configured in a multiple path or link configuration, the present invention can be similarly implemented.
Referring now to FIGS. 8 and 9, description will be first given of operation of the band-width reservation at each burst transmission in a fifth embodiment according to the present invention. Before a burst is sent from the terminal 180, to reserve band-width for the burst transmission, a reservation cell is sent from the terminal 180 to the node 110. The cell includes information denoting the maximum band-width (peak rate) P1 and the minimum band-width P2. It is assumed that the values of P1 and P2 are set to 100 and 50, respectively. Moreover, it is assumed that the links 11 to 13 respectively controlled by the nodes 110 to 180 have remaining band-widths "150", "80", and "120", respectively. On receiving the reservation cell from the terminal 180, since the remaining band-width of the first link 11 is "150", the node 110 reserves the maximum band-width "100" for the transmission and then sends the cell to the node 120 controlling the second link 12. The remaining band-width of the node 120 is "80". Namely, this band-width is less than the maximum band-width "100" and is not less than the minimum band-width "50". Consequently, the remaining band-width "80" is reserved for the link 12 and then the cell is transmitted to the node 130. Since there is the remaining band-width equal to or more than the maximum band-width "100" for the third link 13, the node 130 reserves the maximum band-width "100" and then transmits the cell to the node 140. On receiving the cell, the node 140 recognizes according to information of the cell (indicating P1=100 and P2=50 sent from the initiating terminal 180 and the band-widths "100", "80", and "100" reserved by the respective nodes) that the band-widths have been reserved up to the last link 13. Resultantly, an ACK cell notifying the reserved minimum band-width "80" is sent via the nodes 130, 120, and 110 to the terminal 180. Receiving the ACK cell indicating the reservation of the band-width "80", the terminal 180 transmits the burst at the transmission rate "80". After the burst is completely transmitted therefrom, the terminal 180 releases the reserved band-widths.
In this connection, in a case where the remaining band-width is at most the minimum band-width "50" in either one of the links, the burst transfer is inhibited and an NACK cell is sent to the transmission source terminal 180. Furthermore, to avoid the deadlock state of the system, the band-widths already reserved for intermediate links related to the transmission are released. In this case, the terminal 180 again tries a band-width reservation when the back-off time is elapsed thereafter. Each node can control the remaining band-width of the associated link according to a table.
FIG. 10 shows an example of operation to reserve a band-width for each burst transmission in a sixth embodiment according to the present invention. Like in the embodiment of FIG. 9, the sixth embodiment is implemented in the ATM network shown in FIG. 8. Prior to a transmission of a burst, to request a band-width reservation, the source terminal 180 sends a reservation cell to the node 110. As for the requested band-width, the maximum band-width P1 is "100" and the minimum band-width P2 is "50". The remaining band-widths of the links 11 to 13 are set as "150", "80", and "120", respectively. The node 110 reserves the maximum band-width "100" for the link 11. The remaining band-width of the second link 12 is "80", which is less than the maximum band-width "100" and is not less than the minimum band-width "50". Consequently, the node 120 reserves the remaining band-width "80". The remaining band-width of the link 13 is "80" or more, which is not less than the band-width "80" reserved for the link 12. In consequence, the node 130 reserves the band-width "80" for the third link 13. The node 140 recognizes according to the cell from the node 130 that the band-width reservation is completed up to the final link, thereby sending an ACK cell notifying the reserved band-width "80" via the nodes 130, 120, and 110 to the initiating terminal 180. When relaying the ACK cell, the node 110 which has the band-width "100" reserved in excess releases the excess "20" of band-width and then updates the pertinent entry of the table such that the table indicates the reserved band-width "80". Operations thereafter are conducted in substantially the same manner as for the embodiment of FIG. 9.
FIG. 11 shows an example of operation of the band-width reservation at a burst transmission in a seventh embodiment according to the present invention. In the sixth embodiment of FIG. 10, in a case where each of the remaining band-widths is not less than the maximum band-width, the maximum band-width is reserved. However, at an arbitrary node that has a remaining band-width within a range between the maximum band-width and the minimum band-width, both inclusive, and the entire range of the remaining band-width is used to reserve a corresponding band-width, if a preceding node thereto has reserved the maximum band-width. The corresponding band-width reserved is then applied as a request band-width, i.e. an updated maximum band-width, to a subsequent node, while the minimum band-width is held as is. In the seventh embodiment, a request band-width determined at an associated node based on a function f(P1, P2, C) is reserved to save the remaining band-widths to some extent, thereby lowering the block probability of burst transmission. Also, the seventh embodiment is materialized for use with the ATM network of FIG. 8. For the links 11 to 13 of the virtual channel (VC) to transfer the burst from the initiating terminal 180 to the destination terminal 190, the remaining band-widths (C) are "150", "80", and "120", respectively. In this situation, the request band-width is calculated according to a function f(P1, P2, C) with respect to the maximum request band-width or the band-width P1 allocated by a preceding node, the minimum request band-width P2, and the remaining band-width C of the pertinent link. In this embodiment, the function f(P1, P2, C) is as follows. ##EQU1## Namely, for the link 11, the remaining band-width is "150" and hence P1(100)>150/2>P2 (50). In consequence, there is reserved C/2=75. For the link 12, the remaining band-width is "80" and hence 80/2<P2 (50); consequently, there is reserved P2=50. Moreover, the remaining band-width is "120" for the link 13 and the band-width reserved by the previous link is P1=50<C/2. In consequence, P1=50 is reserved for the transmission. Like in the embodiment of FIG. 10, when the band-width reservation is completed up to the last link, and ACK cell containing the reserved band-width "50" is transmitted to the source terminal 180. In the repeating operation of the ACK cell, the node 110 having excessively reserved the band-width releases the excess band-width portion "25" and then updates the table to denote the reservation band-width "50". Operations thereafter are similar to those of the embodiments above.
As above, in accordance with the embodiments, even when the maximum band-width is missing in a link, if the remaining band-width is not less than the minimum band-width, there can be allocated a band-width thereto according to the remaining band-width. This resultantly reduces the block probability of burst transmission and hence increases the network utilization efficiency.
FIG. 12 shows an illustration of the ATM network to which an eighth embodiment is applied in accordance with the present invention. The network includes ATM nodes 110 to 160. Between the adjacent nodes 110 and 120, 120 and 130, 130 and 140, 140 and 150, 150 and 160, and 110 and 160, there are formed links 11 to 16, respectively. It is assumed that each link has a link band-width capacity "150", a virtual channel (VC) to transfer a burst from a transmission source terminal 180 to a destination terminal 190 includes a chain of nodes 110-120-130-140 and links 11 to 13, and a virtual channel (VC) to transfer a burst from a initiating terminal 200 to a partner terminal 170 includes a chain of nodes 160-110-120-130 and links 16, 11, and 12.
FIGS. 13 and 14 schematically show examples of a congestion control operation in a band-width reservation for a burst transmission in the eighth embodiment according to the present invention.
Before transmitting a burst from the terminal 180 to the terminal 190, to issue a request for band-width reservation, a reservation cell is sent from the node 110 to the node 140. In the reservation, it is assumed that the remaining band-widths of the links 11 to 16 are "150", "150", "0", "0", "150", and "150", respectively.
The band-width requested by the terminal 180 is between the maximum band-width (peak rate) P1 and the minimum band-width P2. It is assumed that P1 and P2 take values "150" and "10", respectively. In this case, the remaining band-width of the link 13 is "0", namely, there is missing the remaining band-width P2=10 as the minimum band-width. Consequently, the reservation is rejected and a NACK cell is sent to the transmitting terminal 180 as shown in FIG. 13. In addition, to prevent the deadlock of the system, the band-widths already reserved for intermediate links are released. When the back-off time is elapsed thereafter, the initiating terminal 180 attempts a reservation again. In the operation of the terminal 180, to decrease the block probability of the burst transmission, when an NACK cell is received N times (N is a predetermined value), the maximum request band-width is lowered to P1'. In the diagram of FIG. 13, the values of N and P1' are set to one and 75, respectively. Namely, when the transmission side receives an NACK cell once, the band-width reservation is attempted with the maximum band-width P1' and the minimum band-width P2 set to 75 and 10, respectively. In an operation of the terminal 180 to reserve band-widths again, assume that communications from other terminals using the links 13 and 14 are completed and the remaining band-width is "150" for each link. Since each of the remaining band-widths of the links is more than the maximum band-width "75", the maximum band-width "75" is reserved for each link so as to initiate the burst transmission. In this situation, the remaining band-widths of the links 11 to 16 are "75", "75", "75", "150", "150", and "150", respectively.
Assume that a band-width reservation is requested by the terminal 200 using the links 16, 11, and 12 in this state.
In a case where the reservation request is similarly issued with a maximum band-width P1 and a minimum band-width P2 set respectively to 150 and 10, since the remaining band-width of the link 16 is "150", an attempt is made to reserve the band-width "150". However, since the remaining band-width of the links 11 and 12 is "75", only the band-width "75" is reserved as shown in FIG. 14 and then an ACK cell reporting the reservation of the band-width "75" is sent to the source terminal 200. In this case, the link 16 having excessively reserved the band-width releases the excess band-width "75" and the reserved band-width is set to "75". On receiving the ACK cell, the terminal 180 initiates transmitting the burst at the peak rate "75". After the transmission is completed, a cell denoting the termination of the transmission is sent to release the reserved band-widths.
As above, the band-widths to be allocated are flexibly changed according to the remaining band-widths. This consequently lowers the block probability of the burst transmission.
In accordance with the present invention as described above, the maximum request band-width is reduced according to the number of failed attempts of band-width reservation. Moreover, even when there is missing the maximum band-width for a link, if the remaining band-width is equal to or more than the minimum band-width, there can be allocated a band-width for the transmission. Consequently, even in a network operated for an application fully using the link capacity to the maximum extent, the block probability of the burst transmission is minimized and the network utilization efficiency is improved.
While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by those embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.
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In an ATM network using a burst-level band-width allocation, a source terminal reserves, before a burst transmission, band-widths according to a peak rate of the burst and then sends the burst therethrough. When the transmission is finished, the band-widths are released. Where there exists a link to which the peak rate is not assigned, a non-reserving acknowledgement signal (NACK) is sent to the terminal and the reserved band-widths are released. On receiving the NACK, the terminal allocates a band-width with peak rate lower than that of the first request after a back-off time has elapsed, thereby minimizing the probability of a blocked transmission. The source terminal declares a minimum band-width together with the peak rate (maximum band-width) in the band-width request operation. Each node allocates the peak rate when the remaining band-width of a link controlled by the node is sufficient to allocate the peak rate. Even if the remaining band-width is insufficient, when the band-width is not less than the minimum band-width, there is allocated a band-width equal to or more than the minimum band-width and equal to or less than the peak rate according to the remaining band-width, thereby transferring the burst.
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[0001] This application claims the benefit of the Patent Korean Application No. P2004-88269, filed on Nov. 2, 2004, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a washing machine, and more particularly, to a door assembly for a washing machine capable of preventing the surrounding where a door glass is stuck to a door frame by adhesives from being contaminated.
[0004] 2. Discussion of the Related Art
[0005] Generally, washing machines are home appliances which remove dirt from clothing items, clothes and beddings (hereinafter, ‘the laundry’) by using washing liquid and water (hereinafter, ‘washing water’).
[0006] FIG. 1 is a sectional view of a first embodiment of a related art washing machine.
[0007] As shown in FIG. 1 , the related art washing machine includes a base plate 1 for defining a base, a cabinet 2 defining a circumferential surface, a top cover 10 for defining a top and having a laundry entrance 8 for loading the laundry, and a door coupled to the top cover 10 for opening/closing the door 20 .
[0008] There is a control part 15 at the top cover 10 for controlling the washing machine.
[0009] The door includes a rear door 22 coupled to the top cover 10 , and a front door 24 coupled to the rear door 22 .
[0010] The rear and front door 22 and 24 are folded or unfolded as necessary. That is, when loading the laundry, the rear and front door 22 and 24 are folded to open the laundry entrance 8 , whereas during a washing cycle, the rear and front door 22 and 24 are unfolded to close the laundry entrance 8 .
[0011] However, the related art washing machine has a problem that it is difficult to check whether the washing cycle is under the process, or not, because the door 20 is not transparent enough to see through.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention is directed to a door assembly for a washing machine that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0013] An object of the present invention is to provide a door assembly for a washing machine capable of being handled to open the inside of the washing machine for a user's convenience, as well as the user seeing through the inside of the washing machine.
[0014] Another object of the present invention is to provide a door assembly for a washing machine capable of preventing adhesives from leaking out in a manufacturing process of the door assembly, thereby stopping the contamination of an exterior of the door assembly.
[0015] 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.
[0016] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, an door assembly for a washing machine includes a top cover having a laundry entrance: a door frame coupled to the top cover, having an opening part on a surface thereof; a door glass put on an upper surface of the door frame for covering the opening part; a main recess part insertedly formed on a portion of an upper surface of the door fame which the door glass are in a close contact with.
[0017] At that time, a glass seating part insertedly formed in the upper surface of the door frame is further included for allowing the door glass seated thereon, and the glass seating part allows the main recess part formed on the surface thereof.
[0018] The depth in which the glass seating part is inserted is the same as or deeper than the thickness of the door glass.
[0019] Also, a sub recess part formed on the surface of the glass seating part is further included for receiving the adhesives flown over from the main recess part.
[0020] The sub recess part is formed outer, compared with the main recess part.
[0021] The sub recess part is formed along the circumferential surface of the main recess part.
[0022] The sub recess part is narrower in width than the main recess part.
[0023] The sub recess part is spaced apart at a predetermined distance from an inner circumferential surface of the glass seating part.
[0024] Also, an opaque sheet on a circumference of the upper surface of the door glass is further included.
[0025] 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
[0026] 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:
[0027] FIG. 1 is a sectional view of a related art washing machine.
[0028] FIG. 2 is a perspective view, when a first embodiment of a washing machine according to the present invention is closed.
[0029] FIG. 3 is a perspective view, when a first embodiment of a washing machine according to the present invention is closed.
[0030] FIG. 4 is an exploded perspective view illustrating a door of FIGS. 2 and 3 .
[0031] FIG. 5 is a sectional view illustrating an A-A line of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] 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.
[0033] FIG. 2 is a perspective view, when a first embodiment of a washing machine according to the present invention is closed. FIG. 3 is a perspective view, when a first embodiment of a washing machine according to the present invention is closed. FIG. 4 is an exploded perspective view illustrating a door of FIGS. 2 and 3 . FIG. 5 is a sectional view illustrating an A-A line of FIG. 2 .
[0034] As shown in FIGS. 2 to 5 , the door assembly for the washing machine according to the first embodiment of the present invention includes a top cover 52 and a door 50 .
[0035] The door 50 includes a door frame 60 and a door glass 70 .
[0036] First of all, the top cover 52 will be described.
[0037] The top cover 52 is a portion where the door 50 is mounted, and defines a top of the washing machine. The top cover 52 has a square shape, and an accommodating part 53 having an upper side thereof opened is formed in rear of the top cover 52 .
[0038] Many kinds of sub assembly components (not shown) such as a water supply valve or a water level sensor are provided in the accommodating part 53 .
[0039] A control panel 55 is provided on an upper portion of the accommodating part 53 for managing operation of the washing machine. There is a control board (not shown) within the control panel 55 for controlling the washing operation based on the control panel 55 .
[0040] Furthermore, a door seating part 56 is formed on an upper surface of the top cover 52 for allowing the door 50 to seat thereon, and a laundry entrance 51 is formed in a center of the door seating part 56 .
[0041] The door seating part 56 is big enough to accommodate the door frame 60 .
[0042] Also, the door seating part 56 is big enough to minimize an aperture between the door frame 60 and the top cover 52 when the door frame is accommodated.
[0043] Specifically, the door seating part 56 in a front-and-rear direction may be formed in a size to have an aperture ti big enough for the user's hand or finger to be inserted fully, compared with the size for a front and rear direction of the door frame 60 .
[0044] A front portion 57 of the door seating part 56 is formed higher than a rear portion thereof, and inclined downwardly from an end of the front portion toward the rear portion. Preferably, the inclined surface is formed concavely round.
[0045] Next, the door frame 60 will be described.
[0046] First of all, the door frame 60 is coupled to the top cover 52 .
[0047] Also, an opening part 58 corresponding to the laundry entrance 51 is formed on the door frame 60 .
[0048] The opening part 58 may be formed almost the same as the laundry entrance 51 of the top cover 52 . Alternatively, the opening part 58 may be larger or smaller than the laundry entrance 51 .
[0049] Also, the door frame 60 made of one material such as plastic injected resin or metal is hinged to the top cover.
[0050] For that, hinge shafts 62 are provided each at a first side of a rear surface of the door frame 60 , or each at a first side of the accommodation part 53 of the top cover 52 . Hinge holes 63 rotatably connected to the hinge shafts 62 are formed at a second side of the door frame 60 or the accommodation part 53 .
[0051] Thus, once the front of the door frame 60 is lifted upwardly, the door 50 rotates upwardly to open the laundry entrance 51 . Therewith, the front portion 61 of the door frame 60 is thinner than the other portions thereof. That is, when the door frame 60 is seated on the door seating part 56 , the front portion 61 is spaced apart at a predetermined distance from a base of the door seating part 56 . That structure enables the user to grasp the front portion 61 of the door frame 60 without any difficulties.
[0052] At that time, the end of the front portion 61 of the door frame 60 is more inclined than the front portion 57 of the door seating part 56 . Thus, the end of the front portion 61 of the door frame 60 may not come in contact with the front portion 57 of the door seating part 56 .
[0053] Therefore, the user may grasp the front portion 61 of the door frame 60 through the aperture t 1 between the door frame 60 and the door seating part 56 more easily.
[0054] Still further, a glass seating part 64 is insertedly formed on a front surface of the door frame 60 . The door glass 70 is seated in the glass seating part 64 .
[0055] The glass seating part 64 has a shape corresponding to the door glass 70 , and is formed larger than the door glass 70 .
[0056] Especially, the size difference between the glass seating part 64 and the door glass 70 is enough that a small aperture t 2 may be formed between an inner circumference of the glass seating part 64 and an outer circumference of the door glass 70 .
[0057] Preferably, the depth in that the glass seating part 64 is inserted is the same as the thickness of the door glass 70 or deeper than the door glass 70 . That is so that the door glass 70 may not more projected than the upper surface of the door frame 60 , when seating the door glass 70 on the glass seating part 64 .
[0058] On the other hand, a main recess part is formed in a portion of the door frame 60 , where the door glass 70 is contacted, in other words, the upper surface of the glass seating part 64 . Adhesives C are applied to the main recess part 65 .
[0059] The main recess part 65 is a recess part in which the upper surface of the glass seating part 64 is inserted.
[0060] The main recess part 65 may be formed along all the circumference portions of the opening part 58 on the upper surface of the glass seating part 64 . Alternatively, although not described, the main recess part 65 may be partially formed on the upper surface of the glass seating part 64 .
[0061] Also, the first embodiment of the present invention discloses that a sub recess part 66 is further formed on the glass seating part 64 .
[0062] The sub recess part 66 is for holding over-flown adhesives in case that the adhesives applied to the main recess part 65 are over flown.
[0063] Especially, the sub recess part 66 is formed outer, compared with the main recess part 65 , and narrower than the main recess part 65 . Regardless to say, the sub recess part 66 also may be formed along all the circumference portions of the main recess part 65 .
[0064] Furthermore, the sub recess part 66 may be spaced apart at a predetermined distance t 2 from an inner circumferential surface of the glass seating part 64 . the distance t 2 is the same as the aperture t 2 between the glass seating part 64 and the door glass 70 .
[0065] Still further, a division rib 67 is further formed on the glass seating part 64 for dividing the sub recess part 65 from the main recess part 66 . The division rib 67 is high enough for the adhesives applied to the main recess part 65 to go over into the sub recess part 66 .
[0066] Next, the door glass 70 will be described.
[0067] First of all, the door glass 70 is a window for seeing through the inside of the washing machine from an outside, and is made of transparent material.
[0068] The door glass 70 is stuck to the glass seating part 64 of the door frame by adhesives (C) for covering the opening part 58 of the door frame 60 .
[0069] An opaque sheet 72 is further provided on a circumference of the upper surface of the door glass 70 .
[0070] The opaque sheet 72 is a film so as not to see through a below portion thereof, in other words, the portion where the door glass 70 and the door frame 60 are stuck. Then, the opaque sheet 72 is provided on the upper circumference surface of the door glass 70 , the portion not corresponding to the laundry entrance 51 and the opening part 58 .
[0071] On the other hand, the reference number 74 is a seating rib projected at the glass seating part 64 . The seating rib 74 forms the sub recess part 66 , and is seated at a downside edge of the door glass 70 .
[0072] An assembly process of the door assembly according to the present invention will be described.
[0073] First, as shown in FIG. 4 , the adhesives C are applied to the main recess part 65 of the door frame 60 .
[0074] Hence, the door glass 70 is seated on the glass seating part 64 .
[0075] In that case, the portion of the door glass 70 downside, facing the main recess part 65 is stuck on the adhesives C, whereas the other portions thereof is in a close contact with the portion facing the glass seating part 64 .
[0076] If the adhesives C are applied to the entire main recess part 65 or some of the main recess part 65 too much in the middle of seating the door glass 60 on the glass seating part 64 , the adhesives C are over flown from the main recess part 65 .
[0077] However, the adhesives C go across the division rib 67 into the sub recess part 66 . Continuously, the adhesives are flown along the sub recess part 66 . Thus, the adhesives are prevented from being over flown outside of the sub recess part 66 . Then, the adhesives C′ flown into the sub recess part 66 are stuck to the surface of the door glass 70 facing the sub recess 66 .
[0078] On the other hand, if the adhesives C are applied too much, the adhesives C may be over flown to the outside of the sub recess part 66 . However, the over flown adhesives C are stopped from being leaked into an outside by the inner circumferential surface of the glass seating part 64 . Also, the adhesives are flown along the aperture t 2 between the door glass 60 and the glass seating part 64 to allow the outer circumferential surface of the door glass 60 and the inner circumferential surface of the glass seating part 64 stuck together.
[0079] As described above, the door assembly for a washing machine according to the present invention has the following advantageous effect. First, the user may see through the inside of the washing machine due to the door assembly according to the present invention, as well as may open the washing machine more easily.
[0080] Furthermore, when connecting the door glass 70 to the door frame 60 , the adhesives are prevented from being leaked outside of the aperture between the door frame 60 and the door glass 70 by the main and sub recess part 65 and 66 .
[0081] Still further, since the door assembly for the washing machine according to the present invention has the glass seating part 64 on the upper surface of the door frame 60 . Thus, the adhesives may stay in the inner wall side of the glass seating part, although the adhesives are over flown outside of the sub recess part 66 , thereby preventing the adhesives from being over flown to an outside. Also the portion around the adhesives may be prevented from being contaminated.
[0082] Still further, since the door assembly for the washing machine according to the present invention has the division rib on the glass seating part 64 for divide the main recess part 65 into the sub recess part 66 , the worker may apply the adhesives to the main and sub recess part 65 and 66 more easily.
[0083] 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 invention provided they come within the scope of the appended claims and their equivalents.
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The present invention relates to a door assembly for a washing machine comprising a main recess part on the door frame for allowing adhesives applied thereto and a sub recess part for receiving the adhesives flown over from the main recess part. Thus, when sticking the door glass to the door frame, the adhesives are not leaked out, thereby preventing the surrounding of the adhesives from being contaminated.
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BACKGROUND OF THE INVENTION
[0001] 1. Related Applications
[0002] This applications claims the priority benefit of U.S. Patent Application No. 60/715,964, filed Sep. 9, 2005, entitled NEGATIVE PHOTORESIST FOR SILICON KOH ETCH WITHOUT SILICON NITRIDE, incorporated by reference herein.
[0003] 2. Field of the Invention
[0004] The present invention is concerned with new photoresists for use in the manufacture of microelectronic devices such as those used in microelectromechanical systems (MEMS).
[0005] 3. Description of the Prior Art
[0006] It is common in silicon etching processes to utilize a thin (100- to 300-nm) silicon nitride or silicon dioxide coating on the silicon substrate as a mask for patterned etching or as a passivating layer to enclose active circuitry. In the prior art, etch protective coatings or masks for MEMS fabrication processes have been selected primarily by using a trial-and-error method because there are no general purpose protective coatings on the market. The etch selectivity of the etchants to various materials is often used as a guide for MEMS process engineers. With a much lower etch rate than silicon, films of silicon nitride have been used as a protective layer or hardmask during KOH or TMAH bulk silicon etching. Silicon dioxide has a higher etch rate than silicon nitride, Therefore, it is only used as a protective/mask layer for very short etches. Gold (Au), chromium (Cr), and boron (B) have also been reportedly used in some situations. Non-patterned, hard-baked photoresists have been used as masks, but they are readily etched in alkaline solutions. Polymethyl methacrylate was also evaluated as an etch mask for KOH. However, because of saponification of the ester group, the masking time of this polymer was found to decrease sharply from 165 minutes at 60° C. to 15 minutes at 90° C.
[0007] Regardless of the protective coating or mask selected, a photoresist layer to be patterned must be applied to the protective coating or mask so that the pattern can be transferred to the underlying substrate. However, this can only be carried out after the protective coating or mask has been applied, thus requiring time and expense to apply and later etch this protective layer or mask, which is very difficult to remove.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes these problems by providing spin-applied, photosensitive coating systems that replace prior art masks or protective coatings, and that eliminate the need for additional photoresists in the system. The inventive systems protect device features from corrosion and other forms of attack during deep-etching processes that utilize concentrated aqueous bases.
[0009] The invention provides a photosensitive composition useful as a protective layer. The composition comprises a polymer and a photoacid generator, and the polymer comprises styrene-containing monomers, acrylonitrile-containing monomers, and epoxy-containing monomers. The invention also provides methods of using these photosensitive compositions in conjunction with a primer layer to form microelectronic structures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] In more detail, these systems comprise a primer layer that is applied to a microelectronic substrate surface, and a photosensitive layer that is applied to the primer layer.
Primer Layer
[0011] Preferred primer layers are formed from primer layer compositions including a silane dispersed or dissolved in a solvent system. Aromatic and organo silanes are particularly preferred silanes for use in the primer layers of the invention. Furthermore, it is preferred that the silane include at least one (and more preferably 2-3) group per mole of compound, or per repeat unit of polymer, that reacts with epoxy groups to form covalent bonds so that adhesion to a silicon substrate is very strong. One preferred such group is an amine group.
[0012] Preferred silanes include aminoalkoxysilanes, preferably from about C 1 to about C 8 alkoxys, more preferably from about C 1 to about C 4 alkoxys, and even more preferably from about C 1 to about C 3 alkoxys. Even more preferably, the aminoalkoxysilane is an aminoalkylalkoxysilane, preferably from about C 1 to about C 8 alkyls, more preferably from about C 1 to about C 4 alkyls, and even more preferably from about C 1 to about C 3 alkyls. Phenylaminoalkylalkoxysilanes are also preferred. Some examples of the foregoing include aminopropyltrimethoxysilane, aminiopropyltriethoxysilane, N-phenylaminopropyltrimethoxysilane, N-phenylaminopropyltriethoxysilane, 3-glycidoxpropyltrimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, and 3-mercaptopropyl-trimethoxysilane.
[0013] Other preferred silanes include phenylsilanes such as phenyltrimethoxysilane, phenyltrichlorosilane, phenyltriethoxysilane, phenyltriacetoxysilane, and diphenylsilanes such as diphenyldimethoxysilane, diphenyldichlorosilane, and diphenylsilanediol. The most preferred silanes include 2-phenylethyltrialkoxysilane p/m-chlorophenyltrimethoxysilane, p/m-bromophenyltrimethoxysilane, (pim-chloromethyl)phenyltrimethoxysilanie 2-(p/m-methoxy)phenylethyltrimethoxysilane, 2-(p/m-chloromethyl)phenylethyltrimethoxysilane, 3,4-dichlorophenyltnichlorosilane, 3-phenoxypropyltrichlorosilane, 3-(N-phenylamino)propyltnimethoxysilane, and 2-(diphenylphosphino)ethyltriethoxysilane.
[0014] Some preferred silanes for use in the present invention can also be represented by the general formula
wherein:
each of i, j, and k is individually selected from the group consisting of 0 and 1, and if one of i and j is 1, then the other of i and j is 0; each R 4 is individually selected from the group consisting of hydrogen, the halogens, C 1 -C 8 (preferably C 1 -C 4 ) alkyls, C 1 -(C (preferably C 1 -C 4 ) alkoxys, C 1 -C 8 (preferably C 1 -C 4 ) haloalkyls, aminos, and C 1 -C 8 (preferably C 1 -C 4 ) alkylaminos; each R 5 is individually selected from the group consisting of C 1 -C 8 (preferably C 1 -C 4 ) aliphatic groups; each R 6 is individually selected from the group consisting of hydrogen and haloalkyls (preferably C 1 -C8, more preferably C 1 -C 4 ); each X is individually selected from the group consisting of halogens, hydroxyls, C 1 -C 4 alkoxys and C 1 -C 4 carboxyls; Y is selected from the group consisting of oxygen and sulfur; Z is selected from the group consisting of nitrogen and phosphorus; and each d is individually selected from the group consisting of 0 and 1. An effective primer layer composition according to the invention is a mixture of a diphenyidialkoxysilane (e.g., diphenyldimethoxysilane) and a phenyltrialkoxysilane, (e.g., phenyltrimethoxysilane) or, even more preferably, a mixture of diphenylsilanediol and phenyltrimethoxysilane in a solution of 1 -methoxy-2-propanol or 1-propoxy-2-propanol with from about 5-10% by weight water. A particularly effective primer layer composition for photosensitive layers comprising a poly(styrene-co-acrylonitrile) polymer is an alcohol and water solution containing from about 0.1 -t1.0% (preferably from about 0.25-0.5%) by weight diphenylsilanediol and from about 0.1-1.0% (preferably from about 0.25-0.5%) by weight of phenyltrimethoxysilane. Upon heating, diphenylsilanediol and phenylsilanetriol (the hydrolysis product of phenyltrimethoxysilane) condense to from siloxane bonds and establish a three-dimensional silicone coating layer on the substrate.
[0024] Another preferred silane has the formula
wherein:
each R 7 is individually selected from the group consisting of hydrogen, the halogens, C 1 -C 8 (preferably C 1 -C 4 ) alkyls, C 1 -C, (preferably C 1 -C 4 ) alkoxys, C 1 -C, (preferably C 1 -C 4 ) haloalkyls, aminos, and C 1 -C 8 (preferably C 1 -C 4 ) alkylaminos; and each R 8 is individually selected from the group consisting of C 1 -C 8 (preferably C 1 -C 4 ) aliphatic groups.
[0027] Silanes having this structure are not only compatible with styrene-containing copolymers, but they are also reactive with ester, benzyl chloride, and/or epoxy groups, and they are excellent adhesion promoters. One particularly preferred silane within the scope of this formula is
[0028] This silane is 3-[N-phenylamino]propyltrimetlioxysilane (mentioned above), and it is commercially available from Lancaster Synthesis and Gelest Corporation,
[0029] The silane should be included in the primer layer composition at a level of from about 0.1% to about 3% by weight, preferably from about 0.2% to about 2% by weight, and even more preferably from about 0.5% to about 1% by weight, based upon the total weight of solids in the primer layer composition taken as 100% by weight
[0030] The solvent system utilized in the primer layer composition should have a boiling point of from about 100° C. to about 220° C., and preferably from about 140° C. to about 180° C. The solvent system should be utilized at a level of from about 30% to about 99.9% by weight, and preferably from about 40% to about 80% by weight, based upon the total weight of the primer layer composition taken as 100% by weight. Preferred solvent systems include a solvent selected from the group consisting of methanol, ethanol, isopropanol, butanol, 1-methoxy-2-propanol, ethylene glycol monomethyl ether, and 1-propoxy-2-propanol, and mixtures thereof. In one preferred embodiment, water is included in the solvent system at a level of from about 20% to about 60% by weight, and preferably from about 20% to about 40% by weight, based upon the total weight of the primer layer composition taken as 100% by weight.
[0031] The primer layer composition can also include a catalyst. Suitable catalysts include any inorganic or organic acid (e.g., hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid) or an inorganic or organic base (e.g., potassium hydroxide, TMAH, ammonia, amines). The catalyst is preferably present in the primer layer composition at levels of from about 0.01% to about 0.5% by weight, more preferably from about 0.1% to about 0.3% by weight, and even more preferably from about 0.02% to about 0.03% by weight, based upon the total weight of solids in the primer layer composition taken as 100% by weight.
[0032] Finally, the primer layer can also include a number of optional ingredients, such as a surfactant. In one embodiment, from about 100 ppm to about 150 ppm of a surfactant such as FC4430 (available from 3M) or Triton X-100 (available from 3M) can be added to make a uniform primer coating that is defect-free.
The Photosensitive Layer
[0033] The photosensitive layer is formed from a composition comprising a polymer dispersed or dissolved in a solvent system. A preferred polymer is a terpolymer comprising recurring: styrene monomers; acrylonitrile monomers; and monomers comprising functional groups that react with amines.
[0034] Preferred styrene monomers have the formula
[0035] Preferred acrylonitrile monomers have the formula
[0036] Preferred monomers comprising functional groups for reacting with amines include monomers comprising one or more epoxy groups (e.g., glycidyl methacrylate, glycidyl acrylate, vinylbenzoyl glycidyl ether). One example is represented by the formula
In each of the above formulas (I)-(III):
each R 1 is individually selected from the group consisting of hydrogen and C 1 -C 8 (and preferably C 1 -C 4 ) alkyls; and each R 2 is individually selected from the group consisting of hydrogen, C 1 -C 8 (and preferably C 1 -C 4 ) alkyls, and C 1 -C 8 (and preferably C 1 -C 4 ) alkoxys.
[0040] The polymer preferably comprises from about 35% to about 75% by weight of monomer (I), more preferably from about 40% to about 70% by weight of monomer (I), and even more preferably from about 50% to about 65% by weight of monomer (I). The polymer preferably comprises from about 20% to about 40% by weight of monomer (II), more preferably from about 25% to about 35% by weight of monomer (II), and even more preferably from about 25% to about 30% by weight of monomer (II). Finally, the polymer preferably comprises from about 5% to about 15% by weight of monomer (III), more preferably from about 6% to about 12% by weight of monomer (III), and even more preferably from about 8% to about 10% by weight of monomer (III). Each of the above percentages by weight is based upon the total weight of the polymer taken as 100% by weight.
[0041] It is preferred that the polymer have a weight average molecular weight of from about 10,000 Daltons to about 80,000 Daltons, preferably from about 20,000 Daltons to about 60,000 Daltons, and even more preferably from about 30,000 Daltons to about 50,000 Daltons.
[0042] Monomers other than monomers (I), (II), and (III) can also be present in the polymer, if desired. When other monomers are present, the combined weight of monomers (I), (II), and (III) in the polymer is preferably at least about 60% by weight, and more preferably from about 70% to about 90% by weight, based upon the total weight of the polymer taken as 100% by weight. Examples of suitable other monomers include those having functional groups that can react with groups in the primer layer for achieving chemical bonding between the two layers. These monomers may have, by way of example, haloalkyl (e.g., benzyl chloride, 2-chloroethyl methacrylate), ester (methacrylates, acrylates, maleates, fumarates, isocyanates), or anhydride functional groups, which react readily with functional groups such as hydroxyl, amino, or oxiranyl groups that can be present in the primer layer.
[0043] The polymer should be included in the photosensitive layer composition at a level of from about 90% to about 98% by weight, and preferably from about 90% to about 95% by weight, based upon the total weight of solids in the photosensitive layer composition taken as 100% by weight.
[0044] The photosensitive composition will also comprise a photoacid generator (PAG). The PAG generates a strong acid or superacid when exposed to actinic radiation such as UV light. Examples of suitable PAGs include those selected from the group consisting of triarylsulfonium hexafluoroantimonate, tiylsulfonluim hexafluorophosphate, diaryliodonium hexafluoroantimonate, diaryliodonium hexafluorophosphate,
where each R 3 is individually selected from the group consisting of C 3 H 7 , C 8 H 17 , CH 3 C 6 H 4 , and camphor. The PAGs of formulas (IV) and (V) are sold by Ciba Specialty Chemicals as The CGI 13XX Family and The CGI 26X Family, respectively.
[0045] The PAG should be included in the photosensitive composition at a level of from about 2% to about 10% by weight, and preferably from about 5% to about 8% by weight, based upon the total weight of solids in the photosensitive composition taken as 100% by weight.
[0046] The solvent system utilized in the photosensitive composition should have a boiling point of from about 120° C. to about 200° C., and preferably from about 130° C. to about 180° C. The solvent system should be utilized at a level of from about 70% to about 95% by weight, and preferably from about 80% to about 90% by weight, based upon the total weight of the photosensitive composition taken as 100% by weight. Preferred solvent systems include a solvent selected from the group consisting of methyl isoamyl ketone, di(ethylene glycol) dimethyl ether, propylene glycol monomethyl ether acetate, ethyl lactate, cyclohexanone, and mixtures thereof.
Application Process
[0047] Preferred substrates for use in this process include those comprising silicon. Some particularly preferred substrates are selected from the group consisting of Si substrates, SiO 2 substrates, Si 3 N 4 substrates, SiO2 on silicon substrates, Si 3 N 4 on silicon substrates, glass substrates, quartz substrates, ceramic substrates, semiconductor substrates, and metal substrates.
[0048] The silane and any other components are dissolved in the primer solvent system to form the silane composition. This composition is then spin-applied onto the substrate at about 500-5,000 rpm, and preferably from about 1000-3,000 rpm, for about 30-90 seconds, and preferably for about 60 seconds. It is then baked at a temperature of from about 60-110° C. for about 60-180 seconds (preferably about 120 seconds), and then at about 150-250° C. for about 60-180 seconds (preferably about 120 seconds) in order to condense the silane molecules into a continuous film that is bonded to surface hydroxyl groups present on typical microelectronic substrates. That is, the hydrolyzed silane reacts with the silanol groups present in the silicon-containing substrate and also self-crosslinks by condensation. It is preferred that the primer layer have an average thickness (as measured by an ellipsometer over 5 different points) of less than about 50 nm and more preferably from about 20 nm to about 30 nm.
[0049] For the photosensitive layer, the polymer, PAG, and any other components are dissolved in the solvent system and spin coated onto the substrate at about 1,000-5,000 rpm, and preferably from about 1,000-2,000 rpm, for about 30-90 seconds, and preferably about 60 seconds. It is then baked at a temperature of from about 100-120° C. for about 60-180 seconds (preferably about 120 seconds). The polymer solids level and spinning conditions are typically adjusted to achieve an average coating thickness after baking (as measured by an ellipsometer over 5 different points) of from about 500 nm to about 3,000 nm, and preferably from about 1,000 nm to about 2,000 nm, depending upon the degree of coverage required over device topography on the substrate. Advantageously, the epoxy or other reactive group in the photosensitive layer polymer form covalent bonds with an amine or other reactive group on the silane of the primer layer.
[0050] The photosensitive layer is then imaged by exposing it to UV light with a wavelength of from about 150-500 nm (e.g., about 248 nm or about 365 nm), preferably in a dose of about 500 mJ/cm 2 . The coating is then preferably post-exposure baked at about 110° C. to about 30° C. for about 2 minutes, and developed with a solvent for about 1 minute. Finally, the coating is baked at about 200° C. to about 250° C. for about 5 minutes.
[0051] Exposure to light causes the PAG to generate an acid, and this acid initiates crosslinking of the polymer (preferably via the epoxy groups) in the photosensitive layer. The crossliniked epoxy groups will have the structure
[0052] The exposed areas become substantially insoluble (e.g., less than about 1% by weight soluble, preferably less than about 0.05% soluble, and more preferably about 0% soluble) in typical solvent developers such as propylene glycol monomethyl ether acetate, methyl isoamyl ketone, and ethyl acetoacetate. The unexposed areas remain soluble in these developers and are thus readily removed during developing. As a result, the pattern can be easily transferred with no additional etching steps to remove the protective layer being needed.
[0053] Practicing the present invention will result in a protective layer system that suffers little or no undercutting during etching processes. That is, the layer systems will exhibit less than about 100 μm, preferably less than about 70 μm, and more preferably less than about 50 μm of undercutting when subjected for about 2 hours (or even about 3 hours) to etching in an approximately 30-35% by weight aqueous KOH solution having a temperature of about 83-87° C. Undercutting is determined by measuring the width of overhanging protective layer at the edge of etched areas as observed under a confocal microscope. 5 Furthermore, the inventive protective systems will experience very little or no etchant penetration during etching processes. Thus, when subjected for about 2 hours (or even about 3 hours) to etching in an approximately 30-35% by weight aqueous KOH solution having a temperature of about 83-87 ° C., the inventive protective systems will have less than about 0.1 pinholes per cm 2 of substrate, and preferably less than about 0.05 pinholes per cm 2 of substrate, when observed under a microscope at 10× magnification. This is different from prior art photosensitive layers, which would dissolve relatively quickly in KOH and thus required the presence of a separate protective layer such as a silicon nitride layer.
EXAMPLES
[0054] The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
Example 1
[0000] 1. Terpolymer Synthesis in Cyclopentanone
[0055] A solution was made by dissolving 67.50 g of styrene, 25.00 g of acrylonitrile, 7.50 g of glycidyl methacrylate, and 1.25 g of 2,2′-azobisisobutyronitrile in 400 g of cyclopentanone, all of which were obtained from Aldrich. The solution was heated to 65° C. under nitrogen while undergoing magnetic stirring. The polymerization was allowed to proceed at 65° C. for 98 hours. The actual yield was determined by solids analysis to be 97% of the theoretical yield.
[0000] 2. Topcoat Solution Formulation
[0056] In this preparation procedure, 25.01 g of propylene glycol methyl ether acetate (PGMEA, General Chemical) and 1.03 g of UVI-6976 (a triarylsulfonium hexafluoroantimonate; a photoacid generator obtained from Dow Chemical) were added to 50.03 g of the terpolymer solution synthesized in Part 1 of this Example. The resulting solution was filtered through a 0.1-μm membrane filter.
[0000] 3. Primer Solution Formulation
[0057] To make a primer solution, 1.02 g of N-phenylaminopropyltrimethoxysilane (obtained from Gelest) were dissolved in a mixture of 120.4 g of propylene glycol propyl ether (obtained from General Chemical) and 80.2 g of deionized water. The solution was filtered through a 0.1-μm membrane filter.
[0000] 4. Preparation and Patterning of Negative Photoresist Coating
[0058] The primer solution in Part 3 of this Example was spin coated onto a silicon wafer at 1,500 rpm for 1 minute. The primer coating was baked at 75° C. for 2 minutes and then at 180° C. for 2 minutes. The topcoat solution of Part 2 of this Example was then spin coated over the primer layer at 1,500 rpm for 1 minute. The topcoat was baked at 100° C. for 2 minutes. The coating was imaged by exposing it to UV light at 2)0 a wavelength of 365 nm in a dose of 500 mJ/cm 2 , baking at 130° C. for 2 minutes, and developing with acetone for 1 minute. Finally, the combination was baked at 230° C. for 5 minutes. A negative pattern was obtained.
[0000] 5. Etching of Silicon Wafer
[0059] The wafer prepared and patterned in Part 4 of this Example was etched in 30% KOH aqueous solution at 85° C. for 1 hour. The silicon was etched 70 μm deep in areas without the polymer coating. The polymer-coated areas remained intact. The pattern was transferred to the silicon wafer in essentially the same manner as is the case with prior art silicon nitride masking methods.
Example 2
[0000] 1. Terpolymer Synthesis in PGMEA
[0060] A solution was made by dissolving 27.07 g of styrene, 10.00 g of acrylonitrile, 3.08 g of glycidyl methacrylate, and 0.51 g of dicumyl peroxide (obtained from Aldrich) in 160 g of PGMEA. The solution was heated to 120° C. under nitrogen while undergoing magnetic stirring. The polymerization was allowed to proceed at 120° C. for 24 hours. The actual yield was determined by solids analysis to be 95.5% of the theoretical yield.
[0000] 2. Topcoat Solution Formulation
[0061] In this preparation procedure, 4.54 g of PGMEA and 0.114 g of UVI-6976 were added to 5.03 g of the terpolymer solution synthesized in Part 1 of this Example. The solution was filtered through a 0.1 μm membrane filter.
[0000] 3. Preparation and Patterning of Negative Photoresist Coating
[0062] The primer solution of Part 2 of Example 1 was spin coated onto a silicon wafer at 1,500 rpm for 1 minute. The primer coating was baked at 60° C. for 5 minutes and at 180° C. for 2 minutes. The topcoat solution from Part 2 of this Example was then spin coated onto the wafer at 1,500 rpm for 1 minute. The topcoat was baked at 100° C. for 2 minutes. After the coating was imaged by exposing it to UV light at 254 nm in a dose of 500 mJ/cm 2 , it was baked at 130° C. for 2 minutes and then developed with PGMEA for 1 minute. The coating was finally baked at 230 ° C. for 5 minutes. A negative pattern was obtained.
[0000] 4. Etching of Silicon Wafer
[0063] The wafer prepared and patterned in Part 3 of this Example was etched in 30% KOH aqueous solution at 80° C. for 1 hour. The silicon was etched 58 μm deep in the areas without the polymer coating. The polymer-coated areas remained intact The pattern was transferred to the silicon wafer in essentially the same way as with prior art silicon nitride masking methods.
Example 3
[0000] 1. Terpolymer Synthesis in PGMEA
[0064] A solution was made by dissolving 168.0 g of styrene, 84.0 g of acrylonitrile, 28.3 g of glycidyl methacrylate, and 7.0 g of dicumyl peroxide in 1,120 g of PGMEA. The solution was heated to 120° C. under nitrogen while undergoing magnetic stirring. The polymerization was allowed to proceed at 120° C. for 28 hours. The actual yield was found by solid analysis to be 97.5% of the theoretical. The terpolymer was precipitated in isopropanol, filtered, and dried overnight under vacuum at 50° C.
[0000] 2. Topcoat Solution Formulation
[0065] In this preparation procedure, 32.8 g of the terpolymer synthesized in Part 1 of this Example were dissolved in 140.0 g of PGMEA and 40.0 g of ethyl acetylacetate. Next, 6.0 g of UVI-6976 were added, and the solution was filtered through a 0.1-μm membrane filter.
[0000] 3. Primer Solution Formulation
[0066] To prepare a primer solution, 2,04 g of N-phenylaminopropyltrimethoxysilane were dissolved in a mixture of 77.50 g of propylene glycol propyl ether (PnP), 120.14 g of deionized water, 0.51 g of acetic acid, and 0.03 g of FC4430 (a surfactant). The solution was stirred magnetically for more than 2 hours. It was filtered through a 0.1-μm membrane filter.
[0000] 4. Preparation and Patterning of Negative Photoresist Coating
[0067] The primer solution prepared in Part 3 of this Example was spin coated onto a silicon wafer at 1,500 rpm for 1 minute. The primer coating was baked at 100° C. for 1 minute and then at 205 ° C. for 1 minute. The topcoat solution from Part 2 of this Example was spin coated over the primer layer at 1,500 rpm for I minute. The topcoat was baked at 110° C. for 2 minutes. The coating was imaged by exposing it to UV light at a wavelength of 365 nm in a dose of 500 mJ/cm 2 , baking at 130 ° C. for 2 minutes, and developing with PGMEA for 1 minute. Finally, the combination was baked at 230° C. for 5 minutes. A negative pattern was obtained.
[0000] 5. Etching of Silicon Wafer
[0068] The wafer prepared and patterned in Part 4 of this Example was etched in 30% KOH aqueous solution at 75° C. for 4 hours. The silicon was etched 178 μm deep in the areas without the polymer coating. The polymer-coated area remained intact. The pattern was transferred to the silicon wafer in essentially the same manner as prior art silicon nitride masking methods.
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New photoresists for use during the production of semiconductor and MEMS devices are provided. The primer layer preferably comprises a silane dissolved or dispersed in a solvent system. The photoresist layer includes copolymers prepared from styrene, acrylonitrile, and epoxy-containing monomers. The photoresist layer comprises a photoacid generator, and is preferably negative-acting.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention generally pertains to electronic power conversion circuits, and, more specifically, to high frequency, switched mode electronic power converters. The subject matter relates to new adaptive timing circuits that achieve optimal switch turn on timing for switches in high efficiency zero voltage switching power converters.
2. Description of Related Art
Zero voltage switching (ZVS) power converters have been demonstrated to provide significant efficiency advantages over conventional hard switching power converters, particularly for off line power supplies. The ZVS power converters eliminate drain circuit switching losses and some of the gate circuit switching losses, they eliminate rectifier reverse recovery effects, and, when the die sizes of the switches are optimized for minimum power loss they also achieve significant reductions in channel conduction losses.
In order to achieve the maximum benefit of zero voltage switching it is important to optimally time the zero voltage turn on transition. The problem is illustrated in FIG. 1 . The nature of the drain source voltage transition is dependent on the drain circuit current and the available stored drain circuit energy at the beginning of the transition, as illustrated in FIG. 1 . The nature of the drain source voltage transition is also dependent on the amount of voltage swing. Ideally there would always be sufficient drain circuit energy to drive the drain source voltage to zero volts and the switch would be enabled at the instant that the drain source voltage reaches zero volts. In practice, the time needed to complete the transition to zero volts varies greatly and, in some cases, there may be insufficient energy available in the drain circuit to drive the drain source voltage to zero volts. For a transition in which the drain source voltage is driven to zero volts we want to enable the switch at the instant that the drain source voltage reaches zero. If the switch is turned on after the drain source voltage reaches zero volts then there will be a period of time in which the body diode of the switch conducts and there is also the possibility that the drain circuit current will reverse and increase the drain source voltage above zero before the switch is turned on. If the body diode is allowed to conduct then there will be additional forward voltage conduction losses associated with body diode conduction, as well as reverse recovery effects which will keep the body diode in a low impedance state for a time whether or not the body diode is reverse biased. Many ZVS circuits use a fixed delay time for turn on timing of the main switch. If the fixed delay time is optimal for the condition in which there is ample sufficient energy to drive the transition to zero volts then for the condition in which there is only adequate energy to drive the transition to zero volts the turn on timing may be premature and result in considerable turn on switching losses, as illustrated in FIG. 1 . We can solve the problem by using a circuit that detects the drain source voltage and turns on the switch when its drain source voltage reaches zero volts. An example of a circuit that accomplishes optimal turn on timing for the case in which there is sufficient energy to drive the drain source voltage to zero volts is illustrated in FIG. 2 and is the subject of U.S. Pat. No. 6,580,255. The FIG. 2 circuit relies on a drain connected diode to pull the gate of a P channel mosfet low in order to enable the gate of a N channel power mosfet switch as its drain source voltage reaches zero volts.
For the case in which there is insufficient energy to drive the drain source voltage to zero the adaptive timing circuit illustrated in FIG. 2 is inadequate by itself. If the drain diode in FIG. 2 is not forward biased because the drain source voltage does not reach zero then the switch will not turn on. If a mechanism is employed that results in a maximum delay time before the switch turns on then, if the maximum delay time is equal to the time that it takes for the drain source voltage to reach its minimum, then large switching losses can be avoided, however, the time that it will take for the drain to reach a minimum is highly variable and depends on both the amount of drain circuit energy available and the off state voltage of the switch. U.S. Pat. No. 6,580,255 also reveals a circuit that can sense the minimum drain voltage and enable the switch at its minimum voltage. This circuit together with the FIG. 2 circuit is illustrated in FIG. 3 . The operation of the FIG. 3 circuit is illustrated in FIG. 4 where the main switch is turned on optimally for both the sufficient energy condition and the insufficient energy condition. For the insufficient energy condition the drain connected capacitor C INSUF forward biases the base emitter junction of a NPN bipolar transistor Q INSUF when the drain source voltage reaches a minimum and begins to reverse direction. When Q INSUF turns on then the gate of a P channel mosfet M INSUF is enabled which allows charge to flow to the gate of the power mosfet main switch before its drain source voltage can rise up significantly, thereby minimizing turn on transition switching losses in M MAIN . Most of the components of the FIG. 3 circuit can be accomplished with a low voltage application specific integrated circuit (ASIC) with the exception of the drain diode, indicated as D DRAIN in FIG. 2 and the capacitor C INSUF , illustrated in FIG. 3 . It would be beneficial to reduce the number of or eliminate the components that cannot be implemented in a low voltage ASIC.
OBJECTS AND ADVANTAGES
An object of the subject invention is to reveal new adaptive gate drive timing circuits that can provide optimal turn on timing for the initial condition in which there is sufficient energy to drive the transition to zero volts and for the initial condition in which there is insufficient energy to drive the turn on transition to zero volts that do not rely on a high voltage rectifier.
Another object of the subject invention is to reveal new adaptive gate drive timing circuits that can provide optimal turn on timing for the initial condition in which there is sufficient energy to drive the transition to zero volts and for the initial condition in which there is insufficient energy to drive the turn on transition to zero volts that can be accomplished with a low voltage ASIC without the use of any high voltage components.
Further objects and advantages of my invention will become apparent from a consideration of the drawings and ensuing description.
These and other objects of the invention are provided by novel circuit techniques that rely on the sensing of a capacitor discharge current and the sensing of the absence of capacitor discharge current to initiate the turn on transition of a main switch in a zero voltage switching power conversion circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by reference to the drawings.
FIG. 1 illustrates turn on transition drain source voltage wave forms for a variety of common initial conditions.
FIG. 2 illustrates an adaptive gate drive timing circuit that achieves optimal turn on timing for the energy sufficient initial condition relying on a high voltage rectifier according to the prior art.
FIG. 3 illustrates an adaptive gate drive timing circuit that achieves optimal turn on timing for both the energy sufficient initial condition and the energy insufficient initial condition relying on a high voltage rectifier and a high voltage capacitor according to the prior art.
FIG. 4 illustrates turn on transition drain source voltage wave forms with optimal timing for both the energy sufficient and the energy insufficient initial conditions for a variety of common initial conditions.
FIG. 5 illustrates an adaptive gate drive timing circuit which achieves optimal gate drive timing for both the energy sufficient initial condition and the energy insufficient initial condition without relying on a high voltage rectifier according to the subject invention.
FIG. 6 illustrates an example of a discharge current detector circuit that is responsive to the discharge current in a drain connected capacitor according to the subject invention.
FIG. 7 illustrates a digital logic and driver circuit that is responsive to the sequence of output states of the discharge current detector circuit of FIG. 6 according to the subject invention.
FIG. 8 illustrates an adaptive gate drive timing circuit that is responsive to the discharge current of an intrinsic gate drain capacitor of a mosfet to accomplish optimal timing without the use of high voltage components according to the subject invention.
FIG. 9 illustrates the relationship between gate drain capacitance and drain source voltage and the relationship between gate source capacitance and drain source voltage for a typical mosfet.
SUMMARY
The subject invention reveals new adaptive gate drive timing circuits for achieving optimal switch timing in zero voltage switching power converters for both the energy sufficient initial condition and the energy insufficient initial condition without the use of a high voltage rectifier. The subject invention also reveals a new adaptive gate drive timing circuit that achieves optimal switch timing without the use of any high voltage components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 illustrates an adaptive gate drive timing circuit that provides optimal gate drive timing for a mosfet M POWER in a zero voltage switching power converter according to the subject invention. In FIG. 5 a first terminal of a capacitor C DRAIN is connected to a drain terminal of the mosfet M POWER and a second terminal of C DRAIN is connected to an input terminal of a discharge current detector circuit. An output terminal of the discharge current detector circuit is connected to a terminal PR* of a flip flop 1 and to a first input of a three input NAND gate. A pulse width modulated (PWM) control signal is connected to a CLR* terminal of flip flop 1 , a CLR* terminal of a flip flop 2 , and to a second input of the three input NAND gate. A Q output of flip flop 1 is connected to a third input of the three input NAND gate. An output of the three input NAND gate is connected to the PR* input of flip flop 2 . A Q output of flip flop 2 is connected to an input terminal of a driver. An output of the driver is coupled to a gate terminal of the mosfet M POWER .
A discharge current detector circuit with the C DRAIN capacitor is illustrated in FIG. 6 . The second terminal of C DRAIN is connected to a first terminal of a resistor R 3 , a first terminal of a resistor R 4 , and a first terminal of a resistor R 5 . A second terminal of resistor R 5 is connected to a non-inverting input of a comparator U 1 . A second terminal of resistor R 3 is connected to an inverting input of comparator U 1 , to a first terminal of resistor R 1 , a first terminal of a capacitor C BIAS , and to a first terminal of a resistor R 2 . A second terminal of resistor R 4 is connected to a positive supply voltage rail, to a second terminal of resistor R 1 , and to a positive supply terminal of U 1 . An output terminal of U 1 , labeled UP/DOWN*, serves as the output terminal of the discharge current detector. A second terminal of C BIAS is connected to a second terminal of R 2 , to a negative supply voltage rail, and to a negative supply terminal of U 1 .
In operation a turn on transition is initiated when a PWM control signal, used for regulating a current or a voltage at an input or output of a power supply, transitions to a logic high state. Prior to the beginning of the turn on transition the PWM control signal is in a logic low state, which forces the Q outputs of flip flop 1 and flip flop 2 to be in logic low states and the Q* outputs of flip flop 1 and flip flop 2 to be in logic high states. A low PWM control signal also forces the output of the NAND gate to be in a logic high state. The output of the discharge current detector circuit is high when there is no discharge current, which is the typical case at the instant that the PWM control signal transitions to the high state initiating the turn on transition. The discharge current detector circuit is biased such that, even if there is a small discharge current, the output of the discharge current detector will be high. Soon after the PWM control signal goes high the drain terminal voltage of M POWER begins to fall, which forces the output of the discharge current detector circuit to a logic low state. The output of the NAND gate remains high since the output signal of the discharge current detector is in a logic low state. A logic low state at the PR* input of flip flop 1 forces the Q output of flip flop 1 to a logic high state. When the drain voltage of M POWER has reached a point where it is no longer falling, or falling only very slowly, then the output of the discharge current detector transitions from low to high and the output of the NAND gate transitions from high to low. The logic low output of the NAND gate forces the Q output of flip flop 2 to a high state and causes the driver to enable the gate of M POWER . Whether the cause of the change in output state of the discharge current detector results from the drain source voltage of M POWER reaching zero volts or from the drain source voltage of M POWER reaching a minimum voltage is inconsequential and has the same effect, which is the desired effect of turning on the mosfet M POWER at the optimal instant. When the gate of M POWER is enabled the drain of M POWER begins to fall again, if the drain source voltage has not yet reached zero volts. When the drain source voltage begins to fall again the output of the discharge current detector changes from a logic high state to a logic low state, forcing the output of the NAND gate high. A logic high signal at the PR* input of flip flop 2 has no effect on its outputs, so the turn on transition of M POWER proceeds without interruption or delay. At the end of the on state of the power supply of which M POWER is a part the PWM control signal is driven to a logic low state clearing both flip flops so that the Q output of flip flop 2 transitions to a logic low state and the driver drives the gate of M POWER low initiating a turn off transition. The logic low PWM input to the NAND gate and the logic low input to the NAND gate from flip flop 1 force the NAND gate output to be logic high while the PWM control signal is low so that the Q output of flip flop 2 must remain low as long as the PWM control signal is low, regardless of the output of the discharge current detector circuit.
When the drain voltage is falling rapidly the capacitor C DRAIN is discharging and the non-inverting input to the comparator U 1 in FIG. 6 is driven low through R 5 . R 5 serves to limit the current at the non-inverting input to U 1 which will typically have intrinsic input protection diodes so that its inputs cannot be driven beyond the supply rails. A comparator without intrinsic input protection diodes is unsuitable for this application. While the drain voltage is falling the output of U 1 is low. When the drain voltage is invariant the non-inverting input of U 1 is biased slightly higher than the inverting input of U 1 so that the U 1 output is in a logic high state. C DRAIN is typically a very small value capacitor, a picofarad or a few picofarads is sufficient for most off line applications, but for lower voltage applications 10 picofarads or a few tens of picofarads may be more suitable. R 1 and R 2 can be set so that the voltage at the inverting input to U 1 is near to the mid point of the supply voltage range. C BIAS should be sufficiently large that the inverting input voltage is not driven to the supply rails through R 3 while C DRAIN is charging or discharging. R 4 and R 3 bias the non-inverting input to U 1 slightly higher than the inverting input to U 1 so that the output to U 1 will be high if there is either no discharge current or small discharge current. Typically R 4 would be larger than R 3 . If C BIAS is sufficiently large and R 3 sufficiently small the maximum charge and discharge currents may be insufficient to drive the non-inverting input of U 1 to a supply rail and the value of R 5 can be reduced to zero. The value of the components C DRAIN , C BIAS , R 3 , R 4 , and R 5 have an effect on the response time of the circuit. Minimal values for all provides the fastest response, but may be incompatible with other design goals such as low power consumption and U 1 input circuit protection.
Another embodiment of the subject invention is illustrated in FIG. 7 . The FIG. 7 embodiment adds an OR gate U 5 and a delay network which includes a capacitor C DELAY , a resistor R DELAY , and a diode D DELAY to the FIG. 5 adaptive gate drive timing circuit. The addition of the delay network and the OR gate effectively places a maximum delay time on the turn on transition from the time that the PWM control signal transitions to the high state until the gate of M POWER is enabled. The establishment of a maximum delay time provides a start up mechanism for the power supply circuit when there is zero initial drain circuit energy. The resistor R DELAY and capacitor C DELAY set the maximum delay time and the diode D DELAY provides a means to avoid any delay in the turn off transition for M POWER .
Another embodiment of the subject invention is illustrated in FIG. 8 . The FIG. 8 embodiment relies on the intrinsic gate drain capacitance of the mosfet M POWER to provide a discharge current that can be sensed to provide optimal gate drive timing. In the FIG. 8 circuit the intrinsic gate drain capacitance of the mosfet is the drain connected capacitor for discharge current sensing. In the FIG. 8 circuit the gate of the mosfet must be sensed in order to sense the discharge current of the gate drain capacitance. This arrangement has the advantage that no discrete high voltage capacitor is required and no other high voltage components are required to accomplish optimal gate drive timing. It also has the advantage of a relatively large value drain connected capacitance, since the intrinsic gate drain capacitance is effectively much larger than a few picofarads. The disadvantage of this arrangement is that there is also a gate source capacitance connected at the gate terminal of M POWER and the gate terminal of M POWER is the terminal of M POWER that must be controlled, so that we are attempting to control and drive the same terminal that we are sensing. In the FIG. 8 circuit the gate terminal is sensed prior to the time that it is driven and controlled. The effect of the additional capacitance connected at the gate terminal is to absorb some of the charge of the gate drain capacitance as it discharges. Both the gate drain capacitance and gate source capacitance are non-linear and dependent on drain source voltage, but the gate drain capacitance is highly dependent on drain source voltage over the entire range of drain source voltage and the gate source capacitance is only highly dependent on drain source voltage in the region near zero volts, as illustrated in FIG. 9 . In the FIG. 8 circuit the discharge current of the intrinsic gate drain capacitance C GD is sensed initially through C SLOPE in the manner described above for the FIG. 6 discharge current detector. The discharge current in C GD drives the gate voltage of M POWER low which is sensed by the comparator U 1 through C SLOPE . As the gate of M POWER is driven lower in voltage by the discharge current of C GD the base emitter junction of NPN bipolar transistor Q N becomes forward biased. When Q N becomes forward biased it provides the signal indicating the presence of the discharge current at the output of comparator U 1 . Shortly thereafter the open collector output of U 1 enters its high impedance state. When the discharge current of C GD ceases the current in Q N ceases and the collector voltage of Q N transitions to a logic high state triggering a logic high input to the driver which enables the gate of M POWER through rectifiers D 1 and D 2 . The PNP bipolar transistor exists to speed up the turn off transition of M POWER but plays no role in discharge current sensing. Also, components C COUPLE , Z 1 , D 3 , R 7 , and R 8 play no role in discharge current sensing, but these components play a role in setting the voltage range of the gate to provide full enhancement and a high speed turn off transition for low turn off transition switching losses. The FIG. 8 circuit relies on the sequencing logic illustrated in FIG. 5 and FIG. 7 , but the sequencing circuit is not illustrated in FIG. 8 . The FIG. 8 circuit provides optimal turn on timing under all initial conditions without using high voltage circuit elements.
CONCLUSION, RAMIFICATIONS, AND SCOPE OF INVENTION
Thus the reader will see that an adaptive gate drive timing circuit that relies on detection of a discharge current in a drain connected capacitance can provide optimal switch turn on timing for a zero voltage switching power converter for both energy sufficient and energy insufficient initial conditions, thereby obviating a high voltage rectifier and enabling the use of a low voltage ASIC for optimal switch turn on timing with no high voltage components.
While my above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather, as exemplifications or preferred embodiments thereof. Many other variations are possible. For example, circuits similar to the circuits shown but with polarity of the input or output reversed or the polarity of switches reversed from that illustrated in the figures shall be considered embodiments of the subject invention. Also, other discharge current detection circuits are possible, including circuits that sense a voltage difference at the terminals of a current sensing resistor placed to conduct all or some of the discharge current and other sequencing circuits are possible using different sets of logic circuit elements. Also the illustrations apply the new technique to a N channel power mosfet, but the technique applies equally to P channel power mosfets, to JFETs, and to IGBTs and bipolar transistors, which should be considered embodiments of the subject invention. Also, my description is illustrated using a PWM control signal, but other forms of modulation are possible to establish the timing necessary for turn on and turn off of the controlled switch and these other modulation forms should be considered embodiments of this invention. Also, the examples provided illustrate the application of the novel adaptive gate drive timing circuit to a ZVS main switch in a power supply, but the adaptive gate drive timing circuit can also be used to drive and optimally time a turn on transition for a synchronous rectifier and that application should be considered an embodiment of the subject invention.
Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
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The subject invention reveals new adaptive gate drive timing circuits that are optimal for both sufficient energy and insufficient energy conditions for optimal turn on transition timing of a power mosfet in a zero voltage switching power supply. The circuit does not rely on a rectifier connected to the drain of the power mosfet to detect the zero voltage condition of the mosfet. The circuit relies on the detection of a discharge current in a capacitance connected to the drain of the power mosfet. Turn on of the mosfet is held off while discharge current exists and the gate of the mosfet is enabled at the instant that the discharge current drops to zero. In one embodiment of the invention discharge current of the intrinsic gate drain capacitance of the mosfet is relied upon as the source of timing information.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of pending U.S. application Ser. No. 11/277,304 entitled “Method and Apparatus to Complete a Well Having Tubing Inserted Through a Valve” filed Mar. 23, 2006, which is a divisional application of U.S. application Ser. No. 10/708,338 entitled “Method and Apparatus to Complete a Well Having Tubing Inserted Through a Valve” filed Feb. 25, 2004 now U.S. Pat. No. 7,082,996 issued on Aug. 1, 2006, which claims the benefit of U.S. Provisional Application Ser. No. 60/319,972 filed Feb. 25, 2003 entitled Method and Apparatus to Complete a Well Having Tubing Inserted Through a Valve. Each of the above referenced applications is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for maintaining a capillary tube or a small diameter continuous hydraulic conduit in a well bore to inject fluids into or produce fluids from a well; specifically, the method and apparatus for inserting a capillary tube through a well head and production tubing past the wellhead master valves and/or a down hole safety valve and selectively removing the capillary tube if the valve must be closed and reinserting the tube when the valve is re-opened
2. Description of the Related Art
In the drilling and completion of oil and gas wells throughout the world, the need to insert small diameter continuous hydraulic conduits or tubes into the well's production tubing has arisen on numerous occasions and for a variety of purposes. Typically, this was accomplished by lowering the continuous hydraulic conduit through the well head, it's master valves, and then down through the production tubing, through any sub-surface safety valves and on down into the well bore from a surface spool system. Substantial cost savings result from the ability to quickly move onto a wellhead site and dispose a small diameter conduit down the well bore without the need of workover rigs or large coiled tubing injector head assemblies. Previously, when the treatment or task was completed, the tubing was withdrawn from the well bore, since it was imprudent to leave a conduit or tube suspended through a safety valve or well head master valve. Very often, it is beneficial to leave the small diameter tubing in the well bore, for example, to chemically treat the well below the safety valve or well head master valves; as, for example, by extending the tube on down the well bore to the production zone. Since these tubes extend past both the well head valves and one or more downhole safety valves, if the well pressures must be controlled, the small diameter continuous hydraulic conduit must be capable of being withdrawn from the well bore before the wellhead valve or the downhole safety valve is closed.
The ability to selectively or automatically move the small diameter continuous hydraulic conduit into and out of a well valve without completely removing the conduit from the well has heretofore not been accomplished.
BRIEF SUMMARY OF THE INVENTION
The present invention discloses a system for manipulating a continuous hydraulic conduit in a producing well. The system is made up of an extraction device providing a longitudinal passage and a piston moveable in said longitudinal passage attached to a first continuous hydraulic conduit. Attached to the end of the first continuous hydraulic conduit is a stinger providing a profile on its outer lateral surface to engage a tubing hanger assembly. When setting the tubing hanger, a setting stinger is used to move the hanger to the desired position, then pressure on the continuous tubing is released, which thereby releases the tubing hanger to set in the lateral surface of the tubular member. The setting stinger is then removed and the production stinger is inserted into the polished bore of the tubing hanger thereby providing continuous hydraulic communication to the tubing hung below in the tubing hanger.
The system is connected to a hydraulic control system for delivery of hydraulic pressure to a well valve and to the extraction device with hydraulic attachment fittings, so that the hydraulic pressure on the well valve and on the piston may be controlled to selectively move the piston down when inserting the stinger in the tubing hanger and selectively move the piston up when removing the conduit out of the hanger and past the closing well valve. A tubing hanger assembly for insertion below a well valve provides a polished bore through its longitudinal axis, and is attachable to the well bore and provides attachment to a second continuous hydraulic conduit which can be suspended from the hanger to the production zone of the well. The system can provide a check valve at the end of the conduit to prevent ingress of well fluids into the hydraulic conduit. The system can also be deployed without a check valve to produce fluids up the continuous hydraulic conduit formed by the insertion of the sealing section into the polished bore below the valve. A second conduit hangs from the tubing hanger located adjacent and below the well valve which must be able to close, to the production zone so that the treatments introduced into the well can be introduced where such treatments are most efficacious or, alternatively, to allow the production of fluids up the well.
The tubing hanger provides a landing tool having an enlarged upper throat to facilitate the guidance of the sealing stinger into the polished bore, which allows well fluids to flow up the well bore past the tubing hanger and a longitudinally spaced polished bore for accepting the setting stinger connected to the distal end of the first continuous hydraulic conduit; said stinger providing at least one hydraulic port communicating from its interior to its lateral exterior face, further providing a groove to activate a latching piston and providing dynamic seals for sealingly engaging the interior surface of the polished bore of the tubing hanger. The first hydraulic port on the interior surface of the landing tool communicates with the continuous hydraulic conduit selectively activating a latching piston, which engages a lateral surface on the slick stinger. This permits the first hydraulic conduit to act as a setting line when pressure is introduced through the conduit to hold the latch in engagement with the tubing hanger. A second hydraulic port on the interior surface of the landing tool communicates with the continuous hydraulic conduit for engaging a plurality of slips which are held out of engagement from the inner surface of the well tubing or casing until pressure is released or lowered in the latched tubing hanger assembly from the control panel at the surface. This lower pressure permits the springs that hold the slips from engagement to overcome the hydraulic pressure from the continuous conduit and move into engagement. As the slips engage the inner surface of the tubing or casing, the weight of the second continuous hydraulic conduit sets the teeth on the outer surface of the slips to bite the casing or tubing.
A tubing hanger supports a second length of continuous hydraulic conduit in a well bore to allow continuous fluid communication from the surface through the distal end of the first continuous hydraulic conduit to the distal end of said second continuous hydraulic conduit as previously described.
A production stinger is inserted in the polished bore of the tubing hanger which thereby allows fluid communication from the well head through the first hydraulic conduit into the second hydraulic conduit to the production zone. As previously noted, when pressure drops on a safety valve, the extraction device removes the first hydraulic conduit past the safety valve allowing it to close to seal the well off. In an alternative embodiment, the stinger on the production stinger is fabricated from a frangible material to break if the stinger is not removed before the safety valve is closed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic view of the hydraulic control panel and extraction device of the present invention with the hydraulic lines disposed on a wellhead.
FIG. 2 is a schematic side view of a tubing hanger with the slick stinger inserted in a polished bore therethrough.
FIG. 3 is a schematic side view of the tubing hanger of FIG. 2 depicting the slick stinger withdrawn from the polished bore.
FIG. 4 is a schematic view of an extraction device and slick stinger in the inserted position.
FIG. 5 is a schematic view of the extraction device and slick stinger in the withdrawn position.
FIG. 6 is a schematic view of the extraction device mounted on a wellhead with a knock off connector in the inserted position.
FIG. 7 is a schematic view of the extraction device mounted on a wellhead with a knock off connector in the withdrawn position.
FIG. 8A is a cross-sectional side view of the tubing hanger including six cross-sectional end views of the hanger with the setting stinger engaged under pressure.
FIG. 8B is a cross-sectional view of the tubing hanger including six cross-sectional end views of the hanger with the hydraulic pressure released engaging the tool.
FIG. 8C is a cross-sectional view of the tubing hanger including six cross-sectional end views of the hanger released from the setting stinger.
FIG. 8D is a cross-sectional view of the tubing hanger including six cross-sectional end views of the hanger connected to the setting stinger with pressure applied to set the secondary slips.
FIG. 9 is a schematic cross-sectional view of an alternative embodiment of a side-entry spool for wellhead insertion of a small diameter hydraulic conduit into a well.
FIG. 10 is a cross-sectional view drawing of a tubing hanger assembly having an integral extraction device in accordance with an alternative embodiment of the present invention.
FIG. 11 is a close-up cross sectional drawing of the tubing hanger assembly of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 discloses the surface portion of the present invention. A wellhead WH is set over a producing well. Wellhead WH provides a number of valves permitting fluid communication with various tubulars hung in the well bore. When a well is completed, the operator or driller will frequently insert a down hole valve (or safety valve) and a hydraulic control tube extending down the well parallel to the production tubing with the hydraulic tube located on the outside diameter of the production tubing which may be actuated by the release of hydraulic pressure to close off flow through the valve. These control valves are normally held open with hydraulic pressure and the release of pressure causes them to close. Additionally, the valves (by way of example only, at 30 ) at the well head WH can be hydraulically actuated automatically to shut off a well that experiences a leak in the hydraulic control line that controls the valve or any catastrophic failure of the well, for example the platform is destroyed by fire, explosion, hurricane, or a ship hits it, then the down hole valves will close as the surface destruction of the platform and/or well head will cause the pressure in the control system to leak pressure. Various hydraulic control systems can be used to control the actuation of these hydraulically actuated valves. Control panel 10 is a schematic of any number of control panels that open and close hydraulic pressure. Hydraulic line 12 can be connected to either a wellhead valve or to a downhole safety valve as required in a manner well known to those skilled in the art. Hydraulic line 14 is connected to the hydraulic port of the extraction device 20 which is connected to the top of the well head WH by knock off connector 23 . Control panel 10 can selectively and automatically activate, in a staged manner, pressure through line 14 to move a piston in extraction device 20 to engage or disengage a continuous hydraulic conduit from a polished bore and thereby removing the hydraulic line past a well valve which may then be closed as a result of activation of the control panel 10 by any leak in the hydraulic system of the safety valve.
FIG. 2 is a schematic view of the tubing hanger providing the means for inserting the distal end of the hydraulic conduit from the surface into a polished bore which mates and seals the conduit to a second hydraulic conduit which is set by the tubing hanger in the well. Since the tubing hanger 80 is adjacent and below safety valve 40 , in order for safety valve 40 to close, the hydraulic line 22 to which is attached the production stinger 25 , must be withdrawn up the well bore to a point above the safety valve 40 . Once withdrawn above as more clearly shown in FIG. 3 , by manipulation of extraction device 20 shown in FIG. 1 , safety valve 40 may be safely and effectively closed.
FIG. 4 discloses the relative position of the elements of the present invention when the continuous hydraulic conduit is seated in the polished bore receptacle of tubing hanger 80 . Hydraulic pressure is delivered by the control panel 10 to hydraulic port 35 that moves the piston 30 down the cylinder of the extraction device 20 , all as more clearly shown in FIG. 5 . The hydraulic pressure that moves the piston and then holds it in position is connected to the continuously pressurized hydraulic line that holds the safety valve in an open position. This communicating connection of the hydraulic pressure and continual holding of the same pressure on the piston and the down hole safety valve is accomplished through control panel 10 .
FIG. 6 is a closer view of the extraction device 20 of the present invention with the spring or resilient member 36 in a compressed state, resulting from the introduction of hydraulic pressure through port 35 to the cylinder 21 thereby driving the sealing piston 30 , together with the first continuous hydraulic conduit 22 carried therein, down into the well bore, through connector 22 . As pressure is introduced into the hydraulic side of the piston, piston 30 is driven to compress the spring 36 , shown in FIG. 7 in its uncompressed state. A second resilient member or spring 37 may be inserted at the end of the cylinder 21 to act as a shock absorber to prevent damage to the tool resulting from expected hydraulic pressure loss within the cylinder 21 of the extraction device 20 . FIG. 6 shows this shock-absorbing spring 37 in its relaxed state because the piston 30 is in compression against spring 36 ; and FIG. 7 shows this shock-absorbing spring in its compressed state absorbing the upward pressure of the piston 30 as hydraulic pressure through port 35 is lessened.
At the installation of the tubing hanger 80 , hydraulic conduit 22 is connected to the setting stinger 25 and hydraulic pressure is increased to set a latch in the tubing hanger 80 . The tubing hanger has been previously prepared with a second small diameter hydraulic conduit hung below it down into the well which was attached to the tubing hanger by means well known to those skilled in the art, such as by Swage-Lok assemblies or the like, by way of example only. This second hydraulic conduit and tubing hanger after being connected to the first hydraulic conduit are lowered into the well bore to a point below the well valve which selectively controls the flow of fluid through the tubular bore. Once the desired location for tubing hanger 80 is reached, pressure is reduced from surface by manipulation of the controls in control panel 10 to bleed pressure from the tube disposed in the well which thereby permits the slips on tubing hanger to move into engagement with the interior surface of the tubular member into which this tubing hanger was inserted. The weight of the second continuous hydraulic conduit sets against the slips causing them to bite into the interior surface of the tubular member. The first continuous hydraulic conduit may then be fully withdrawn. A production stinger 25 A with a longitudinal passage can then be inserted into the polished bore receptacle of the tubing hanger to allow fluid communication from the surface to the production zone in the well, as desired.
During installation, since it is unknown or, at a minimum, unproven at what depth well valve 40 is located, control panel 10 can be used to close valve 40 . Thereafter, the first continuous hydraulic conduit 22 can be lowered or pumped down the well bore until it is stopped by the closed valve 40 . The operator can then register the depth of valve 40 and thereafter withdraw first hydraulic conduit 22 , attach a setting stinger 25 and tubing hanger 80 , latch the first hydraulic conduit 22 into the tubing hanger 80 and lower the entire assembly into the well bore. Since the exact location of the well valve 40 is now known, the tubing hanger may be set adjacent and below well valve 40 . The travel of the piston in the extraction device 20 must be gauged to allow a production stinger 25 A to be removed from the tubing hanger 80 and polished bore by movement of the piston 30 in the extraction device 20 .
FIGS. 8A-8D show the details of the tubing hanger-polished bore receptacle. FIG. 8A is a composite view of the tubing hanger along with six cross-sectional end views; one from the top (A-A) showing the enlarged upper throat 82 allowing the insertion of the stinger into the polished bore to be readily accomplished. As noted the upper throat 82 of the tubing hanger 80 provides numerous flow paths so that fluids may readily flow past the tubing hanger. This upper throat 82 is bowl shaped to catch the production stinger 25 as it is lowered into the tubing hanger polished bore 85 of the tubing hanger 80 . As may be readily appreciated, the downhole connection can alternatively be accomplished by providing an enlarged throat on the distal end of the first hydraulic line with an open path stinger attached to a tubing hanger such that the production stinger is oriented toward the wellhead.
The lower end view of FIG. 8A shows the setting tool with pressure engaged. The cross-sectional view of FIG. 8A through the line A-A shows the enlarged upper throat of the tubing hanger. The cross-sectional view of FIG. 8A through the line B-B shows the latching piston in the engaged position allowing the setting. FIG. 8A shows the tubing hanger as it goes into the well bore.
Pressure is exerted through the first hydraulic conduit 22 into the setting stinger 25 attached to its distal end that provides a bull nose 83 . Tubing hanger 80 affixes a second continuous hydraulic conduit 24 that is attached in hanger 80 in the tubing string. The internal pressure from the first hydraulic conduit 22 enters hydraulic port 86 that thereby engages a latch 86 A into a profile on the external lateral surface of the setting stinger 25 . The setting stinger 25 as more fully shown in the drawings provides a plurality of elastomeric elements O or O-rings, which dynamically engage the inner surface of the polished bore receptacle 85 of the tubing hanger 80 to sealingly engage the tubing hanger. Internal pressure from the first hydraulic conduit 22 also keeps the piston 87 in full extension thereby preventing the slips 81 from moving into contact with the interior lateral wall of the tubular member. When the pressure is reduced as shown in FIG. 8B , spring 88 moves slips 81 into engagement with said wall and releases the latch 86 A. The weight of the second continuous hydraulic conduit 24 , in conjunction with the energy of spring 88 , urges slips 81 to bite into the lateral interior wall of the tubular and set slips 81 .
The setting stinger 25 is then removed leaving the tubing hanger 80 as shown in FIG. 8C . Thereafter, a production stinger 25 A having a longitudinal passageway to permit open communication from the surface hydraulic pumps through the first continuous hydraulic conduit 22 to the production zone serviced by the second continuous hydraulic conduit 24 suspended in the tubing hanger 80 of the present invention.
As additionally shown in FIG. 8D , through the line C-C, an additional slip set 90 can be set to hold the tubing hanger 80 in the well bore. Slip set 90 can be activated by a hydraulic pressure communicating port to a piston for driving the slip into engagement as shown in the drawing.
If the well valves must be closed for any reason, control panel 10 activates hydraulic port 35 to release the pressure on the resilient member 36 which immediately removes the first continuous hydraulic conduit and the attached stinger through the well valve 40 to be closed and thereby allowing control panel 10 to hydraulically close valve 40 . As an additional feature, the production stinger 25 A could be fabricated from a frangible material, such as a ceramic or the like, to permit the well valve to completely close on the stinger in the event the extraction device failed to withdraw the stinger from the tubing hanger in a timely manner.
An alternative embodiment can be utilized for wells only having a series of master valves on the surface for controlling the well. For example as shown in FIG. 9 , a Y-shaped or side-entry spool 100 can be inserted between the wellhead and one of the master valves. If this side-entry spool 100 is to be inserted directly on the wellhead at 102 , the operator could shut in the well by plugging the well at a profile usually located in the wellhead assembly below the primary or first master valve, in a manner well known to those in this industry. Alternatively, if the operator chooses to locate the side-entry spool 100 above the primary or first master valve, that master valve could be closed to control the well while the remainder of the production wellhead is removed and the side-entry spool 100 inserted. The need to close the primary or first master valve is minimized since the secondary master valve located above the side-entry spool can be used to close the well if excessive pressure is experienced.
If the operator desires, a tubing hanger can be set in a profile normally provided in a wellhead below the primary or first master valve to suspend a second small diameter continuous hydraulic. Once the tubing hanger is set in this profile in a manner well known in this industry, the operation of the extraction device could be readily accomplished as described above. The spool 100 would then work in the same manner as the extraction device 20 shown in FIG. 1 .
Although an apparatus and method is disclosed enabling a single hydraulic conduit to be installed through a downhole valve, it should be understood by one skilled in the art that the embodiments and particular structures disclosed may be modified to allow for the passage of two or more hydraulic conduits through a downhole valve. Additionally, the methods disclosed can be performed using larger diameter pipe and tubing, either jointed or continuous.
Referring now to FIG. 10 , an alternative embodiment for a tubing hanger assembly 200 is shown. Tubing hanger assembly 200 is capable of delivering a continuous conduit 202 through a downhole safety valve (not shown) through a stinger 204 . Furthermore, tubing hanger assembly 200 includes a downhole retractor assembly 206 that is hydraulically charged through hydraulic conduit 208 . Tubing hanger assembly 200 is preferably configured to stab a hanger sub (like hanger 80 of FIGS. 2-8 ) located below a downhole safety valve. When hydraulic pressure (preferably pressurized nitrogen gas) is released from hanger assembly 200 retractor assembly 206 retracts and stinger 204 is retracted from hanger 80 and away from safety valve. With stinger clear of safety valve, the valve is free to close without obstructions. The assembly is preferably constructed as a fail-safe system, one whereby losses in pressure resulting, from, for example, pump failures, retract the stinger and close the safety valve.
Referring now to FIG. 11 , the hanger assembly 200 is shown in more detail. To set the system in place, hanger assembly 200 is preferably deployed down production tubing (or a wellbore) with stinger 204 in retracted position and with slips 210 retracted. To extend stinger 204 , hydraulic pressure is applied within conduit 208 which, in turn, is in communications with cylinder 212 . Pressure within cylinder 212 thereby acts upon piston 214 thrusting it downhole compressing retraction spring 216 . Stinger 204 is mechanically connected to piston 214 so pressure in cylinder 212 displaces piston 214 and thereby extends stinger 204 .
With stinger 204 extended, assembly 200 is engaged into the well until the hanger receptacle ( 80 of FIGS. 8A-8D ) is engaged. Stinger 204 , preferably includes elastomeric seals 218 about its outer profile so that stinger 204 can sealingly engage seal bore ( 85 of FIG. 8C ). A central bore 220 in fluid communication with conduit 202 allows fluids flowed therethrough to be delivered from the surface through hanger receptacle 80 and through any additional conduit further hung therefrom. Alignment guide 222 matches the profile of upper throat ( 82 of FIG. 8A ) to allow for proper alignment therewith.
Once slips 210 are extended, stinger 204 can be extend thereby locking assembly 200 in place within the production string. This can be accomplished by any means already known in the art, but may be activated hydraulically or by axially loading assembly 200 . With slips 210 set and stinger 204 extended and properly received by hanger receptacle 80 , the system is ready for use. Should an event arise where the safety valve (located along tubular member between retractor 206 and stinger 204 ) needs to be closed, pressure within conduit 208 is released, causing retraction springs 216 to displace piston 214 upstream and retract stinger 204 attached thereto. Assembly 200 is preferably positioned such that the retraction of stinger 204 is enough to clear stinger 204 from hanger receptacle 80 and from safety valve.
Those familiar with well completions may readily substitute many well-known tubing hangers or utilize various setting methods which will accomplish the task of setting a hanger and suspending a tubular member below. The present invention for assembly of a continuous hydraulic conduit below a well valve while retaining the capacity for extracting a portion of the hydraulic conduit above the well valve to permit its closure can be practiced with these other well known tubing hanger assemblies and methods for setting them in a well without departing from the spirit or intent of this invention.
One skilled in the art will realize that the embodiments disclosed are illustrative only and that the scope and content of the invention is to be determined by the scope of the claims attached hereto.
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A method and apparatus for inserting a small diameter continuous hydraulic conduit or capillary tube down a well bore is presented. The methods and apparatus allow either the injection of chemicals to enhance production of oil and gas, or to provide a conduit for production up through the small diameter tubing in marginal wells, into a hanger below a well valve to permit its removal from below the valve if the valve should be required to be closed and its reinsertion without pulling the tubing from the well bore.
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FIELD OF THE INVENTION
The invention relates to two piece packages in which the cover is distinct from the container. More particularly, the invention relates to display packages of two piece construction wherein the container mounts the article for display and the cover, in the upright position, provides a surface for advertising or similar copy.
BACKGROUND OF THE INVENTION
Boxes comprised of a container section and a separate cover section has been known for many years. Similarly, display packages have been popular for displaying various articles such as cameras, binoculars, cosmetics and many other items which are marketably enhanced by attractive display.
Typically, the prior efforts at two-piece packages having a cover releasibly attached to the box are characterized by tabs on the cover member which attach to slots cut into the body of the container section. Another early design is the box cover with a depending attachment member that fits tightly against the back wall of the container and essentially forms a force fit to retain the cover. Illustrative of the prior art two-piece containers are Weiss (U.S. Pat. No. 1,058,929), Schoettle (U.S. Pat. No. 2,003,224) and Warren (U.S. Pat. No. 1,192,359).
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a display package separately formed of a display container and a cover.
It is a further object of the present invention to provide a display container of plastic having an appropriately formed recess to accept a retaining member hingedly mounted to the separate cover.
It is another object of the present invention to provide a container comprised of a display section and a cover section which cover section in the open position is maintained in a stable perpendicular position and which provides a surface for advertising or similar copy.
It is still another object of the invention to provide a package which in the closed mode safely stores the article contained therein and in the open mode forms an attractive display mount.
The display package of the present invention is comprised of a flocked plastic container member having cavities formed therein which cavities are in the contour of the article which the package is adapted to display. The container member also has formed therein, in the back surface, a recess extending essentially the length of the container which recess is provided with overlapping edges on each end and undercuts intermediately disposed along the upper edge. A centrally disposed tab extending upwardly from the bottom of the recess is also contemplated.
The cover which, in the preferred form is cardboard, is provided with a retaining member hingedly attached to the cover. The retaining member is essentially the size of the recess in the container member and is provided with a slot through which the tab extending from the bottom of the recess can fit. A small finite hinge member between the retaining member and the cover edge affords free movement of the cover from the fully closed position to an orientation essentially perpendicular to the box when in the open position.
DESCRIPTION OF THE DRAWINGS
The invention will be better understood when considered with the following drawings wherein:
FIG. 1 is an isometric view of the display package of the present invention in the closed mode;
FIG. 2 is the isometric view of FIG. 1 with a partial cut-away showing the means for attaching the cover;
FIG. 3 is an isometric view of the container section showing the cover attachment inserted in the container attachment recess;
FIG. 4 is an exploded view of the display package showing the recess of the container section and the retaining member of the cover section;
FIG. 5 is an isometric view of the display package in the open position;
FIG. 6 is a side elevational view taken through line 6--6 of FIG. 3;
FIG. 7 is a sectional elevational view of the recess of the container section and a partial sectional of the retaining member inserted in the recess;
FIG. 8 is a sectional view taken through line 8--8 of FIG. 7;
FIG. 9 is a sectional view taken through line 9--9 of FIG. 3;
FIG. 10 is a sectional view taken through line 10--10 of FIG. 3;
FIG. 11 is a sectional view taken through line 11--11 of FIG. 3; and
FIG. 12 is a view of the retaining member of the cover and cover shown flattened.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The display package 2 of the present invention is provided to display any of a variety of articles such as cameras, binoculars, cosmetics, medical or electronic equipment, etc. The display package 2 is adapted to attractively display the article accommodated by the package and at the same time provide a cover which in the open position has the additional feature or function of a display surface for advertising or similar copy.
The display package 2 of the present invention shown in FIGS. 1 and 2 in the closed mode is comprised essentially of a container member 4 and a cover 6.
The container member 4 of the display package 2 is molded to afford contour fitting cavities 8 for the article which is being displayed. As illustrated in FIG. 3, essentially four cavities 8 have been formed in the particular display container member 4. Of course, more than or less than four cavities 8 can be formed in the container member 4 depending on the article being displayed. The container member 4 can be made of many different materials. However, vacuum formable plastics such as high impact styrene, polyvinyl chloride and acetates are particularly suitable materials for the container member 4. In the preferred form the display container member is formed of flocked plastic.
The display container member 4 is also provided with a recess 10 extending along essentially the entire length of the rear of the container member 4, as best seen in FIGS. 2, 4 and 7. The recess 10 is provided with overlapping edge members 14 and 16 at either end and depressions 18 and 20 immediately below each of the edge members 14 and 16. Protuberances or undercuts 22 and 24 are strategically located along the upper edge of the recess 10. A tab 26 is also provided to extend upwardly from the bottom of the recess 10 at an intermediate position.
The cover 6 of the present invention is sized to cover the entire display container member 4 and is provided with a retaining member 28, best seen in FIGS. 3, 7 and 12. The retaining member 28 is essentially the length of the recess 10 and is configured to conform to the contour of the recess 10. The retaining member 28 is provided with edges 30 and 32 which are formed on a bias. The edges 30 and 32 thus form an incline which facilitates insertion behind the overlapping edge members 14 and 16 in the rear of the display container member 4. A centrally disposed opening 34 is also provided to cooperate with the tab 26 extending upwardly from the bottom of the recess 10, as seen in FIG. 11. A hinge 36 is provided between the retaining member 28 and the back edge 38 of the cover 6. The hinge 36 extends essentially the length of the retaining member 28. As seen in FIGS. 10 and 11, a score line 40 is formed between the hinge 36 and the retaining member 28 and a second score line 42 is formed between the hinge 36 and the back edge 38 of the cover 6. In practice, it has been found that a cover of cardboard material such as rigid boxboard or folding boxboard is particularly suitable for use as the material for the cover 6.
A flap 44 which fits within the area of the cover 6 is provided for advertising or similar copy. The flap 44 is secured at one edge to the cover 6 along the top inside edge 48 of the cover as seen in FIG. 6, and can pivot outwardly or nest within the contour of the cover 6.
Assembly of the display package 2 occurs by inserting the inclined edges 30 and 32 of the retaining member 28 into the recess 10 with the inclined edges 30 and 32 under the overlapping edge members 14 and 16 respectively. The depressions 18 and 20 in the recess provide an area into which the inclined edges 30 and 32 can be accommodated by virtue of the force imposed by the location of the overlapping edge members 14 and 16 as illustrated in FIG. 9. The protuberances or undercuts 22 and 24 formed along the upper edge of the recess 10 bear against the edge 46 of the retaining member and provide further surface to maintain the retaining member 28 in the recess 10. The opening 34 fits over the tab 26 extending upwardly from the bottom of the recess 10 to complete the force bearing members on the retaining member 28.
As best seen in FIG. 5, the display package 2 can be opened with the container member 4 displaying the package contents and with the flap 44 in the cover 6 providing a surface for advertising or similar copy.
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A display package comprised of a display container section and a hinged cover attached together by a retaining member on the cover and a mating recess in the display container section in which the retaining member is secured. The recess is provided with strategically located overlapping edges and protuberances or undercuts to grip the cover retaining member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improvement of a thermoelectric material useful for power generation, refrigeration, and the like, and also to a sensor using the thermoelectric material. More specifically, the invention relates to a thermoelectric material using a material having a Seebeck effect and a sensor using the same thermoelectric material, and to a method of manufacturing the same.
2. Description of the Prior Art
The Seebeck effect is a phenomenon wherein, when a temperature difference arises between two different points of an electrically conductive material, an electromotive force is developed in proportion to the temperature difference. The electromotive force consists of two components, i.e., an electromotive force due to distribution of charge carrier density caused by a migration of charge carriers for keeping constant free energy of the charge carriers within the material, and another electromotive force due to an interaction between charge carriers and heat flow, namely, phonon flow from higher- to lower-temperature portions.
These charge carriers and phonons behave differently between a surface portion (up to about 100 Å in depth) and an internal portion of the material. Therefore, thermoelectric effects of the material such as thermal electromotive force (i.e., Seebeck electromotive force) are different between its surface portion and internal portion. For thin films having a thickness on the order up to 1 μm or fine particles having a diameter on the order up to 1 μm, the surface portion (interface portion) occupies larger part relative to the internal portion so that the thermoelectric effect in the surface portion can no longer be an ignorable phenomenon.
Generally, a surface of a thermoelectric material has atmospheric gasses such as oxygen, nitrogen, steam, carbon dioxide and the like adsorbed thereon, which, it is considered, would affect the thermoelectric effects on the surface portion (interface portion). Obeying Langmuir's adsorption isotherm, an adsorption amount of atmospheric gas increases with increasing the pressure of the atmospheric gas so that the higher the pressure of the atmospheric gas, the greater the change in the thermal electromotive force.
Thermoelectric materials capable of interconversion between temperature difference and electromotive force have been manufactured heretofore, as bulk materials, by melt-casting a thermoelectric material or calcining a powdery material at a high temperature, and their resulting fine structures are shown in FIGS. 7 and 8, respectively.
Referring to FIGS. 7 and 8, in the conventional material prepared by melt-casting a thermoelectric material, crystal grains are arranged densely and continuously although a small amount of cracks 13 and pores 14 may exist as shown in FIG. 7. In the conventional powder product calcined at a high temperature, the particles are partly fused and electrically linked to each other as shown by reference numeral 15 in FIG. 8. On the other hand, there can be obtained thin-film type thermoelectric materials formed through deposition on a glass substrate or organic membrane or other methods. In either case of the conventional methods, thermoelectric materials have been provided in a structure as dense as possible so that their electrical conductivity and mechanical strength as a bulk material would be enhanced for increased practicability.
Sensors using such thermoelectric materials are in most cases implemented by making use of a function of detecting temperature difference. Examples of such sensors include temperature sensors or electric thermometers incorporating alloy thermocouples such as iron/gold--chromel and alumel--chromel thermocouples. An example of the sensors can be found in an application for detecting an extinction of a pilot burner of a boiler by sensing a change in temperature difference.
Although there have already been developed semiconductor sensors using changes in electric resistance and sensors using enzyme electrode reactions as gas-pressure sensors or specified-substance oriented sensors, no sensors have been proposed yet to which any thermoelectric phenomenon has been applied.
Conventional thermoelectric materials have been used as materials for converting temperature difference into electricity due to thermal electromotive force or obtaining temperature difference by conducting an electric current through the materials. As for sensors using these materials, which have been applied only for detecting temperature difference, there is a difficulty in measuring other physical quantities such as gas pressure, concentration of a substance in a solution.
SUMMARY OF THE INVENTION
In order to solve the foregoing problems involved in the prior arts, an essential objective of the present invention is to provide an improvement of performance of thermoelectric materials and to provide a method of manufacturing a sensor using the thermoelectric material having Seebeck effect, allowing the sensor capable to detect a gas pressure and concentration of specific substances quantitatively.
In order to achieve the aforementioned objectives, a thermoelectric material according to the present invention comprises a structure such that fine particles of a material exhibiting Seebeck effect are electrically linked partially in a loose-contact state with one another. It is to be noted here that the term "loose-contact state" means a semipressure-contact state of fine particles to be electrically linked without fusing, having spaces formed at clearances between any adjacent fine particles when formed in a cold pressing or sintering process.
A method of manufacturing thermoelectric materials according to the present invention comprises a step of compacting fine particles exhibiting Seebeck effect through a cold press forming.
Further, a sensor for measuring gas pressures according to the present invention comprises: a piece of a thermoelectric material in which fine particles exhibiting Seebeck effect are electrically linked in a loose-contact state one another with spaces formed at clearances between adjacent fine particles; means for giving temperature difference between two points inside the piece of the thermoelectric material; and means for detecting thermal electromotive force generated between the two points in the material.
Still further, a sensor for detecting a specific substance according to the present invention comprises: a piece of thermoelectric material in which fine particles exhibiting Seebeck effect are electrically linked in a loose-contact state with one another, the piece of the theromoelectric material being combined with a material having a specificity of adsorption or reaction, having spaces formed at clearances between adjacent fine particles; means for giving temperature difference between two points inside the piece of the thermoelectric material; and means for detecting a thermal electromotive force generated between the two points.
In the above structure, a material having adsorption specificity or reaction specificity is preferably formed in a film-like state mainly on the surface of the particles of thermoelectric material.
According to a feature of the present invention, gas pressure and concentration of a specific substance can be detected correctly in a form of voltage using a thermoelectric material in which fine particles of a material exhibiting Seebeck effect are electrically linked in a loose-contact state with one another with spaces formed at clearances between adjacent fine particles.
According to a manufacturing method of the present invention, the thermoelectric material mentioned above can be manufactured efficiently and rationally.
According to another feature of the present invention, the arrangement of the sensor for measuring a gas pressure, particularly when lower than the air pressure, detects a change in the thermal electromotive force when the gas pressure of the atmosphere is varied, thereby to measure an atmospheric gas pressure.
Furthermore, by constituting a sensor by combining various types of materials having a specificity of adsorption or reaction along with a thermoelectric material, a concentration of a specific substance in a solution or an atmosphere can be detected.
When thermoelectric materials for use in sensors are so constructed that fine particles of thermoelectric materials are electrically linked partially in a loose-contact state one another, high sensitivities of the sensors can be enhanced.
Obeying Langmuir's adsorption isotherm, the amount of adsorbed atmospheric gas increases with increasing the pressure of the atmospheric gas. Therefore, the higher the pressure of the atmospheric gas, the greater the change in the thermoelectric force. Further, when the thermoelectric material is combined with various types of materials having a specificity of adsorption or reaction, adsorption of a specific substance onto the material will cause a change in the thermal electromotive force generated in the material.
Furthermore, the cold-pressed thermoelectric material according to the present invention is more strongly affected by the adsorbed gas since charge carriers and phonons traverse the adsorption layer.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become apparent from the following description taken in conjunction with the preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is a cross sectional view of a fine structure of a thermoelectric material according to the present invention;
FIG. 2 is a graph representing a distribution of Seebeck coefficient of the thermoelectric material with respect to an atmospheric gas pressure according to the present invention;
FIG. 3 is a graph representing a distribution of Seebeck coefficient of another thermoelectric material under an Ar gas atmosphere according to the present invention;
FIG. 4 is a schematic perspective view of a sensor for detecting a gas pressure or a specific substance according to the present invention;
FIG. 5 is a flow chart showing a procedure of producing a sensor for quantitatively detecting a specific substance in an atmospheric gas;
FIG. 6 is a cross sectional view of a fine structure of a thermoelectric material having Fe-Mn-Si particles coated with a thin-film like polyacrylamide gel including enzyme;
FIG. 7 is a cross sectional view of a fine structure of a conventional melt-casted thermoelectric material; and
FIG. 8 is a cross sectional view of a fine structure of a conventional powder-calcined thermoelectric material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following describes preferred embodiments of the present invention With reference to the accompanying drawings.
First, a method of producing a thermoelectric material will be explained below. In the first step, specified amounts of raw materials of Fe, Mn and Si each having purity of not less than 3N (>99.9%) were melted in an arc furnace and then crushed. In this case, Fe and Si are used as basic materials while Mn is used as a doping material. After repeating the cycle of melting/crushing process three times, the composition of the resultant material was analyzed and the ratio of the raw materials was adjusted to derive a composition of Fe 0 .985 Mn 0 .015 Si 2 .
Next, in order to obtain a β-phase, the material having a composition of Fe 0 .985 Mn 0 .015 Si 2 was put into a vacuum sealed glass ample and annealed at 850° C. for eight hours in the glass ample. Then the annealed material was milled in a planetary ball mill for five minutes under an Ar gas atmosphere, and shifted through a mesh to obtain a powder material consisting of particles each having a size of about 5μm in diameter.
Then, the powder material was molded by cold pressing under a pressure in a range of 1000 to 3000 kgw/cm 2 at a room temperature so that the powder material was pelletized. A small amount of ethanol or acetone was added to the powder to enhance the rigidity of the pellets. That is, ethanol or acetone serves as a lubricant to remove cracks or the like in the pellets. Then, Seebeck coefficients for the pellets of the resultant material were measured under various pressures of atmospheric gas.
In this case although Mn was used as a doping material, other materials such as Co, Cr and Al may be used as a doping material.
FIG. 1 shows a fine structure of the thermoelectric material obtained by the above mentioned processes. Each particle of the thermoelectric material having a composition of Fe 0 .985 Mn 0 .015 Si 2 coheres together in a loose-contact state without fusing so that atmospheric gas can be adsorbed onto a surface 3 and fed to be adsorbed to a loose-contact part 4 through a cavity 2. That is, substantially no solid or liquid material exists in the cavity 2.
Seebeck coefficients of the pellets of the thermoelectric material were measured in a container in which the conditions of atmospheric gas (i.e., pressure, species of the gas) can be adjusted.
FIG. 2 shows a distribution of Seebeck coefficients depending on the atmospheric gas pressure when measured under Ar and He gaseous atmospheres. Seebeck coefficient was found to largely depend upon the pressure of atmospheric gas, particularly in a range of the pressure below 100 mmHg. Also, Seebeck coefficient was found to be different between species of He and Ar gaseous atmospheres even at the same pressure. Therefore, the thermoelectric material appears to have a function of identifying species of atmospheric gas to some degree.
The influence of the pressure of atmospheric gas on Seebeck coefficient was also investigated for a basic material of Bi 2Te 3 except for a material of Fe-Si group. The Bi 2Te 3 material having purity of not less than 3N (i.e., >99.9%) was crushed and then shifted through a mesh to obtain a powder material composed of particles each having a size of about 10 μm in diameter. The powder material was pelletized under a pressure of 500 to 2000 kgw/cm 2 . Then Seebeck coefficients for the pellets of the resultant material were measured under various pressures of atmospheric gas.
FIG. 3 shows a distribution of Seebeck coefficients depending on the atmospheric gas pressure when measured under Ar gaseous atmosphere. Seebeck coefficient was found to depend upon the pressure of atmospheric gas, particularly in a range of the pressure below 100 mmHg. It was found that Seebeck coefficients for the material of Bi 2 Te 3 depend upon the pressure of atmospheric gas although the degree of the dependency was not so high as that of the Fe-Si group materials.
The following describes shows an arrangement of a sensor for detecting gas pressure with reference to FIG. 4, which is assembled by using a thermoelectric material according to the present invention.
Referring to FIG. 4, a pellet 5 is provided with a rectangular shaped plate having dimensions of 2 mm×2 mm×10 mm, which is made of the thermoelectric material having a composition of Fe 0 .985 Mn 0 .015 Si 2 . A heater 6 is mounted to one end of the pellet 5 for heating, while a cooling plate 7 serving as a heat sink is attached to the other end of the pellet 5 for discharging heat.
Electric current is applied from a power source (not shown) to the heater 6 for heating through a controller 9. The applied electric current is controlled by the controller 9 in such a manner that the temperature difference between the both ends of the pellet 5 is kept constant at a difference value of 10° C. by providing thermocouples 8. In more detail, each of the thermocouples 8 is connected to the heater plate 6 and the cooling plate 7, where the controller 9 is electrically connected in the loop circuit of the thermocouples 8 to control the heating of the heater 6 by detecting thermoelectric current corresponding to the temperature difference.
A pair of electrodes 10A and 10B, each of which is made of silver paste, are provided in the both end portions of the pellet 5 for measuring thermal electromotive force developed in the pellet 5, where the electrode 10A is positioned in the left side in the figure corresponding to the heater plate 6 while the electrode 10B is positioned in the right side in the figure corresponding to the cooling plate 7 as shown in FIG. 4. The voltage due to the thermal electromotive force in accordance with the temperature difference is measured by means of a voltmeter 12 which is electrically connected across the both electrodes 10A and 10B via silver lead wires 11.
Ar gas was introduced into a chamber or container and it was repeatedly confirmed that the Seebeck coefficients correspond to the gas pressures in a one-by-one manner.
Next, the following describes a method of producing a sensor for quantitatively detecting a specific substance in an atmospheric gas with reference to a flow chart shown in FIG. 5.
It is to be noted here that the basic structure of the sensor for detecting a specific substance is the same as that of the gas-pressure sensor shown in FIG. 4.
As shown in FIG. 5, a powder thermoelectric material having a composition of Fe 0 .985 Mn 0 .015 Si 2 was previously obtained by the production method as described before, which the material was processed into granules each having a size of 5 to 10 μm in diameter. Then, in order to obtain a material having a specificity of adsorption or reaction, formaldehyde dehydrogenase enzyme was mixed into polyacrylamide sol and further mixed with the above processed powder thermoelectric material of Fe 0 .085 Mn 0 .015 Si 2 , thereby to obtain a slurry state, where the polyacrylamide sol is used as a supporting member. The mixed slurry material was atomized in a dried Ar gas atmosphere so that the polyacrylamide sol was gelatinized and then excessive solvent was dispersed by evaporation.
In the resultant powder material obtained by the process mentioned above, there was contained a thin-film like polyacrylamide gel including enzyme, which was formed on the surface of the Fe 0 .985 Mn 0 .015 Si 2 particles, and the film thickness was 0.5-5.0 μm as shown in FIG. 6.
Referring to FIG. 6, the particles 51 of the powder material of Fe 0 .985 Mn 0 .015 Si 2 were coated with a thin-film like polyacrylamide gel 52 including enzyme. In this fine structure of the powder material, there were formed spaces 53, i.e., cavities among the particles. Then the obtained powder material was dispersed in an organic solvent and formed on a glass substrate through a printing method. In the same manner as that for the gas-pressure sensor, a temperature difference of 10° C. was kept constant and the variation in thermal electromotive force was traced. The measurement values of electromotive force for atmospheres of Ar gas containing formaldehyde of 1 ppm, 10 ppm and 100 ppm were respectively 2350 μV, 2550 μV and 2700 μV, which were increased by 300 μV, 500 μV and 650 μV respectively comparing to the value (2050 μV) for pure Ar gas.
The foregoing example is an application of enzyme reaction for sensing a concentration of a specific substance in a gas atmosphere. By using other enzyme systems or antigen-antibody reactions as reactions having specificities, concentration of a specific substance in a solution can also be detected and a wide variety of detectable substances can be selected.
As a method for supporting these materials having adsorption specificities, there can be used a cellulose membrane. Another method can be also adopted by fixing antibodies or enzymes directly on the surface of fine thermoelectric particles through a chemical reaction. On the other hand, although the sensitivity was not very high, gas pressures and concentrations of specific substances could be detected by using a thin film of approximately 1 μm thick instead of fine thermoelectric particles.
As described hereinabove, according to the sensing material in the embodiment, the material has a fine structure in cross section in which fine particles 1 cohere together in a loose-contact state without fusing and an adsorption of atmospheric gas or that of specific substance through an enzyme reaction occurs on the surface 3 and the loose-contact part 4 through the cavity 2 as shown in FIG. 1. When a substance is adsorbed on the surface (the interface), the thermal electromotive force changes depending upon the amount of adsorption and then the system acts as a sensor. Accordingly, a gas pressure and a concentration of a specific substance can be detected in a form of a voltage by using thermoelectric materials.
As described above, according to the present invention, gas pressures and concentrations of specific substances can be detected correctly in a form of voltage by using a thermoelectric material of the present invention by virtue of the structure that fine particles of a material exhibiting the Seebeck effect are electrically linked in a loose-contact state while spaces are formed at clearances among the particles. The sensor of the present invention is very profitable in the industry since gas pressures or concentrations of specific substances can be detected as voltage values.
Although the present invention has been fully described by way of example with reference to the accompanying drawings, it is to be noted here that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention as defined by the appended claims, they should be construed as included therein.
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In a fine structure of a thermoelectric material, fine particles of a material exhibiting Seebeck effect are electrically linked in a loosely contacted state with one another without fusing, having spaces formed at clearances among the fine particles. A method of manufacturing the thermoelectric material comprises a step of compacting fine particles made of a material exhibiting Seebeck effect through a cold pressing. Also, disclosed is a sensor for quantitatively sensing a substance, which comprises a pellet of a powder thermoelectric material, where a temperature difference is generated between two points inside the piece of thermoelectric material. The sensor further includes thermocouples connected to a heater plate (6) and a cooling plate, and a controller which is electrically connected in the loop circuit of the thermocouples for detecting thermoelectric current corresponding to the temperature difference, thereby to control the heating of the heater plate.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. application Ser. No. 09/850,482, filed on May 7, 2001, which is a continuation-in-part application of U.S. application Ser. No. 09/575,480, filed on May 19, 2000 which claims the benefit of U.S. Provisional Application No. 60/204,417 filed May 12, 2000, and a continuation-in-part application of U.S. application Ser. No. 09/061,568, filed on Apr. 16, 1998.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the administration of drug combinations for the prevention and treatment of vascular disease, and more particularly to an intraluminal medical device for the local delivery of one or more therapeutic agents for the prevention and treatment of vascular disease caused by injury.
[0004] 2. Discussion of the Related Art
[0005] Many individuals suffer from circulatory disease caused by a progressive blockage of the blood vessels that perfuse the heart and other major organs with nutrients. More severe blockage of blood vessels in such individuals often leads to hypertension, ischemic injury, stroke, or myocardial infarction. Atherosclerotic lesions, which limit or obstruct coronary blood flow, are the major cause of ischemic heart disease. Percutaneous transluminal coronary angioplasty is a medical procedure whose purpose is to increase blood flow through an artery. Percutaneous transluminal coronary angioplasty is the predominant treatment for coronary vessel stenosis. The increasing use of this procedure is attributable to its relatively high success rate and its minimal invasiveness compared with coronary bypass surgery. A limitation associated with percutaneous transluminal coronary angioplasty is the abrupt closure of the vessel which may occur immediately after the procedure and restenosis which occurs gradually following the procedure. Additionally, restenosis is a chronic problem in patients who have undergone saphenous vein bypass grafting. The mechanism of acute occlusion appears to involve several factors and may result from vascular recoil with resultant closure of the artery and/or deposition of blood platelets and fibrin along the damaged length of the newly opened blood vessel.
[0006] Restenosis after percutaneous transluminal coronary angioplasty is a more gradual process initiated by vascular injury. Multiple processes, including thrombosis, inflammation, growth factor and cytokine release, cell proliferation; cell migration and extracellular matrix synthesis each contribute to the restenotic process.
[0007] While the exact mechanism of restenosis is not completely understood, the general aspects of the restenosis process have been identified. In the normal arterial wall, smooth muscle cells proliferate at a low rate, approximately less than 0.1 percent per day. Smooth muscle cells in the vessel walls exist in a contractile phenotype characterized by eighty to ninety percent of the cell cytoplasmic volume occupied with the contractile apparatus. Endoplasmic reticulum, Golgi, and free ribosomes are few and are located in the perinuclear region. Extracellular matrix surrounds the smooth muscle cells and is rich in heparin-like glycosylaminoglycans which are believed to be responsible for maintaining smooth muscle cells in the contractile phenotypic state (Campbell and Campbell, 1985).
[0008] Upon pressure expansion of an intracoronary balloon catheter during angioplasty, smooth muscle cells within the vessel wall become injured, initiating a thrombotic and inflammatory response. Cell derived growth factors such as platelet derived growth factor, fibroblast growth factor, epidermal growth factor, thrombin, etc., released from platelets, invading macrophages and/or leukocytes, or directly from the smooth muscle cells provoke proliferative and migratory responses in medial smooth muscle cells. These cells undergo a change from the contractile phenotype to a synthetic phenotype characterized by only a few contractile filament bundles, extensive rough endoplasmic reticulum, Golgi and free ribosomes. Proliferation/migration usually begins within one to two days post-injury and peaks several days thereafter (Campbell and Campbell, 1987; Clowes and Schwartz, 1985).
[0009] Daughter cells migrate to the intimal layer of arterial smooth muscle and continue to proliferate and secrete significant amounts of extracellular matrix proteins. Proliferation, migration and extracellular matrix synthesis continue until the damaged endothelial layer is repaired at which time proliferation slows within the intima, usually within seven to fourteen days post-injury. The newly formed tissue is called neointima. The further vascular narrowing that occurs over the next three to six months is due primarily to negative or constrictive remodeling.
[0010] Simultaneous with local proliferation and migration, inflammatory cells invade the site of vascular injury. Within three to seven days post-injury, inflammatory cells have migrated to the deeper layers of the vessel wall. In animal models employing either balloon injury or stent implantation, inflammatory cells may persist at the site of vascular injury for at least thirty days (Tanaka et al., 1993; Edelman et al., 1998). Inflammatory cells therefore are present and may contribute to both the acute and chronic phases of restenosis.
[0011] Numerous agents have been examined for presumed anti-proliferative actions in restenosis and have shown some activity in experimental animal models. Some of the agents which have been shown to successfully reduce the extent of intimal hyperplasia in animal models include: heparin and heparin fragments (Clowes, A. W. and Karnovsky M., Nature 265: 25-26, 1977; Guyton, J. R. et al., Circ. Res., 46: 625-634, 1980; Clowes, A. W. and Clowes, M. M., Lab. Invest. 52: 611-616, 1985; Clowes, A. W. and Clowes, M. M., Circ. Res. 58: 839-845, 1986; Majesky et al., Circ. Res. 61: 296-300, 1987; Snow et al., Am. J. Pathol. 137: 313-330, 1990; Okada, T. et al., Neurosurgery 25: 92-98, 1989), colchicine (Currier, J. W. et al., Circ. 80: 11-66, 1989), taxol (Sollot, S. J. et al., J. Clin. Invest. 95: 1869-1876, 1995), angiotensin converting enzyme (ACE) inhibitors (Powell, J. S. et al., Science, 245: 186-188, 1989), angiopeptin (Lundergan, C. F. et al. Am. J. Cardiol. 17 (Suppl. B):132B-136B, 1991), cyclosporin A (Jonasson, L. et al., Proc. Natl., Acad. Sci., 85: 2303, 1988), goat-anti-rabbit PDGF antibody (Ferns, G. A. A., et al., Science 253: 1129-1132, 1991), terbinafine (Nemecek, G. M. et al., J. Pharmacol. Exp. Thera. 248: 1167-1174, 1989), trapidil (Liu, M. W. et al., Circ. 81: 1089-1093, 1990), tranilast (Fukuyama, J. et al., Eur. J. Pharmacol. 318: 327-332, 1996), interferon-gamma (Hansson, G. K. and Holm, J., Circ. 84: 1266-1272, 1991), rapamycin (Marx, S. O. et al., Circ. Res. 76: 412-417, 1995), corticosteroids (Colburn, M. D. et al., J. Vasc. Surg. 15: 510-518, 1992), see also Berk, B. C. et al., J. Am. Coll. Cardiol. 17: 111B-117B, 1991), ionizing radiation (Weinberger, J. et al., Int. J. Rad. Onc. Biol. Phys. 36: 767-775, 1996), fusion toxins (Farb, A. et al., Circ. Res. 80: 542-550, 1997) antisense oligonucleotides (Simons, M. et al., Nature 359: 67-70, 1992) and gene vectors (Chang, M. W. et al., J. Clin. Invest. 96: 2260-2268, 1995). Anti-proliferative effects on smooth muscle cells in vitro have been demonstrated for many of these agents, including heparin and heparin conjugates, taxol, tranilast, colchicine, ACE inhibitors, fusion toxins, antisense oligonucleotides, rapamycin and ionizing radiation. Thus, agents with diverse mechanisms of smooth muscle cell inhibition may have therapeutic utility in reducing intimal hyperplasia.
[0012] However, in contrast to animal models, attempts in human angioplasty patients to prevent restenosis by systemic pharmacologic means have thus far been unsuccessful. Neither aspirin-dipyridamole, ticlopidine, anti-coagulant therapy (acute heparin, chronic warfarin, hirudin or hirulog), thromboxane receptor antagonism nor steroids have been effective in preventing restenosis, although platelet inhibitors have been effective in preventing acute reocclusion after angioplasty (Mak and Topol, 1997; Lang et al., 1991; Popma et al., 1991). The platelet GP IIb/IIIa receptor, antagonist, Reopro is still under study but has not shown promising results for the reduction in restenosis following angioplasty and stenting. Other agents, which have also been unsuccessful in the prevention of restenosis, include the calcium channel antagonists, prostacyclin mimetics, angiotensin converting enzyme inhibitors, serotonin receptor antagonists, and anti-proliferative agents. These agents must be given systemically, however, and attainment of a therapeutically effective dose may not be possible; anti-proliferative (or anti-restenosis) concentrations may exceed the known toxic concentrations of these agents so that levels sufficient to produce smooth muscle inhibition may not be reached (Mak and Topol, 1997; Lang et al., 1991; Popma et al., 1991).
[0013] Additional clinical trials in which the effectiveness for preventing restenosis utilizing dietary fish oil supplements or cholesterol lowering agents has been examined showing either conflicting or negative results so that no pharmacological agents are as yet clinically available to prevent post-angioplasty restenosis (Mak and Topol, 1997; Franklin and Faxon, 1993: Serruys, P. W. et al., 1993). Recent observations suggest that the antilipid/antioxidant agent, probucol may be useful in preventing restenosis but this work requires confirmation (Tardif et al., 1997; Yokoi, et al., 1997). Probucol is presently not approved for use in the United States and a thirty-day pretreatment period would preclude its use in emergency angioplasty. Additionally, the application of ionizing radiation has shown significant promise in reducing or preventing restenosis after angioplasty in patients with stents (Teirstein et al., 1997). Currently, however, the most effective treatments for restenosis are repeat angioplasty, atherectomy or coronary artery bypass grafting, because no therapeutic agents currently have Food and Drug Administration approval for use for the prevention of post-angioplasty restenosis.
[0014] Unlike systemic pharmacologic therapy, stents have proven effective in significantly reducing restenosis. Typically, stents are balloon-expandable slotted metal tubes (usually, but not limited to, stainless steel), which, when expanded within the lumen of an angioplastied coronary artery, provide structural support through rigid scaffolding to the arterial wall. This support is helpful in maintaining vessel lumen patency. In two randomized clinical trials, stents increased angiographic success after percutaneous transluminal coronary angioplasty, by increasing minimal lumen diameter and reducing, but not eliminating, the incidence of restenosis at six months (Serruys et al., 1994; Fischman et al., 1994).
[0015] Additionally, the heparin coating of stents appears to have the added benefit of producing a reduction in sub-acute thrombosis after stent implantation (Serruys et al., 1996). Thus, sustained mechanical expansion of a stenosed coronary artery with a stent has been shown to provide some measure of restenosis prevention, and the coating of stents with heparin has demonstrated both the feasibility and the clinical usefulness of delivering drugs locally, at the site of injured tissue.
[0016] Accordingly, there exists a need for effective drugs and drug delivery systems for the effective prevention and treatment of neointimal thickening that occurs after percutaneous transluminal coronary angioplasty and stent implantation while minimizing the risk associated with clot formation.
SUMMARY OF THE INVENTION
[0017] The drug combinations and delivery devices of the present invention provide a means for overcoming the difficulties associated with the methods and devices currently in use as briefly described above.
[0018] In accordance with one aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body having an inner surface facing the lumen of a blood vessel and an outer surface facing, and in an expanded state, contacting the innermost wall of a blood vessel, and at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the outer surface of the tubular body.
[0019] In accordance with another aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body including one or more hoop elements configured to be the primary radial load-bearing elements of the expandable scaffold structure and one or more connector elements connecting adjacent hoop elements to form a substantially tubular structure having a luminal surface and an abluminal surface, the one or more connector elements and the one or more hoop elements having a predetermined wall thickness, wherein the wall thickness is defined by the radial distance between the abluminal surface and the luminal surface, and at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the abluminal surface of the tubular body.
[0020] In accordance with another aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body including one or more hoop elements configured to be the primary radial load-bearing elements of the expandable scaffold structure and one or more connector elements connecting adjacent hoop elements to form a substantially tubular structure having a luminal surface facing the lumen of a blood vessel and an abluminal surface facing, and in an expanded state, contacting the innermost wall of a blood vessel, the one or more connector elements and the one or more hoop elements having a predetermined wall thickness, wherein the wall thickness is defined by the radial distance between the luminal surface and the abluminal surface, and at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the abluminal surface of the tubular body.
[0021] In accordance with another aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body including one or more hoop elements configured to be the primary radial load-bearing elements of the stent and one or more connector elements connecting adjacent hoop elements to form a substantially tubular structure having a luminal surface facing the lumen of a blood vessel and an abluminal surface facing, and in an expanded state, contacting the innermost wall of a blood vessel, the one or more connector elements and the one or more hoop elements having a predetermined wall thickness, wherein the wall thickness is defined by the radial distance between the luminal surface and the abluminal surface; and at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the abluminal surface of the tubular body and at least a portion of the wall thickness.
[0022] In accordance with another aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body including one or more hoop elements configured to be the primary radial load-bearing elements of the expandable scaffold structure and one or more connector elements connecting adjacent hoop elements to form a substantially tubular structure having a luminal surface facing the lumen of a blood vessel and an abluminal surface facing, and in an expanded state, contacting the innermost wall of a blood vessel, the one or more connector elements and the one or more hoop elements having a predetermined wall thickness, wherein the wall thickness is defined by the radial distance between the luminal surface and the abluminal surface, at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the abluminal surface of the tubular body; and at least one layer of one or more anti-thrombotic compounds affixed to the at least one anti-proliferative layer.
[0023] In accordance with another aspect, the present invention is directed to an intraluminal medical device. The intraluminal medical device comprising an expandable scaffold structure having a substantially tubular body, the tubular body including one or more hoop elements configured to be the primary radial load-bearing elements of the stent and one or more connector elements connecting adjacent hoop elements to form a substantially tubular structure having a luminal surface facing the lumen of a blood vessel and an abluminal surface facing, and in an expanded state, contacting the innermost wall of a blood vessel, the one or more connector elements and the one or more hoop elements having a predetermined wall thickness, wherein the wall thickness is defined by the radial distance between the luminal surface and the abluminal surface, at least one layer of one or more anti-proliferative compounds affixed only to at least a portion of the abluminal surface of the tubular body and at least a portion of the wall thickness, and at least one layer of one or more anti-thrombotic compounds affixed to the at least one anti-proliferative layer.
[0024] The intraluminal medical device of the present invention utilizes one or more drugs, agents or compounds for the prevention and treatment of vascular disease caused by injury. An intraluminal medical device, for example, a stent may be coated with one or more drugs, agents or compounds that reduce smooth muscle cell proliferation, reduce inflammation and reduce thrombosis. Essentially, stents or other similar medical devices, e.g. grafts, in combination with one or more drugs, agents or compounds which prevent or reduce smooth muscle cell proliferation, reduce thrombosis and reduce inflammation may provide the most efficacious treatment of restenosis and other vascular tissue injury/disease. The local administration of these drugs, agents or compounds will result in higher vessel tissue concentrations and lower toxicity due to reduced dosages than that associated with systemic delivery of the same drugs, agents or compounds.
[0025] The intraluminal medical device of the present invention may be selectively coated with the drugs, agents or compounds such that the most efficient delivery of the drugs, agents or compounds may be achieved. For example, the drugs, agents or compounds for preventing or reducing smooth muscle cell proliferation may be incorporated into the device on the surface which comes in direct contact with the affected tissue while the drugs, agents or compounds for inhibiting coagulation may be incorporated into the device on the surface which comes into contact with the blood. Alternately, nothing may be placed on the surface that comes into contact with the blood.
[0026] The intraluminal medical device of the present invention makes use of various techniques and methodologies of affixing therapeutic drugs, agents or compounds to intraluminal medical devices. Accordingly, delivery of these drugs, agents or compounds may be optimally achieved. Since the drugs, agents or compounds are locally delivered, the patient, as well as the physician, will not have to be concerned with the need for continuous administration, e.g. orally or intravenously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
[0028] FIG. 1 is a view along the length of an exemplary stent (ends not shown) prior to expansion showing the exterior surface of the stent and the characteristic banding pattern in accordance with the present invention.
[0029] FIG. 2 is a perspective view of the stent of FIG. 1 having reservoirs in accordance with the present invention.
[0030] FIG. 3 is a cross-sectional view of a band of the stent of FIG. 1 having drug coatings thereon in accordance with a first exemplary embodiment of the present invention.
[0031] FIG. 4 is a cross-sectional view of a band of the stent of FIG. 1 having drug coatings thereon in accordance with a second exemplary embodiment of the present invention.
[0032] FIG. 5 is a cross-sectional view of a band of the stent of FIG. 1 having drug coatings thereon in accordance with a third exemplary embodiment of the present invention.
[0033] FIG. 6 is a partial, planar representation of a second exemplary stent in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The drug combinations and delivery devices of the present invention may be utilized to effectively prevent and treat vascular disease, and in particular, vascular disease caused by injury. Various medical treatment devices utilized in the treatment of vascular disease may ultimately induce further complications. For example, balloon angioplasty is a procedure utilized to increase blood flow through an artery and is the predominant treatment for coronary vessel stenosis. However, as stated above, the procedure typically causes a certain degree of damage to the vessel wall, thereby potentially exacerbating the problem at a point later in time. Although other procedures and diseases may cause similar injury, the present invention will be described with respect to the treatment of restenosis and related complications following percutaneous transluminal coronary angioplasty.
[0035] As stated previously, the implantation of a coronary stent in conjunction with balloon angioplasty is highly effective in treating acute vessel closure and may reduce the risk of restenosis. Intravascular ultrasound studies (Mintz et al., 1996) suggest that coronary stenting effectively prevents vessel constriction and that most of the late luminal loss after stent implantation is due to plaque growth, probably related to neointimal hyperplasia. The late luminal loss after coronary stenting is almost two times higher than that observed after conventional balloon angioplasty. Thus, inasmuch as stents prevent at least a portion of the restenosis process, a combination of drugs, agents or compounds, which prevents smooth muscle cell proliferation, reduces inflammation and reduces coagulation or prevents smooth muscle cell proliferation by multiple mechanisms, reduces inflammation and reduces coagulation combined with a stent may provide the most efficacious treatment for post-angioplasty restenosis. The systemic use of drugs, agents or compounds in combination with the local delivery of the same or different drugs, agents or compounds may also provide a beneficial treatment option.
[0036] The local delivery of multiple drugs, agents or compounds from a stent has the following advantages; namely, the prevention of vessel recoil and remodeling through the scaffolding action of the stent and the prevention of multiple components of neointimal hyperplasia or restenosis as well as a reduction in inflammation and thrombosis. This local administration of drugs, agents or compounds to stented coronary arteries may also have additional therapeutic benefit. For example, higher tissue concentrations of the drugs, agents, or compounds can be achieved utilizing local delivery, rather than systemic administration. In addition, reduced systemic toxicity may be achieved utilizing local delivery rather than systemic administration while maintaining higher tissue concentrations. Also in utilizing local delivery from a stent rather than systemic administration, a single procedure may suffice with better patient compliance. An additional benefit of combination drug/agent/compound therapy may be to reduce the dose of each of the therapeutic drugs, agents or compounds, thereby limiting their toxicity, while still achieving a reduction in restenosis, inflammation and thrombosis. Local stent-based therapy is therefore a means of improving the therapeutic ratio (efficacy/toxicity) of anti-restenosis, anti-inflammatory, anti-thrombotic drugs, agents or compounds.
[0037] There are a multiplicity of stent designs that may be utilized following percutaneous transluminal coronary angioplasty. Although any number of stent designs may be utilized in accordance with the present invention, for simplicity, one particular stent will be described in exemplary embodiments of the present invention. The skilled artisan will recognize that any number of stents may be utilized in connection with the present invention.
[0038] A stent is commonly used as a tubular structure left inside the lumen of a duct to relieve an obstruction. Commonly, stents are inserted into the lumen in a non-expanded form and are then expanded autonomously, or with the aid of a second device in situ. A typical method of expansion occurs through the use of a catheter-mounted angioplasty balloon which is inflated within the stenosed vessel or body passageway in order to shear and disrupt the obstructions associated with the wall components of the vessel and to obtain an enlarged lumen.
[0039] FIG. 1 illustrates an exemplary stent 100 which may be utilized in accordance with an exemplary embodiment of the present invention. The expandable cylindrical stent 100 comprises a fenestrated structure for placement in a blood vessel, duct or lumen to hold the vessel, duct or lumen open, more particularly for protecting a segment of artery from restenosis after angioplasty. The stent 100 may be expanded circumferentially and maintained in an expanded configuration, that is circumferentially or radially rigid. The stent 100 is axially flexible and when flexed at a band, the stent 100 avoids any externally-protruding component parts.
[0040] The stent 100 generally comprises first and second ends with an intermediate section therebetween. The stent 100 has a longitudinal axis and comprises a plurality of longitudinally disposed bands 102 , wherein each band 102 defines a generally continuous wave along a line segment parallel to the longitudinal axis. A plurality of circumferentially arranged links 104 maintain the bands 102 in a substantially tubular structure. Essentially, each longitudinally disposed band 102 is connected at a plurality of periodic locations, by a short circumferentially arranged link 104 to an adjacent band 102 . The wave associated with each of the bands 102 has approximately the same fundamental spatial frequency in the intermediate section, and the bands 102 are so disposed that the wave associated with them are generally aligned so as to be generally in phase with one another. As illustrated in the figure, each longitudinally arranged band 102 undulates through approximately two cycles before there is a link to an adjacent band 102 .
[0041] The stent 100 may be fabricated utilizing any number of methods. For example, the stent 100 may be fabricated from a hollow or formed stainless steel tube that may be machined using lasers, electric discharge milling, chemical etching or other means. The stent 100 is inserted into the body and placed at the desired site in an unexpanded form. In one embodiment, expansion may be effected in a blood vessel by a balloon catheter, where the final diameter of the stent 100 is a function of the diameter of the balloon catheter used.
[0042] It should be appreciated that a stent 100 in accordance with the present invention may be embodied in a shape-memory material, including, for example, an appropriate alloy of nickel and titanium or stainless steel. In this embodiment after the stent 100 has been formed it may be compressed so as to occupy a space sufficiently small as to permit its insertion in a blood vessel or other tissue by insertion means, wherein the insertion means include a suitable catheter, or flexible rod. On emerging from the catheter, the stent 100 may be configured to expand into the desired configuration where the expansion is automatic or triggered by a change in pressure, temperature or electrical stimulation.
[0043] FIG. 2 illustrates an exemplary embodiment of the present invention utilizing the stent 100 illustrated in FIG. 1 . As illustrated, the stent 100 may be modified to comprise one or more reservoirs 106 . Each of the reservoirs 106 may be opened or closed as desired. These reservoirs 106 may be specifically designed to hold the drugs, agents or compounds to be delivered. Regardless of the design of the stent 100 , it is preferable to have the drugs, agents or compounds dosage applied with enough specificity and a sufficient concentration to provide an effective dosage in the lesion area. In this regard, the reservoir size in the bands 102 is preferably sized to adequately apply the drugs, agents or compounds dosage at the desired location and in the desired amount.
[0044] In an alternate exemplary embodiment, the entire inner and outer surface of the stent 100 may be coated with various drug, agent or compound combinations in therapeutic dosage amounts. A detailed description of various drugs, agents, or compounds as well as exemplary coating techniques is described below. It is, however, important to note that the coating techniques may vary depending on the drugs, agents or compounds. Also, the coating techniques may vary depending on the material forming the stent or other intraluminal medical device.
[0045] Referring to FIG. 6 , there is illustrated a partial planar view of a second exemplary stent 600 in accordance with the present invention. The exemplary stent 600 comprises a plurality of hoop components 602 interconnected by a plurality of flexible connectors 604 . The hoop components 602 are formed as a continuous series of substantially circumferentially oriented radial strut members 606 and alternating radial arc members 608 . Although shown in planar view, the hoop components 602 are essentially ring members that are linked together by the flexible connectors 604 to form a substantially tubular stent structure. The combination of radial strut members 106 and alternating radial arc members 608 form a substantially sinusoidal pattern. Although the hoop components 602 may be designed with any number of design features and assume any number of configurations, in the exemplary embodiment, the radial strut members 606 are wider in their central regions 610 . This design feature may be utilized for a number of purposes, including, increased surface area for drug delivery.
[0046] The flexible connectors 604 are formed from a continuous series of substantially longitudinally oriented flexible strut members 612 and alternating flexible arc members 614 . The flexible connectors 604 , as described above, connect adjacent hoop components 602 together. In this exemplary embodiment, the flexible connectors 604 have a substantially N-shape with one end being connected to a radial arc member on one hoop component and the other end being connected to a radial arc member on an adjacent hoop component. As with the hoop components 602 , the flexible connectors 604 may comprise any number of design features and any number of configurations. In the exemplary embodiment, the ends of the flexible connectors 604 are connected to different portions of the radial arc members of adjacent hoop components for ease of nesting during crimping of the stent. It is interesting to note that with this exemplary configuration, the radial arcs on adjacent hoop components are slightly out of phase, while the radial arcs on every other hoop component are substantially in phase. In addition, it is important to note that not every radial arc on each hoop component need be connected to every radial arc on the adjacent hoop component.
[0047] It is important to note that any number of designs may be utilized for the flexible connectors or connectors in an intraluminal scaffold or stent. For example, in the design described above, the connector comprises two elements, substantially longitudinally oriented strut members and flexible arc members. In alternate designs, however, the connectors may comprise only a substantially longitudinally oriented strut member and no flexible arc member or a flexible arc connector and no substantially longitudinally oriented strut member.
[0048] The substantially tubular structure of the stent 600 provides the scaffolding for maintaining the patentcy of substantially tubular organs, such as arteries. The stent 600 comprises a luminal surface and an abluminal surface. The distance between the two surfaces defines the wall thickness as is described in detail above. The stent 600 has an unexpanded diameter for delivery and an expanded diameter, which roughly corresponds to the normal diameter of the organ into which it is delivered. As tubular organs such as arteries may vary in diameter, different size stents having different sets of unexpanded and expanded diameters may be designed without departing from the spirit of the present invention. As described herein, the stent 600 may be formed form any number of absorbable and non-absorbable metallic materials, including cobalt-based alloys, iron-based alloys, titanium-based alloys, magnesium alloys, refractory-based alloys and refractory metals as well as non-metallic materials such as absorbable and non-absorbable polymers and ceramics.
[0049] Rapamycin is a macroyclic triene antibiotic produced by streptomyces hygroscopicus as disclosed in U.S. Pat. No. 3,929,992. It has been found that rapamycin among other things inhibits the proliferation of vascular smooth muscle cells in vivo. Accordingly, rapamycin may be utilized in treating intimal smooth muscle cell hyperplasia, restenosis, and vascular occlusion in a mammal, particularly following either biologically or mechanically mediated vascular injury, or under conditions that would predispose a mammal to suffering such a vascular injury. Rapamycin functions to inhibit smooth muscle cell proliferation and does not interfere with the re-endothelialization of the vessel walls.
[0050] Rapamycin reduces vascular hyperplasia by antagonizing smooth muscle proliferation in response to mitogenic signals that are released during an angioplasty. Inhibition of growth factor and cytokine mediated smooth muscle proliferation at the late GI phase of the cell cycle is believed to be the dominant mechanism of action of rapamycin. However, rapamycin is also known to prevent T-cell proliferation and differentiation when administered systemically. This is the basis for its immunosuppresive activity and its ability to prevent graft rejection.
[0051] As used herein, rapamycin includes rapamycin and all analogs, derivatives and congeners that bind FKBP12 and possesses the same pharmacologic properties as rapamycin.
[0052] Although the anti-proliferative effects of rapamycin may be achieved through systemic use, superior results may be achieved through the local delivery of the compound. Essentially, rapamycin is effective in the tissues, which are in proximity to the compound, and has diminished effect as the distance from the delivery device increases. In order to take advantage of this effect, one would want rapamycin to be in direct contact with the lumen walls. Accordingly, in a preferred embodiment, rapamycin is incorporated into the outer surface of the stent or portions thereof. Essentially, the rapamycin is preferably incorporated into the stent 100 , illustrated in FIG. 1 , where the stent 100 makes contact with the lumen wall.
[0053] Rapamycin may be incorporated into or affixed to the stent in a number of ways. In the exemplary embodiment, the rapamycin is directly incorporated into a polymeric matrix and sprayed onto the outer surface of the stent. The rapamycin elutes from the polymeric matrix over time and enters the surrounding tissue. The rapamycin preferably remains on the stent for at least three days up to approximately six months, and more preferably between seven and thirty days.
[0054] Any number of non-erodible polymers may be utilized in conjunction with the rapamycin. In the preferred embodiment, the polymeric matrix comprises two layers. The base layer comprises a solution of ethylene-co-vinylacetate and polybutylmethacrylate. The rapamycin is incorporated into this base layer. The outer layer comprises only polybutylmethacrylate and acts as a diffusion barrier to prevent the rapamycin from eluting too quickly. The thickness of the outer layer or top coat determines the rate at which the rapamycin elutes from the matrix. Essentially, the rapamycin elutes from the matrix by diffusion through the polymer molecules. Polymers are permeable and/or semi-permiable, thereby allowing solids, liquids and gases to escape therefrom. The total thickness of the polymeric matrix is in the range from about 1 micron to about 20 microns or greater.
[0055] The ethylene-co-vinylacetate, polybutylmethacrylate and rapamycin solution may be incorporated into or onto the stent in a number of ways. For example, the solution may be sprayed onto the stent or the stent may be dipped into the solution. In one exemplary embodiment, the solution is sprayed onto the stent and then allowed to dry. In another exemplary embodiment, the solution may be electrically charged to one polarity and the stent electrically changed to the opposite polarity. In this manner, the solution and stent will be attracted to one another. In using this type of spraying process, waste may be reduced and more precise control over the thickness of the coat may be achieved.
[0056] Since rapamycin acts by entering the surrounding tissue, it is preferably only affixed to the surface of the stent making contact with one tissue. Typically, only the outer surface of the stent makes contact with the tissue. Accordingly, in a preferred embodiment, only the outer surface of the stent is coated with rapamycin.
[0057] The circulatory system, under normal conditions, has to be self-sealing, otherwise continued blood loss from an injury would be life threatening. Typically, all but the most catastrophic bleeding is rapidly stopped though a process known as hemostasis. Hemostasis occurs through a progression of steps. At high rates of flow, hemostasis is a combination of events involving platelet aggregation and fibrin formation. Platelet aggregation leads to a reduction in the blood flow due to the formation of a cellular plug while a cascade of biochemical steps leads to the formation of a fibrin clot.
[0058] Fibrin clots, as stated above, form in response to injury. There are certain circumstances where blood clotting or clotting in a specific area may pose a health risk. For example, during percutaneous transluminal coronary angioplasty, the endothelial cells of the arterial walls are typically injured, thereby exposing the sub-endothelial cells. Platelets adhere to these exposed cells. The aggregating platelets and the damaged tissue initiate further biochemical process resulting in blood coagulation. Platelet and fibrin blood clots may prevent the normal flow of blood to critical areas. Accordingly, there is a need to control blood clotting in various medical procedures. Compounds that do not allow blood to clot are called anti-coagulants. Essentially, an anti-coagulant is an inhibitor of thrombin formation or function. These compounds include drugs such as heparin and hirudin. As used herein, heparin includes all direct or indirect inhibitors of thrombin or Factor Xa.
[0059] In addition to being an effective anti-coagulant, heparin has also been demonstrated to inhibit smooth muscle cell growth in vivo. Thus, heparin may be effectively utilized in conjunction with rapamycin in the treatment of vascular disease. Essentially, the combination of rapamycin and heparin may inhibit smooth muscle cell growth via two different mechanisms in addition to the heparin acting as an anti-coagulant.
[0060] Because of its multifunctional chemistry, heparin may be immobilized or affixed to a stent in a number of ways. For example, heparin may be immobilized onto a variety of surfaces by various methods, including the photolink methods set forth in U.S. Pat. Nos. 3,959,078 and 4,722,906 to Guire et al. and U.S. Pat. Nos. 5,229,172; 5,308,641; 5,350,800 and 5,415,938 to Cahalan et al. Heparinized surfaces have also been achieved by controlled release from a polymer matrix, for example, silicone rubber, as set forth in U.S. Pat. Nos. 5,837,313; 6,099,562 and 6,120,536 to Ding et al.
[0061] In one exemplary embodiment, heparin may be immobilized onto the stent as briefly described below. The surface onto which the heparin is to be affixed is cleaned with ammonium peroxidisulfate. Once cleaned, alternating layers of polyethylenimine and dextran sulfate are deposited thereon. Preferably, four layers of the polyethylenimine and dextran sulfate are deposited with a final layer of polyethylenimine. Aldehyde-end terminated heparin is then immobilized to this final layer and stabilized with sodium cyanoborohydride. This process is set forth in U.S. Pat. Nos. 4,613,665; 4,810,784 to Larm and U.S. Pat. No. 5 , 049 , 403 to Larm et al.
[0062] Unlike rapamycin, heparin acts on circulating proteins in the blood and heparin need only make contact with blood to be effective. Accordingly, if used in conjunction with a medical device, such as a stent, it would preferably be only on the side that comes into contact with the blood. For example, if heparin is to be administered via a stent, it would only have to be on the inner surface of the stent to be effective.
[0063] In a preferred exemplary embodiment of the invention, a stent may be utilized in combination with rapamycin and heparin to treat vascular disease. In this exemplary embodiment, the heparin is immobilized to the inner surface of the stent so that it is in contact with the blood and the rapamycin is immobilized to the outer surface of the stent so that it is in contact with the surrounding tissue. FIG. 3 illustrates a cross-section of a band 102 of the stent 100 illustrated in FIG. 1 . As illustrated, the band 102 is coated with heparin 108 on its inner surface 110 and with rapamycin 112 on its outer surface 114 .
[0064] In an alternate exemplary embodiment, the stent may comprise a heparin layer immobilized on its inner surface, and rapamycin and heparin on its outer surface. Utilizing current coating techniques, heparin tends to form a stronger bond with the surface it is immobilized to then does rapamycin. Accordingly, it may be possible to first immobilize the rapamycin to the outer surface of the stent and then immobilize a layer of heparin to the rapamycin layer. In this embodiment, the rapamycin may be more securely affixed to the stent while still effectively eluting from its polymeric matrix, through the heparin and into the surrounding tissue. FIG. 4 illustrates a cross-section of a band 102 of the stent 100 illustrated in FIG. 1 . As illustrated, the band 102 is coated with heparin 108 on its inner surface 110 and with rapamycin 112 and heparin 108 on its outer surface 114 .
[0065] There are a number of possible ways to immobilize, i.e., entrapment or covalent linkage with an erodible bond, the heparin layer to the rapamycin layer. For example, heparin may be introduced into the top layer of the polymeric matrix. In other embodiments, different forms of heparin may be directly immobilized onto the top coat of the polymeric matrix, for example, as illustrated in FIG. 5 . As illustrated, a hydrophobic heparin layer 116 may be immobilized onto the top coat layer 118 of the rapamycin layer 112 . A hydrophobic form of heparin is utilized because rapamycin and heparin coatings represent incompatible coating application technologies. Rapamycin is an organic solvent-based coating and heparin is a water-based coating.
[0066] As stated above, a rapamycin coating may be applied to stents by a dip, spray or spin coating method, and/or any combination of these methods. Various polymers may be utilized. For example, as described above, polyethylene-co-vinyl acetate and polybutyl methacrylate blends may be utilized. Other polymers may also be utilized, but not limited to, for example, polyvinylidene fluoride-co-hexafluoropropylene and polyethylbutyl methacrylate-co-hexyl methacrylate. Also as described above, barrier or top coatings may also be applied to modulate the dissolution of rapamycin from the polymer matrix. In the exemplary embodiment described above, a thin layer of heparin is applied to the surface of the polymeric matrix. Because these polymer systems are hydrophobic and incompatible with the hydrophilic heparin, appropriate surface modifications may be required.
[0067] The application of heparin to the surface of the polymeric matrix may be performed in various ways and utilizing various biocompatible materials. For example, in one embodiment, in water or alcoholic solutions, polyethylene imine may be applied on the stents, with care not to degrade the rapamycin (e.g., pH<7, low temperature), followed by the application of sodium heparinate in aqueous or alcoholic solutions. As an extension of this surface modification, covalent heparin may be linked on polyethylene imine using amide-type chemistry (using a carbondiimide activator, e.g. EDC) or reductive amination chemistry (using CBAS-heparin and sodium cyanoborohydride for coupling). In another exemplary embodiment, heparin may be photolinked on the surface, if it is appropriately grafted with photo initiator moieties. Upon application of this modified heparin formulation on the covalent stent surface, light exposure causes cross-linking and immobilization of the heparin on the coating surface. In yet another exemplary embodiment, heparin may be complexed with hydrophobic quaternary ammonium salts, rendering the molecule soluble in organic solvents (e.g. benzalkonium heparinate, troidodecylmethylammonium heparinate). Such a formulation of heparin may be compatible with the hydrophobic rapamycin coating, and may be applied directly on the coating surface, or in the rapamycin/hydrophobic polymer formulation.
[0068] It is important to note that the stent may be formed from any number of materials, including various metals, polymeric materials and ceramic materials. Accordingly, various technologies may be utilized to immobilize the various drug, agent, compound combinations thereon. In addition, the drugs, agents or compounds may be utilized in conjunction with other percutaneously delivered medical devices such as grafts and profusion balloons.
[0069] In addition to utilizing an anti-proliferative and anti-coagulant, anti-inflammatories may also be utilized in combination therewith. One example of such a combination would be the addition of an anti-inflammatory corticosteroid such as dexamethasone with an anti-proliferative, such as rapamycin, cladribine, vincristine, taxol, or a nitric oxide donor and an anti-coagulant, such as heparin. Such combination therapies might result in a better therapeutic effect, i.e., less proliferation as well as less inflammation, a stimulus for proliferation, than would occur with either agent alone. The delivery of a stent comprising an anti-proliferative, anti-coagulant, and an anti-inflammatory to an injured vessel would provide the added therapeutic benefit of limiting the degree of local smooth muscle cell proliferation, reducing a stimulus for proliferation, i.e., inflammation and reducing the effects of coagulation thus enhancing the restenosis-limiting action of the stent.
[0070] In other exemplary embodiments of the inventions, growth factor or cytokine signal transduction inhibitor, such as the ras inhibitor, R115777, or a tyrosine kinase inhibitor, such as tyrphostin, might be combined with an anti-proliferative agent such as taxol, vincristine or rapamycin so that proliferation of smooth muscle cells could be inhibited by different mechanisms. Alternatively, an anti-proliferative agent such as taxol, vincristine or rapamycin could be combined with an inhibitor of extracellular matrix synthesis such as halofuginone. In the above cases, agents acting by different mechanisms could act synergistically to reduce smooth muscle cell proliferation and vascular hyperplasia. This invention is also intended to cover other combinations of two or more such drug agents. As mentioned above, such drugs, agents or compounds could be administered systemically, delivered locally via drug delivery catheter, or formulated for delivery from the surface of a stent, or given as a combination of systemic and local therapy.
[0071] Although only a few therapeutic agents are described above, any number of devices may be utilized to deliver therapeutic and pharmaceutic agents including: anti-proliferative/antimitotic agents including natural products such as vinca alkaloids (i.e. vinblastine, vincristine, and vinorelbine), paclitaxel, epidipodophyllotoxins (i.e. etoposide, teniposide), antibiotics (dactinomycin (actinomycin D) daunorubicin, doxorubicin and idarubicin), anthracyclines, mitoxantrone, bleomycins, plicamycin (mithramycin) and mitomycin, enzymes (L-asparaginase which systemically metabolizes L-asparagine and deprives cells which do not have the capacity to synthesize their own asparagine); antiplatelet agents such as G(GP) II b /III a inhibitors and vitronectin receptor antagonists; anti-proliferative/antimitotic alkylating agents such as nitrogen mustards (mechlorethamine, cyclophosphamide and analogs, melphalan, chlorambucil), ethylenimines and methylmelamines (hexamethylmelamine and thiotepa), alkyl sulfonates-busulfan, nirtosoureas (carmustine (BCNU) and analogs, streptozocin), trazenes—dacarbazinine (DTIC); anti-proliferative/antimitotic antimetabolites such as folic acid analogs (methotrexate), pyrimidine analogs (fluorouracil, floxuridine, and cytarabine), purine analogs and related inhibitors (mercaptopurine, thioguanine, pentostatin and 2-chlorodeoxyadenosine {cladribine}); platinum coordination complexes (cisplatin, carboplatin), procarbazine, hydroxyurea, mitotane, aminoglutethimide; hormones (i.e. estrogen); anti-coagulants (heparin, synthetic heparin salts and other inhibitors of thrombin); fibrinolytic agents (such as tissue plasminogen activator, streptokinase and urokinase), aspirin, dipyridamole, ticlopidine, clopidogrel, abciximab; antimigratory; antisecretory (breveldin); anti-inflammatory: such as adrenocortical steroids (cortisol, cortisone, fludrocortisone, prednisone, prednisolone, 6α-methylprednisolone, triamcinolone, betamethasone, and dexamethasone), non-steroidal agents (salicylic acid derivatives i.e. aspirin; para-aminophenol derivatives i.e. acetaminophen; indole and indene acetic acids (indomethacin, sulindac, and etodalac), heteroaryl acetic acids (tolmetin, diclofenac, and ketorolac), arylpropionic acids (ibuprofen and derivatives), anthranilic acids (mefenamic acid, and meclofenamic acid), enolic acids (piroxicam, tenoxicam, phenylbutazone, and oxyphenthatrazone), nabumetone, gold compounds (auranofin, aurothioglucose, gold sodium thiomalate); immunosuppressives: (cyclosporine, tacrolimus (FK-506), sirolimus (rapamycin), azathioprine, mycophenolate mofetil); angiogenic agents: vascular endothelial growth factor (VEGF), fibroblast growth factor (FGF); angiotensin receptor blockers; nitric oxide donors; antisense oligionucleotides and combinations thereof; cell cycle inhibitors, mTOR inhibitors, and growth factor receptor signal transduction kinase inhibitors; retenoids; cyclin/CDK inhibitors; HMG co-enzyme reductase inhibitors (statins); and protease inhibitors.
[0072] In an alternate exemplary embodiment, a stent or other intraluminal medical device may be coated on a single side or portion thereof. For example, a stent such as illustrated in FIGS. 1, 2 and 6 may be coated on the outer or abluminal surface with an anti-proliferative agent while the inner or luminal surface remains bare. This coating process may be easily achieved and offers a number of advantages, including a reduction in waste, improved deliverability and ease of manufacturing. Stents and other devices may be coated, electrostatic coating utilizing a number of techniques, including spray coating, electrostatic coating and ink jet printing. As described above, coating one surface or a portion thereof is desirable from the therapeutic perspective.
[0073] In yet another alternate exemplary embodiment, a stent or other intraluminal medical device may be coated on a single side or portion thereof as well as on the sides or a portion thereof. For example, as stated herein, a stent has a luminal surface, an abluminal surface and a wall thickness therebetween. In this exemplary embodiment, the abluminal surface or a portion thereof may be coated with an anti-proliferative agent or any other therapetuc agent, and the walls or sides of the device elements may also be coated with the same or different agent depending on function. In this manner, the surface in contact with the blood remains substantially free of any agent or compound.
[0074] While exemplary embodiments of the invention were described with respect to the treatment of restenosis and related complications following percutaneous transluminal coronary angioplasty, it is important to note that the local delivery of drug/drug combinations may be utilized to treat a wide variety of conditions utilizing any number of medical devices, or to enhance the function and/or life of the device. For example, intraocular lenses, placed to restore vision after cataract surgery is often compromised by the formation of a secondary cataract. The latter is often a result of cellular overgrowth on the lens surface and can be potentially minimized by combining a drug or drugs with the device. Other medical devices which often fail due to tissue in-growth or accumulation of proteinaceous material in, on and around the device, such as shunts for hydrocephalus, dialysis grafts, colostomy bag attachment devices, ear drainage tubes, leads for pace makers and implantable defibrillators can also benefit from the device-drug combination approach. Devices which serve to improve the structure and function of tissue or organ may also show benefits when combined with the appropriate agent or agents. For example, improved osteointegration of orthopedic devices to enhance stabilization of the implanted device could potentially be achieved by combining it with agents such as bone-morphogenic protein. Similarly other surgical devices, sutures, staples, anastomosis devices, vertebral disks, bone pins, suture anchors, hemostatic barriers, clamps, screws, plates, clips, vascular implants, tissue adhesives and sealants, tissue scaffolds, various types of dressings, bone substitutes, intraluminal devices, and vascular supports could also provide enhanced patient benefit using this drug-device combination approach. Perivascular wraps may be particularly advantageous, alone or in combination with other medical devices. The perivascular wraps may supply additional drugs to a treatment site. Essentially, any type of medical device may be coated in some fashion with a drug or drug combination which enhances treatment over use of the singular use of the device or pharmaceutical agent.
[0075] Although shown and described is what is believed to be the most practical and preferred embodiments, it is apparent that departures from specific designs and methods described and shown will suggest themselves to those skilled in the art and may be used without departing from the spirit and scope of the invention. The present invention is not restricted to the particular constructions described and illustrated, but should be constructed to cohere with all modifications that may fall within the scope of the appended claims.
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An intralumen medical device comprising anti-inflamatory and anti-thrombotic or anti-coagulant drugs, agents or compounds may be utilized in the treatment of vascular disease. The intralumen medical device is selectively coated with the drugs, agents or compounds for local delivery, thereby increasing their effectiveness and reducing potential toxicity associated with systemic use. The selective coating is utilized to ensure that the specific drugs, agents or compounds come into contact with or are delivered to the appropriate tissues and/or fluids for maximum effectiveness.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/976,496, filed Dec. 22, 2010, which is a continuation-in-part of U.S. patent application Ser. No. 12/460,483, filed Jul. 20, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 11/035,204, filed Jan. 13, 2005, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention is directed to personal makeup products, and in particular, to an improved nail polish applicator.
For many years women have purchased bottles of nail polish having a cap with brush wand, which enables them to colorize their nails in the convenience of their homes while also permitting them to take the bottle with them it in a purse or the like, for touch up as needed while outside the home. However, the proper application of nail polish for achieving a smooth, glossy finish, requires that all polish previously applied to the nails be fully removed. While at home, a woman will typically have a separate bottle of nail polish removing solvent and abrasive pads, amongst other tools for this purpose.
Whereas carrying a nail polish bottle in a purse for touch up does not represent a significant inconvenience, having only the nail polish available for use outside the home limits the circumstances under which the polish can be effectively applied outside the home. Most women would not go to the trouble of placing a nail polish bottle, a polish remover bottle, and a package of removal pads into what in current times is frequently a very modestly sized purse.
For many women, especially those who are outside the home for long periods during the day and must look their best throughout the day, the maintenance of perfectly defined, smooth, shiny nail coloring is an ongoing nuisance.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention, to provide a multi purpose fluid container for an integrated makeup kit, particularly an integrated nail makeup kit, wherein the nail polish, polish applicator brush, nail polish remover solvent, and nail polish remover pads are combined in a size and shape that is easily carried in a modestly sized purse or handbag, but which can quickly and easily be separated into a conventional nail polish applicator bottle with brush, and a jar containing a plurality of nail polish remover pads saturated with solvent.
When separated, each of the bottle and jar can rest on a flat surface, or be readily held in one's hand, such that each can be used independently of the other, in any sequence or order, without danger of spillage or mutual contamination.
In another embodiment, a removable nail file is incorporated into the multi purpose container. When the bottle and jar are separated, the nail file can be easily accessed and utilized independently from the bottle and jar, while the bottle and jar can be operated as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention will be described in further detail with reference to the accompanying drawing, in which:
FIG. 1 is an elevation view of the integrated multi purpose bottle and makeup kit, in the fully closed condition as would be carried in a hand bag or the like;
FIG. 2 is a section view of the integrated multi purpose makeup kit in the fully closed condition corresponding to FIG. 1 ;
FIG. 3 is an exploded section view of FIG. 2 ;
FIG. 4 shows the separated bottles or jars each resting on a flat surface that facilitates independent use;
FIG. 5 is a section view of another embodiment of the multi purpose makeup kit in the fully closed condition;
FIG. 6 is an exploded section view of FIG. 5 ;
FIG. 7 is an elevation view of another embodiment of the integrated multi purpose bottle and makeup kit with two separate nail polish containers;
FIG. 8 is a section view of the integrated multi purpose bottle and makeup kit of FIG. 7 ;
FIG. 9A is an exploded section view of FIG. 8 ;
FIG. 9B is an enlarged view showing the engagement of the nail polish containers and retainer in the embodiment depicted in FIGS. 7-9A ; and
FIG. 10 is an exploded section view of another embodiment of the integrated multi purpose bottle and makeup kit having a nail file disc.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-4 show a multi purpose fluid container in the form of an integrated nail makeup kit comprising an upper container 10 and a lower container 12 , which define an upper chamber 14 and a lower chamber 16 , respectively. The upper container 10 would typically have a cylindrical sidewall 18 and a circular bottom wall 20 which fluidly isolates the upper chamber 14 and from the lower chamber 16 . The lower end or base of the upper container 10 at bottom wall 20 preferably has a flange or rim 22 with internal threads that mate with external threads on a neck 24 that extends from an annular shoulder at the periphery of the upper end of the lower container 12 .
The upper container 10 has an access aperture 26 formed as a bore through an externally threaded neck 28 extending from the top wall. In the preferred product as marketed to consumers, the upper chamber 14 is substantially filled with one form of makeup fluid 30 , in particular, nail polish. The lower chamber 16 holds a different form of makeup that would be used in conjunction with the makeup in the upper chamber. In particular, the lower chamber holds a plurality of pads 36 saturated with any conventional solvent for nail polish. The lower container 12 preferably has a substantially cylindrical sidewall 32 and flat circular bottom wall 34 . The top need not have an upper wall, but rather is preferably open. The bottom wall 20 of the upper container 10 completes the encapsulation of the chamber 16 and thus maintains fluid isolation between chambers 14 and 16 when the upper and lower containers are secured together at the threaded interface 22 , 24 .
Because the solvent in the lower chamber 16 is typically highly volatile, a secure seal should be formed at the confronting surfaces of the lower side of the wall 20 against the rim of the neck 24 of the lower container 12 , or at the tight engagement of the threaded interface 22 , 24 . For example, a resilient annular gasket or the like could be glued to the rim of the neck 28 of container 12 , or the entire underside of the bottom wall 20 could be formed of a resilient gasket material. Moreover, a resilient O-ring 33 could also be located at the confronting surfaces at the bottom of the rim 22 of the upper container 10 and the shoulder at the upper periphery of the lower container 12 . One of ordinary skill in the art could readily design these confronting components in relation to the engagement of the threads to assure that the threads do not engage to the limit before the seal is effectuated.
The cap 38 has a cylindrical or substantially frustoconical handle 40 that is partially hollow such that a stem or wand 42 extends longitudinally from within the handle to a polish applicator brush or the like 44 . At the base of the handle 40 , internal threads 46 are provided at a diameter for engaging the external threads on neck 28 , in a manner that is typical of conventional nail polish bottles.
As may be appreciated from FIGS. 2 and 3 , the threaded brush cap 38 is selectively attachable to the neck 28 for opening and closing the aperture 26 . The brush 44 enters the chamber 14 , which encloses a first working volume, when the cap is attached to the neck and is entirely removed from the first working volume when the cap is detached from the neck. The lower chamber 16 partially encloses a second working volume such that when the threads 22 , 24 are engaged the top 48 of the lower chamber 16 is closed by the bottom wall 20 of the upper chamber and when the threads are disengaged the lower container 12 separates from the upper container 10 whereby the second working volume is exposed through the open top 48 . Clearly, whether the containers 10 , 12 are secured together as in FIG. 1 or detached as in FIG. 3 or 4 , the working volume 14 , 16 and thus the nail polish 30 and the polish remover pads 36 are always isolated from each other.
It should be appreciated that the composite makeup kit, particularly the combination of nail polish applicator bottle 10 and nail polish removal jar 12 , can readily be grasped in the hands and detached from each other for use, as shown in FIGS. 2 and 4 . FIG. 4 shows one subsequent step by which the user has placed the upper container or bottle 10 on a flat surface for ready access to the brush cap 38 while the other container or jar 12 for the saturated pads 36 is on the same flat surface nearby. The base of each container 10 , 12 should be flat or effectively flat for this purpose. Because the solvent that saturates the pads 36 is volatile, the user may wish to remove one or two pads 36 , and then reassemble the containers 10 , 12 before using the pads for removing previously applied polish from a portion of one nail, one entire nail, or all nails in the fingers of one hand. The cap 38 can then be removed from the upper container for applying polish while the pads 36 remain in a fluidly sealed environment.
It should also be appreciated that the number of nails from which polish can be removed by the inventory of pads 36 in chamber 16 , may differ from the number of nails that can be polished by the inventory of polish 30 in upper chamber 14 . This difference would most likely occur because all the pads 36 would be utilized before all of the polish 30 , or, due to the volatility of the solvent, some of the pads would become ineffective for removing polish. If the latter condition occurs, the user at her convenience at home, could easily detach the upper and lower containers 10 , 12 and pour solvent into chamber 16 through the open end 48 thereby replenishing the effectiveness of the pads. Furthermore, replacement pads can be made available as an after market item, provided they have the same area foot print as the cross section of the chamber 16 .
Although many configurations of the upper container 10 and lower container 12 and their inter-engagement are within the scope of the present invention, in the preferred embodiment, the overall shape is cylindrical with a length of the composite bottle (without cap) of approximately 2-4 inches, and an outer diameter or equivalent cross sectional dimension between opposed walls in the range of about 1-2 inches. The overall axial length of the upper container 10 and the lower container 12 are about equal and in most instances would not differ by more than a 60%-40% ratio. For an example with reference to FIG. 1 , the overall height h 1 of the lower bottle is preferably 1.0-1.5 inch, the overall height h 2 of the upper bottle including cap is preferably 2.0-2.5 inch, and the outer diameter d is about 1.5 inch. The cross section would typically be circular, but other cross sectional shapes such as oval, rectangular, or other polygon are also possible. It is not necessary that the cross sectional shape of the upper and lower containers 10 , 12 or working volumes 14 , 16 be identical. As a practical matter, the diameter of chamber 16 or similar cross dimension of a non-circular chamber, should be large enough to receive a pad that is large enough (e.g., at least ¾ in diameter) to be easily used for removing previously applied polish.
FIGS. 5 and 6 depict another embodiment of the multi purpose fluid container kit. This embodiment also comprises an upper container 50 defining an upper chamber 54 , and a lower container 52 defining a lower chamber 56 . The upper container 50 and lower container 52 can be formed generally identical to the upper and lower containers, 10 and 12 , in the previously disclosed embodiments. Preferably, the lower end or base of the upper container 50 at the bottom wall 58 has an externally threaded rim 60 configured to mate with the internal threads on the neck 62 of the lower container 52 . Preferably, both of the upper and lower bottom walls, 58 and 59 , are effectively flat.
As in the previous embodiments, the upper container 50 has an access aperture 64 formed as a bore through an externally threaded neck 66 extending from the top wall 68 . The upper chamber is configured to receive a longitudinally extending applicator wand attached to a frustoconical handle (represented collectively as reference numeral 78 in FIG. 6 ). Preferably, the upper chamber 54 holds makeup, such as nail polish, and the lower chamber 56 holds a plurality of pads 68 saturated with nail polish solvent.
Unlike the embodiment of FIGS. 1-4 , this embodiment has a removable impermeable cover 70 that is positionable within the inner boundaries of the lower container side wall 74 . The cover 70 is a fluid-impermeable unit that is configured to isolate the pads and solvent in the lower chamber 52 from the external environment, including the bottom wall 58 of the upper container when the container kit is in the closed condition ( FIG. 5 ). The cover 70 is generally circular and defines an outer radial edge and top and bottom surfaces. The top surface is preferably fit with a manually gripable dome shaped handle 76 . As depicted, the outer radial edge of the cover 70 comprises a pair of flexible lips 72 . Thus, when engaged, the cup seal isolates the solvent and pads from the external environment, including the outer surface of the bottom wall 58 .
In an alternate embodiment, the lips can be configured to engage an O-ring or like unit to enhance the isolation between the pads and the outer environment (not shown). When the cup seal 70 is positioned within the lower cavity 56 above the pads 68 , the O-ring is compressed by the side wall 74 , resulting in effective pressure on the inner surface of the side wall 74 .
Similar to the FIGS. 1-4 embodiment, a user can detach the nail polish applicator bottle 50 and nail polish removal jar 52 . Due to the effective flatness of the respective bottom walls, 58 and 59 , the applicator bottle and nail polish removal jar can each be placed on a relatively flat surface, such as a tabletop, for use. A user can grip the handle 76 and lift the cover 70 to expose the pads 68 , remove a pad, and then replace the cover within the lower cavity above the pads, re-sealing the pads and solvent from the open air.
The cover 70 prevents nail polish removing solvent that is present in the lower chamber 56 from depositing on the bottom surface of the upper container 50 when the kit is in the closed condition. Accidental damage of a tabletop or like furniture with finish-removing solvent during use of the makeup kit is therefore avoided. Additionally, the cover 70 reduces or prevents evaporation of the typically highly volatile solvent while the kit is in use without requiring the user to re-attach the upper and lower chambers.
With reference to FIGS. 7-9 , an additional embodiment of the integrated nail makeup kit is disclosed. As can be seen, this embodiment features two separate upper containers, 100 and 101 , rather than the single upper container of the previous embodiments. Each respective upper container has a side wall ( 102 and 103 ) and bottom wall ( 106 and 107 ) which respectively define separate first and second upper chambers, 108 and 109 . The first and second upper containers, 100 and 101 , have access apertures, 110 and 111 . Each of the access apertures, 110 and 111 is formed as a bore through an externally threaded neck, 112 and 113 , that extends from the top wall, 114 and 115 , of the respective upper containers, 100 and 101 .
As shown, each of the upper containers, 100 and 101 , is fit with a cylindrical or substantially frustoconical handle, 116 and 117 , that is partially hollow and fit with internal threads for mating with the external threads of the respective necks, 112 and 113 . The handles, 116 and 117 , can have generally identical configurations to the handle 38 of the previous embodiment, with longitudinally-extending wands, 118 and 119 , fit with polish applicator brushes, 120 and 121 , opposite the handles, 116 and 117 .
In this embodiment, the lower container 104 is substantially identical to the lower container 12 of the previous embodiment. The lower container 104 has a substantially cylindrical side wall 122 and a substantially flat bottom wall 124 which collectively define a lower chamber 126 . Within the lower chamber is disposed a plurality of pads 128 that are saturated in nail polish solvent.
As indicated in FIGS. 7-9 , at least a portion of the outer surface of each of the upper container side walls, 102 and 103 , is configured to allow a generally flush meeting of the respective upper containers, 100 and 101 . In the depicted embodiment, each of the respective portions is generally flat (see reference numerals 130 and 131 , FIG. 9A ). However, other complementary configurations for these portions of the side walls are possible. Here, when the flat side wall portion 130 of the first upper container 100 is positioned against the flat side wall portion 131 of the second upper container, grooves 162 and 163 in the lower portions of the respective upper containers, are retained in ridges 164 and 165 of a bottle retainer 160 . FIGS. 7 and 8 depict the makeup kit in its secured or “closed” configuration. As can be seen in FIG. 8 , when in the closed configuration, the bottle retainer is capable of securing the two upper containers 100 and 101 . Similar to the previous embodiments which featured a single bottom wall 20 , when in the secured configuration, the bottle retainer 160 seals the lower chamber 126 from the external environment, and thus help prevent evaporation of the solvent therein.
FIGS. 9A & 9B depict an exploded view of the embodiment depicted in FIGS. 7 and 8 . Between the upper containers, 100 and 101 , and lower container 104 is positioned the bottle retainer 160 . The retainer 160 is configured to receive and retain the lower portion of each upper container 100 and 101 . A central wall 166 separates the retainer into two wells 172 and 173 . The lower portions of the respective upper containers are retained in wells 172 and 173 when the makeup kit is in the closed configuration. In this embodiment, the retainer 160 is configured for mating with the lower portion of each upper container via the retainer ridges 164 and 165 and grooves 162 and 163 in the upper container lower portions. The lower outer surface of the retainer 160 is fit with threading 168 that mates with the inner threading 134 of the lower container 104 . The retainer piece allows the user to remove one or both of the upper containers 100 or 101 from the wells 172 and 173 while maintaining a hermetic seal on the lower container 104 . The retainer piece allows the user to employ the upper containers 100 or 101 , while simultaneously ensuring that the volatile solvent does not evaporate during use.
Like the previous embodiments, this embodiment can include a resilient O-ring 136 and impermeable cover 170 or similar sealing element positioned at the confronting surfaces of the upper periphery of the lower container 104 and the bottom of the outer surface of the retainer 160 . A removable cover, such as that depicted by reference numeral 138 , can be included to conceal and help prevent wear or breakage of the handles, 116 and 117 . Since the first and second upper chambers, 108 and 109 , are completely isolated from each other at all times, each chamber can be filled with a different color, type, or style of nail polish fluid, thus offering variety to the consumer. Notably, this embodiment of the makeup kit is not limited in shape, size or number of upper containers.
Any of the disclosed embodiments of the makeup kit can include additional beautification utensils, such as, for example the nail file or sanding disc 140 shown in FIG. 10 . The nail file 140 is positioned and secured between the upper container 142 and lower container 144 . Also depicted in FIG. 10 is a modification to the removable cover 146 , here having a flexible tab 148 in place of a gripable handle 76 of the previous embodiment. A removable plastic or foil seal, like that depicted as reference numeral 150 in FIG. 9 , can be fixed to the upper rim 152 of the lower container 104 to completely seal the lower chamber 126 prior to an initial use of a solvent saturated pad 128 .
While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.
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A multi purpose fluid container for an integrated makeup kit, particularly an integrated nail makeup kit, nail polish, a polish applicator brush, nail file, nail polish remover solvent, and nail polish remover pads are combined in a convenient size and shape for facile transport in a modestly sized purse or handbag, but which can quickly and easily be separated into a nail polish applicator bottle with brush, a nail file, and a jar containing a plurality of nail polish remover pads saturated with solvent. When separated, the bottles and jar can rest on a flat surface, or be readily held in one's hand, such that the bottles and jar can be used independently of each other, in any sequence or order, without danger of spillage or contamination, and the nail file can be utilized independently from the bottle and jar.
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This invention relates generally to a molding system for producing thermosetting resin molded products, and in particular to a system which employs electrically-heated mold inserts which may be easily and quickly installed in and removed from a master frame.
BACKGROUND OF THE INVENTION
A mold system which employs interchangeable inserts for producing different molded parts is disclosed in my U.S. Pat. No. 4,828,479, issued on May 9, 1989. In that patent, I disclose a master frame which consists of an injection side and an ejection side each with its own interchangeable insert, and which, when the sections of the master frame are assembled in molding condition, produce molded pieces one at a time. The frame sides are separable along a parting line or plane for molded part removal. Each of the inserts is provided with a liquid channel and means is provided for pumping liquid through the channel from an external liquid coolant or heater source.
Obviously, when changing from one production job to another, removal of one or more of the inserts requires the liquid flow to be discontinued during replacement. More importantly, using liquid for heating has limitations, particularly when used for molding thermosetting plastic materials which require temperatures on the order of 400 to 600 degrees Fahrenheit. It is known to use electrical heater bands for heating molds, but if heater bands were employed with an interchangeable mold insert system such as that disclosed in my aforementioned '479 patent, the wiring connections to the heater bands would present a problem during replacement of inserts. The electrical connections to the bands would have to be disconnected, or if left intact, the bands would have to be separated from the inserts. Otherwise, if the bands and wires were to remain with their individual inserts, the wires would have to be "snaked" through openings in the master frame. It is avoidance of these problems which is addressed by the present invention. The solution adapts the disclosed type of molding system for electrical heating of the mold inserts and thereby provides for improved molding operations in connection with molding of thermosetting plastics.
SUMMARY OF THE INVENTION
In accordance with this invention, mold inserts having heater bands and their electrical wiring leads affixed to the inserts are interchangeably mounted in a master frame, while maintaining the heaters and their wiring intact with the inserts during replacement. The heaters and their wiring become permanent parts of each insert and can be removed or installed as a unit. The unit also consists of plugs at the ends of the wiring remote from the heating element, for attachment to controls and a power source.
To accommodate replacement of such units, there is provided a closable recess that extends from the bore or cavity which receives the mold insert, to an outer portion of the master frame. The recess permits passage of the wiring heater band into and out of the recess laterally whenever the recess is open. When the parts are in molding condition, the recess is covered by a closure member which is preferably guided essentially radially inward from the outer edge of the master frame toward the bore. The closure member is then fastened to a portion of the master frame to become a part of the frame during molding.
Since it is necessary to closely maintain the mold insert at a preselected temperature according to the thermosetting material being molded, a temperature-controlling thermocouple is provided. The thermocouple has a temperature-sensing end or tip which extends into a hole in the insert during molding. By mounting the thermocouple in the recess closure member, the tip of the thermocouple can be directed into the insert hole as the closure member is placed into position. This manner of thermocouple mounting also insures that the thermocouple tip is removed from the mold insert prior to lateral removal of the insert from its cavity. Parts interference would occur if the thermocouple were not removed first, and this invention eliminates the need for an operator to remember to first remove the thermocouple. Thus, the recess closure member is also a thermocouple retainer in the preferred form of the invention. The retainer serves not only to open or close the recess for lateral movement of the wiring into and out of the bore or cavity along with the mold insert and heater, but it also places the tip of the thermocouple into and out of operative, temperature-sensing position.
The retainer can support the thermocouple permanently, so that the same thermocouple can be employed when changing to a different mold insert. The heater band wiring is free of or unconnected to the retainer, so that each mold insert can be kept intact with the heater band and its wiring and plug, and be independent of the retainer. Preferably, the internal cavity of the master frame adjacent the external surface of the heater band, when the insert is mounted in operative condition, is provided with a heat insulating band. This minimizes heat transfer outwardly into the master frame. Insulating means can also be provided at external surfaces of the master frame to prevent dissipation of heat from the frame to the surrounding atmosphere. This not only provides for better heat retention within the mold insert, but also conserves electrical energy.
The primary object of the invention is to provide a molding system having interchangeable mold inserts and an electrical heater and associated wiring for each of the mold inserts, each heater, wiring and insert being easily removed from or installed in a master frame section as a unit.
A more specific object of my invention is to provide a recess or channel from a cavity of a master frame to its external surface, and to further provide a thermocouple retainer which serves to close the recess and simultaneously install the thermocouple internally of the mold insert.
Other objects and advantages will be apparent from the accompanying description in which reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a pair of mold master frame sections separable along a parting plane, each section having its own mold insert and means for electrically heating the inserts.
FIG. 2 is a vertical view, partly in cross-section, of the injection side of the mold shown at the right side of FIG. 1.
FIG. 3 is a vertical view, partly in cross-section, of the ejection side of the mold shown at the left side of FIG. 1.
FIG. 4 is a fragmentary, exploded, isometric view illustrating a mold insert and its wiring positioned in the injection side of master frame and also illustrating details of the elements of the thermocouple retainer.
FIG. 5 is a view similar to that of FIG. 4 but showing the ejection side of the master frame and the thermocouple retainer.
FIG. 6 is an enlarged fragmentary, vertical cross-sectional view of the retainer and thermocouple in their operative positions in the injection side of the mold.
DETAILED DESCRIPTION
Referring now to FIG. 1, the master frame 10 consists of two sections comprising an injection side 12 and an ejection side 14. The sides 12 and 14 are shown in separated fashion, and when assembled for molding, pins 16 in side 12 fit into holes 18 in side 14 to align the master frame sections. An injection mold insert 20 is mounted in the injection side 12, and an ejection mold insert 22 is mounted in ejection side 14 in a manner disclosed in my U.S. Pat. No. 4,828,479. When the pins 16 are engaged in the holes 18, the two sides 12 and 14 can be held together in conventional fashion. The two assembled sides 12 and 14 thus become the master frame 10, enabling the hot thermosetting material to be used with this invention to pass from side 12 through a hole 24 into a part cavity 26 formed in the ejection mold insert 22. When the sides 12 and 14 are together, it will be seen that the faces of the two inserts 20 and 22 and the surrounding area of the injection and ejection sides 12 and 14 lie in a common plane which will be designated hereinafter as a parting plane 28. (FIGS. 2 and 3.) The mutually confronting surfaces of the inserts 20 and 22 will be in contact and lie in the parting plane 28 except for cavities therein, such as cavity 26, that determine the shapes of the parts to be molded.
For uniform heat distribution and maintenance at a preset temperature, the mold inserts are heated by band heaters 30 and 32 which are wrapped snugly around the cylindrical recessed portions of their respective inserts for efficient heat transfer to the inserts. The heater bands or heaters are supplied with electricity through wiring 34 and 36, which are adapted to be plugged into a power supply (not shown). Each heater and associated wiring and electrical plug 38 (FIG. 4) is kept together as a single unit. Each heater band is preferably kept intact with its mold insert by fastening it thereto by means of clamps 40 and 42 with respective screws 44 and 46 in conventional fashion. Since the heaters, clamps, wiring and plugs are the same for each insert, a description of one will suffice for both. The clamps, the screws and the heaters are known in the molding art. A further detailed description is therefore unnecessary.
Although not essential, I prefer to employ use of an insulator element 48 internally of each cylindrical bore or insert cavity for receiving the mold inserts. The inner surface of the insulator 48 is spaced a small distance from the outer surface of the heater and clamps to provide clearance for installation and removal of the inserts. Insulators 48 occupy essentially most of the internal peripheral portion of the bore, i.e., all but that portion where the wires 34 and 36 pass through channels or recesses 50 and 52 machined in the injection and ejection sides 12 and 14 respectively. Recess 50 is depicted in its open condition in FIG. 4, showing how wiring 34 passes upwardly from its heater through a portion of the recess 50. The area where the wiring 34 attaches to its heater remains uncovered by insulator 48, allowing for passage of the wiring 34 through the insulator.
Referring primarily to FIG. 4 and FIG. 2, the recess 50, when all parts are in molding position, is closed by a recess closure means, hereinafter referred to as a thermocouple retainer 54. The retainer 54 is moved essentially radially with respect to the mold insert 20 and is guided in its movement by tongue-and-groove ways on opposite sides of the recess 50. While any of several types of ways may be used, I show them in the form of female guide slots 56 and male guide rails 58. The retainer is provided with a lug portion 60 through which a bolt 62 passes freely. Bolt 62 has a lock nut 64 fastened to it below the lug 60 by means of a dowel pin 66. The lock nut 64 serves as a collar to retain bolt 62 with the retainer 54 whenever the retainer has been separated from the master frame 10. A threaded hole 68 is provided in a shoulder in the master frame to receive the threaded end of the bolt 62 when the retainer 54 closes the recess 50.
In order to sense and maintain proper temperature of the mold inserts, a thermocouple 70 is provided. The thermocouple is connected to a temperature controller (not shown) by means of wiring 72 and a plug 74. For maximum efficiency of operation of the thermocouple 70, its tip is designed to protrude inwardly of the mold insert into a drilled hole 76. Because of the fact that the thermocouple extends inwardly of an insert, it is essential that the thermocouple must be removed from operative position whenever a mold insert is being removed or installed relative to its frame section. To avoid the possibility of the operator causing damage to the thermocouple by removing an insert while the end of the thermocouple 70 is still in the hole 76, the thermocouple is mounted in the retainer 54. Since it is already essential to remove the retainer 54 from the channel 50 in order to permit the wiring 34 to be removed laterally as the insert is moved from its frame section, removal of the retainer in the outward direction along the way provided by slots 56 and rails 58 also withdraws the tip of the thermocouple 70 from the hole 76. This not only minimizes the number of operations necessary to make a change of mold inserts, but it also reduces the risk of damage to a thermocouple by an inattentive operator if the thermocouple were separate from the retainer 54.
The thermocouple and its associated attaching elements are shown in enlarged fashion in FIG. 6, which will now be described. It will be seen that the outer tip of the thermocouple extends inwardly of the mold insert 20 and bottoms in the hole 76. Bottoming is assured by a compression spring 78 which is seated between a shoulder 80 integral with the thermocouple 70 approximately one-half inch inwardly from its end. The opposite end of the spring 78 fits against the internal shoulder of a bayonet cap 82 fastened onto a hollow tube 84 threaded into the outer surface of the retainer 54. Tube 84 has a radially-extending pin 86 which is received in a conventional L-shaped bayonet slot 88 (FIG. 4) provided in cap 82. The same thermocouple is used for replacement of a given mold insert, and, except for replacement of a defective thermocouple on occasion, tube 84, bayonet cap 82, and spring 78 become permanent parts of their respective retainer 54. The shoulder 80 can pass freely through a drilled hole 90 in the retainer 54. When the retainer 54 is removed from the master frame, the tip of the thermocouple 70 is biased outwardly of the retainer 54 by the compression spring 78. This provides a spring bias so that the tip of the thermocouple 70 bottoms in the hole 76 when the retainer 54 is reinstalled into its master frame section after a new mold insert has been placed in position. The bottoming provides for effective temperature sensing and control of the insert during the molding operation.
It will be seen that I have provided for ease of replacement of heated mold inserts with their wiring and heating elements intact, enabling them to be laterally moved through an essentially radial recess which is provided when the retainer 54 has been removed. It will also be seen that one can utilize the retainer 54 to mount a thermocouple in order to simplify the operation by manipulation of a single bolt 62 to not only remove the thermocouple but also to provide the recess through which the wiring of the heater can pass freely.
Various modifications may be made in the details of the parts without departing from the spirit and scope of the claims.
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A master frame supports interchangeable mold inserts, each of which is provided with its own electrical heater and associated wiring. A recess is provided in the master frame to allow for lateral movement of the wiring, heater and mold inserts as a unit during installation and replacement. A closure member in the form of a thermocouple retainer is provided to support a temperature-controlling thermocouple inwardly of a hole within each mold insert as well as to close the recess during a molding operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. national phase of International Application No. PCT/US2014/025289, filed on Mar. 13, 2014, which claims the benefit of priority to U.S. Provisional Application No. 61/781,988, filed Mar. 14, 2013. The contents of the foregoing applications are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to compounds that inhibit bromodomain-containing proteins from binding acetylated proteins, to processes for preparing these compounds, to pharmaceutical compositions containing these compounds, and to methods of using these compounds for treating a wide variety of conditions and disorders.
BACKGROUND OF THE INVENTION
Epigenetic chromatin remodeling is a central mechanism for the regulation of gene expression. Pharmacological modulation of epigenetic change represents a new mode of therapeutic interventions for cancer and inflammation. Emerging evidence suggests that such epigenetic modulations may also provide therapeutic means for obesity, as well as metabolic, cardiovascular, neurodegenerative, psychiatric and infectious diseases.
The eukaryotic genome is organized into a basic packaging unit called a nucleosome, which is comprised of approximately 147 base pairs of double-stranded DNA helix wound around a histone octamer, which, in turn, consists of two subunits each of H2A, H2B, H3, and H4 proteins. Nucleosomes are further packaged into chromatin structures, which can exist in a relatively loose state of euchromatin or in a tightly packed heterochromatin structure. Transition from heterochromatin to euchromatin allows transcription of genes, although not all of the genes in euchromatin structure are transcribed. This transition from heterochromatin to euchromatin is controlled by post-translational modifications of histone proteins, including acetylation of lysine residues in H3/H4 proteins. Histone acetylation is catalyzed by histone acetyltransferases (HATs), resulting in open euchromatin structures that allow transcription of genes including tumor suppressor genes. Conversely, histone deacetylation leads to suppression of such genes and this activity is catalyzed by histone deacetylases (HDACs). Inhibition of histone deacetylases is a mode of cancer treatment and vorinostat (Zolinza®), a histone deacetylase inhibitor, has been shown to be an effective drug for cutaneous T-cell lymphoma in humans.
Histone acetylation also is monitored by bromodomain-containing proteins. Bromodomains are approximately 110 amino acid-long evolutionary conserved modules that bind to acetyllysine residues of acetylated proteins and are present in a number of chromatin-associated proteins including HATs. Bromodomains were first identified as a motif in Drosophila Brahma from which the name was derived but are also found in proteins in humans and yeast either as single-copy or contiguously repeated domains, and are thought to confer specificity for the complex pattern of epigenetic modifications known as the histone code (Cell. 1992 Feb. 7; 68(3):561-72; J Biomol Screen. 2011 December; 16(10):1170-85). The human genome encodes approximately 50 bromodomain-containing proteins (Bioinformatics. 2004 Jun. 12; 20(9):1416-27), some of which may be involved in etiology of cancer, inflammation, obesity, metabolic, cardiovascular, neurodegenerative, psychiatric and infectious diseases (Med Chem Commun. 2012 Jan. 4 3(2):123-134; Curr Opin Drug Discov Devel. 2009 September; 12(5):659-65; Discov Med. 2010 December; 10(55):489-99; FEBS Lett. 2010 Aug. 4; 584(15):3260-8; J Virol. 2006 September; 80(18):8909-19; J Virol. 2005 July; 79(14):8920-32; Curr Opin Pharmacol. 2008 February; 8(1):57-64). Thus, inhibition and/or modulation of bromodomain-containing proteins may present a new mode of pharmacological intervention for such diseases. For example, inhibition of bromodomain and extra-terminal domain (BET) family of proteins, which play a key role in controlling cell fate and cell cycle progression by recruiting transcriptional regulators to specific genomic locations (Front Biosci. 2001 Aug. 1; 6:D1008-18; J Biol Chem. 2007 May 4; 282(18):13141-5), is of particular interest as a treatment for cancer. Inhibition of the BET family of proteins was shown to be effective in rodent models for human NUT midline carcinoma, multiple myeloma, Burkitt's lymphoma and acute myeloid leukemia by indirectly reducing the expression of a proto-oncogene MYC (Nature. 2010 Dec. 23; 468(7327):1067-73; Cell. 2011 Sep. 16; 146(6):904-1; Proc Natl Acad Sci USA. 2011 Oct. 4; 108(40):16669-74). Bromodomain-containing proteins bind to acetyllysine residues of proteins including acetylated histones as well as acetylated non-histone proteins, such as transcription factors and the HIV-1 Tat protein.
Of approximately 50 bromodomain-containing proteins encoded by human genome, BET proteins represent a small protein family that includes BRD2, BRD3, BRD4 and BRDT and contains two tandem bromodomains and an extraterminal domain (J Biol Chem. 2007 May 4; 282(18):13141-5). BET proteins bind to acetylated nucleosomes and are thought to function by opening chromatin structure and/or by facilitating transcriptional initiation (Front Biosci. 2001 Aug. 1; 6:D1008-18). Inhibition of BET proteins was shown to be an effective mode of intervention in rodent models of human NUT midline carcinoma, multiple myeloma, Burkitt's lymphoma and acute myeloid leukemia by suppressing the expression of MYC gene (Nature. 2010 Dec. 23; 468(7327):1067-73; Cell. 2011 Sep. 16; 146(6):904-1; Proc Natl Acad Sci USA. 2011 Oct. 4; 108(40):16669-74), as well as MYCN gene (Cancer Discov. 2013 March: 3(3) 308-23). MYC and homologous genes are some of the most overexpressed genes in human cancers; however, there has not been a pharmaceutical compound that directly antagonizes the activity of proteins encoded by the genes to date partly due to the lack of effective drug binding sites.
Thus, there exists a need for a means of indirect suppression of the expression of the MYC and homologous genes by inhibiting bromodomains of BET proteins which provide an effective mode of treatment for various diseases and conditions, including various cancers.
SUMMARY OF THE INVENTION
The present invention includes compounds which bind to and otherwise modulate acetylated protein binding to bromodomain-containing proteins. The present invention also relates to pharmaceutically acceptable salts prepared from these compounds.
According to one aspect, the present invention includes a compound as represented by Formula I:
wherein:
R 1 and R 2 are independently —H, C 1 -C 6 alkyl optionally substituted with halo or alkoxy, or C 2 -C 6 alkene optionally substituted with halo or alkoxy; or
R 1 and R 2 form a six-membered aryl or heteroaryl ring optionally substituted with halo, alkyl, alkoxy, aryl, —S(O) 2 —R 6 , —NH—(R 5 )—(R 6 ), S(O) 2 —NR 5 —R 6 , C(O) 2 —NR 5 —R 6 , heterocycle, or heteroaryl ring, the heterocycle and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur,
wherein the heterocycle and heteroaryl are optionally substituted with one or more hydroxyl, alkyl, alkoxy, amido, sulfamido, halo, or —C(O) 2 -alkyl, wherein R 5 is —C(O)— or —S(O) 2 —, and wherein R 6 is one or more —H, alkyl, C 2 -C 6 alkene, cycloalkyl, aryl, heterocycle, or heteroaryl ring, the heterocycle or heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, and wherein each C 2 -C 6 alkene, cycloalkyl, aryl, heterocycle, or heteroaryl is optionally substituted with hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine;
R 3 and R 4 are independently
C 1 -C 7 alkyl optionally substituted with hydroxyl, heterocycle, or heteroaryl, the heterocycle and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the heterocycle and heteroaryl are optionally substituted with one or more substituents selected from hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine; C 2 -C 7 alkene optionally substituted with hydroxyl, heterocycle, or heteroaryl, the heterocycle and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the heterocycle and heteroaryl are optionally substituted with one or more substituents selected from hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine; —NC(O)R 7 , wherein R 7 is C 1 -C 7 alkyl or C 2 -C 7 alkene; or R 3 and R 4 form a ring (i), (ii), (iii), (iv), (v), or (vi)
wherein,
A is N or CH;
X is O, S or NH;
R 8 is
halo; C 1 -C 6 alkyl optionally substituted with aryl, heterocycle, or heteroaryl, the heterocycle and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the heterocycle and heteroaryl are optionally substituted with one or more substituents selected from hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine; C 2 -C 6 alkene optionally substituted with aryl, heterocycle, or heteroaryl, the heterocycle and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the heterocycle and heteroaryl are optionally substituted with one or more substituents selected from hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine;
wherein R 15 and R 16 are alkyl or cycloalkyl or heterocycle, or R 15 and R 16 can form a heterocycle;
—C(O)—R 17 , wherein R 17 is alkyl, cycloalkyl or heterocycle;
—S—R 18 , wherein R 18 is alkyl, aryl, or cycloalkyl;
—S—C(O)—N(R 15 R 16 );
a five-membered heterocycle or heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the five-membered heterocycle and heteroaryl are optionally substituted with one or more halo, alkyl, alkoxy, sulfur, heterocycle or heteroaryl ring, or one or more of R 1 , R 2 , R 3 or R 4 groups;
wherein B is O, S, or NH,
wherein R 10 and R 11 are independently —H; alkyl; aryl; heterocycle; heterocyclyl; or heteroaryl, the heterocycle, heterocyclyl, and heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the aryl, heterocycle, heterocyclyl, and heteroaryl are optionally substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine, and
wherein R 12 is —H or alkyl;
R 9 is H; OH; aryl; heterocycle; heteroaryl; —SO 2 —NH—Z; —NH—Z; or —O—SO 2 —R 13 ,
wherein the heterocycle and heteroaryl have one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, and wherein the heterocycle and heteroaryl are optionally substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, mono or dialkylsubstituted amine,
wherein R 13 is heterocycle or heteroaryl, the heterocycle and heteroaryl optionally substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, mono or dialkylsubstituted amine, or R 8 , and
wherein Z is alkyl, heteroaryl, or aryl, wherein the alkyl, heteroaryl, or aryl is optionally substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine; and
R 14 is —H or C 1 -C 6 alkyl optionally substituted with aryl, wherein the aryl is optionally substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine.
According to one embodiment, X is O. According to one embodiment, R 8 is
wherein R 10 and R 11 are independently —H; alkyl; aryl; or a five-membered or six-membered heterocycle, heterocyclyl, or heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the aryl, five-membered or six-membered heterocycle, heterocyclyl, or heteroaryl are optionally substituted with alkyl, halo, alkoxy, or —N(CH 3 ) 2 .
According to an alternative embodiment, R 8 is
wherein R 10 and R 11 are independently —H; alkyl; aryl; or a five-membered or six-membered heterocycle, heterocyclyl, or heteroaryl having one to three heteroatoms independently selected from the group consisting of oxygen, nitrogen and sulfur, wherein the aryl, five-membered or six-membered heterocycle, heterocyclyl, or heteroaryl are optionally substituted with alkyl, halo, alkoxy, or —N(CH 3 ) 2 , and wherein R 12 is H or alkyl.
According to another embodiment, R 1 and R 2 form a six-membered aryl ring, the six-membered aryl ring substituted with one or more hydroxyl, sulfhydryl, CN, CF 3 , NO 2 , halo, alkyl, aryl, alkoxy, carboxyamido, sulfamido, or mono or dialkylsubstituted amine, and wherein R 3 and R 4 form a ring (i). According to such an embodiment, R 9 may be —O—SO 2 —R 13 . According to yet another such embodiment, R 8 may be —S—R 18 . According to yet another such embodiment, R 8 may be —S—C(O)—N(R 15 R 16 ).
According to one embodiment, R 11 is phenyl optionally substituted with one or more alkyl, halo, —OCH 3 , or —N(CH 3 ) 2 .
According to one embodiment, R 9 is —SO 2 —NH—Z, —NH—Z, or —O—SO 2 —R 13 .
According to one embodiment, R 1 and R 2 form an optionally substituted six-membered aryl ring.
According to another aspect, compounds of Formula 1A, IB, IC and ID are provided,
including pharmaceutically acceptable salts and isomers thereof. According to such an embodiment, R 1A is selected from alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl including nitrogen, oxygen or sulfur as a heteroatom of the heterocycloalkyl, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7A , NC(O)OR 7A , CONR 7A R 8A , NR 7A COR 8A , NR 7A SO 2 R 8A , NR 9A CONR 7A R 8A , and NR 7A R 8A , wherein NR 7A R 8A optionally forms a substituted or unsubstituted mono or bicyclic ring having one to four heteroatoms selected from N, O and S, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen;
wherein R 7A , R 8A and R 9A are each independently selected from hydrogen, alkyl, heteroalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen; or R 7A and R 8A optionally form a 4, 5, 6 or 7-member ring; R 2A is hydrogen, alkyl, C(O)OR 7A , CONR 7A R 8A , NR 7A R 8A , NR 7A COR 8A , NR 7A SO 2 R 8A , or NR 9A CONR 7A R 8A ; R 3A is hydrogen or alkyl; R 4A is alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl includes nitrogen, oxygen or sulfur as a heteroatom, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7A , NC(O)OR 7A , CONR 7A R 8A , NR 7A R 8A , NR 7A COR 8A , NR 7A SO 2 R 8A , and NR 7A CONR 8A R 9A ; and wherein R 7A , R 8A and R 9A are as defined above; R 5A and R 6A are independently selected from hydrogen, alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl wherein the heteroatom is nitrogen, oxygen or sulfur, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7A , NC(O)OR 7A , CONR 7A R 8A , NR 7A R 8A , NR 7A COR 8A , NR 7A SO 2 R 8A , NR 7A CONR 8A R 9A ; and wherein R 7A , R 8A and R 9A are as defined above; L 1A is —(C—R 10A R 11A ) nA — wherein R 10A and R 11A are independently selected from hydrogen and alkyl and nA is 1, 2, or 3; L 2A and L 3A are independently selected from —(C—R 10A R 11A ) n —, —CON(R 7A )—, —SO 2 N(R 7A )—, —R 7A CON(R 8A )— and —OCON(R 7A ); wherein n is 1, 2, or 3; provided when L 1A =0, and L 2A =0, R 1A is a phenyl ring substituted with at least one methyl group, and R 2A cannot be hydrogen. R 1B is selected from substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl wherein the heterocycloalkyl includes nitrogen, oxygen or sulfur as a heteroatom, wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7B , NC(O)OR 7B , CONR 7B R 8B , NR 7B R 8B , NR 7B COR 8B , NR 7B SO 2 R 8B , and NR 9B CONR 7B R 8B ;
wherein R 7B , R 8B and R 9B are as each independently selected from hydrogen, alkyl, heteroalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl; wherein NR 7B R 8B optionally form a substituted or unsubstituted mono or bicyclic ring including one to four heteroatoms selected from N, O and S; and wherein R 7B and R 8B may form a 4, 5, 6 or 7-member ring; wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen;
R 2B is selected from hydrogen, substituted or unsubstituted alkyl group, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl heteroatom is nitrogen, oxygen or sulfur;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, COOR 7B , CONR 7B R 8B , NR 7B R 8B NR 7B COR 8B , and NR 7B SO 2 R 8B ;
R 3B and R 4B are independently selected from hydrogen and substituted or unsubstituted alkyl; R 5B is selected from hydrogen and substituted or unsubstituted alkyl; L B is —(C—R 10B R 11B ) nB — wherein R 10B and R 11B are independently selected from hydrogen and alkyl; and nB is 0, 1, 2, or 3; X is selected from O, S and NR 12B wherein R 12B is selected from hydrogen or alkyl; Y is selected from —(C—R 10B R 11B ) mB —, O, —NR 7B R 8B , —N(R 7B )CO—, —SO 2 N(R 7B )— and —NR 7B CON(R 8B )—, provided that when Y is 0, nB=0, mB=0 and R 5B is methyl, R 3B and R 4B cannot be methyl; R 1c is selected from alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl wherein the heteroaryl and heterocycloalkyl include nitrogen, oxygen or sulfur as a heteroatom, and wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7C , NC(O)OR 7C , CONR 7C R 8C , NR 7C R 8C , NR 7C COR 8C , NR 7C SO 2 R 8C , NR 9C CONR 7C R 8C ;
wherein R 7C , R 8C and R 9C are as each independently selected from hydrogen, alkyl, heteroalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl; wherein NR 7C R 8C optionally forms a substituted or unsubstituted mono or bicyclic ring having one to four heteroatoms selected from N, O and S; and wherein R 7C and R 8C may form a 4, 5, 6 or 7-member cyclic ring system; wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen;
R 2C is selected from hydrogen and alkyl group; R 3C is hydrogen or alkyl; R 4C is selected from aklyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl and heteroaryl include nitrogen, oxygen or sulfur as a heteroatom;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7C , NC(O)OR 7C , CONR 7C R 8C , NR 7C R 8C , NR 7C COR 8C , NR 7C SO 2 R 8C , NR 7C CONR 8C R 9C ; and wherein R 7C , R 8C and R 9C are as defined above;
R 5C and R 6C are independently selected from hydrogen, alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl and heteroaryl include nitrogen, oxygen or sulfur as a heteroatom;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7C , NC(O)O R 7C C, CONR 7C R 8C , NR 7C R 8C , NR 7C COR 8C , NR 7C SO 2 R 8C , NR 7C CONR 8C R 9C ; and wherein R 7C , R 8C and R 9C are as defined above;
L 1C is —(C—R 10C R 11C ) nC — wherein R 10C and R 11C are independently selected from hydrogen and alkyl and nC is 0, 1, 2, or 3; L 2C is selected from the group consisting of —(C—R 10C R 11C ) n —, —CON(R 7C )—, —SO 2 N(R 7C )—, —NR 7C CON(R 8C )—, and —OCON(R 7C ); R 1C and R 2C are connected to make a substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl wherein the heteroatom is nitrogen, oxygen or sulfur;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7 , NC(O)OR 7 , CONR 7 R 8 , NR 7 R 8 , NR 7 COR 8 , NR 7 SO 2 R 8 , NR 7 CONR 8 R 9 ; provided R 2C cannot be hydrogen when L 1C =0 and R 1C is a phenyl ring substituted with hydrogen and methyl group, L 2c -R 4c is hydrogen;
R 1D is selected from substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl and heteroaryl include nitrogen, oxygen or sulfur as a heteroatom;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7D , NC(O)OR 7D , CONR 7D R 8D , NR 7D R 8D , NR 7D COR 8D , NR 7D SO 2 R 8D , NR 9D CONR 7D R 8D ; wherein R 7D , R 8D and R 9D are as each independently selected from hydrogen, alkyl, heteroalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted cycloalkyl, and substituted or unsubstituted heterocycloalkyl; wherein NR 7D R 8D optionally form a substituted or unsubstituted mono or bicyclic ring having one to four heteroatoms selected from N, O and S; and wherein R 7D and R 8D may form a 4, 5, 6 or 7-member cyclic ring; wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen;
R 2D is selected from hydrogen and substituted or unsubstituted alkyl group, COR 7D , CONR 7D R 8D , SO 2 R 7D ; provided R 2D cannot be hydrogen when R 1D is a phenyl ring. R 3D is selected from hydrogen and alkyl group, heteroalkyl; substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl,
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7D , NC(O)OR 7D , CONR 7D R 8D , NR 7D R 8D , NR 7D COR 8D , NR 7D SO 2 R 8D , NR 7D CONR 8D R 9D ; and wherein R 7D , R 8D and R 9D are as defined above;
R 4D is selected from aklyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl and heteroaryl include nitrogen, oxygen or sulfur as a heteroatom;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7D , NC(O)OR 7D , CONR 7D R 8D , NR 7D R 8D , NR 7D COR 8D , NR 7D SO 2 R 8D , NR 7D CONR 8D R 9D ; and wherein R 7D , R 8D and R 9D are as defined above;
R 5D and R 8D are selected from hydrogen, alkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted cycloalkyl and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl and heteroaryl include nitrogen, oxygen or sulfur as a heteroatom;
wherein said substitutions are selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl, halogen, CN, CF 3 , NO 2 , COOR 7D , NC(O)OR 7D , CONR 7D R 8D , NR 7D R 8D , NR 7D COR 8D , NR 7D SO 2 R 8D , NR 7D CONR SD R 9D ; and wherein R 7D , R 8D and R 9D are as defined above; and
X D is selected from the group consisting of CH 2 , C(O)N(R 7D )—, O, N—R 7D , and S, where in R 7D is defined as above.
According to another aspect, compounds of Formula 1A are provided
According to one embodiment, R 1A is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to such an embodiment, R 3A may be hydrogen. According to one embodiment, R 4A is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 6A and R 5A are independently selected from hydrogen, substituted or unsubstituted aryl, and substituted or unsubstituted heteroaryl. According to one embodiment, R 10A and R 11A are independently selected from hydrogen and methyl and n is 1 or 2. According to one embodiment, L 2A is selected from the group consisting of alkyl, —CONR 7A R 8A , and —SO 2 NR 7A R 8A .
According to an alternative embodiment, R 2A is NC(O)OR 7A . According to one embodiment, R 3A is hydrogen. According to one embodiment, R 4A is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 5A and R 6A are independently selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, L 1A is —(C—R 10A R 11A ) nA — wherein R 10A and R 11A are independently selected from hydrogen and methyl and nA is 1 or 2. According to one embodiment, L 2A is selected from alkyl, CONR 7A R 8A , and SO 2 NR 7A R 8A . According to one embodiment, R 1A is selected from substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl; R 2A and R 3A are hydrogen; R 4A is selected from substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl; R 6A and R 5A is selected from substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl; L 1A is —(C—R 10A R 11A ) nA — wherein R 1A and R 11A are independently selected from hydrogen and methyl and nA is 1 or 2; and L 2A is selected from the group consisting of alkyl, —CONR 7 R 8A , and —SO 2 NR 7 R 8A . According to one embodiment, R 6A and R 5A are independently selected from hydrogen
wherein R 12A and R 13A are independently selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen.
According to another aspect, compounds having the structure of Formula 1B are provided
According to one embodiment, R 1B is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 2B is selected from hydrogen, substituted or unsubstituted alkyl group and substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl includes nitrogen, oxygen or sulfur as a heteroatom. According to one embodiment, R 1B is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 2B is selected from hydrogen, substituted or unsubstituted alkyl group, or substituted or unsubstituted heterocycloalkyl, wherein the heterocycloalkyl or heteroaryl includes nitrogen, oxygen or sulfur as a heteroatom.
According to another aspect, compounds having the structure of Formula 1C are provided
According to one embodiment, wherein R 1C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to such an embodiment, R 1C is hydrogen. According to one embodiment, R 4C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 6C and R 5C are independently selected from hydrogen, substituted or unsubstituted aryl, and substituted or unsubstituted heteroaryl. According to one embodiment, L 1C is —(C—R 10C R 11C ) nC — wherein R 10C and R 11C are independently selected from hydrogen and methyl and nC is 1 or 2. According to one embodiment, L 2C is selected from alkyl, CONR 7C R 8C , and SO 2 NR 7C R 8C .
According to an alternative embodiment, R 2C is hydrogen. According to one embodiment, R 3C is hydrogen. According to one embodiment, R 4C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 5C and R 6C are independently selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, L 1C is —(C—R 10C R 11C ) n — wherein R 10C and R 11C are independently selected from hydrogen and methyl and n is 1 or 2. According to one embodiment, L 2C is selected from the group consisting of alkyl, —CONR 7C R 8C , and SO 2 NR 7C R 8C . According to one embodiment, R 3C is hydrogen. According to one embodiment, R 1C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 2C and R 3C are hydrogen; R 4C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 6C and R 5C is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; L 1C is —(C—R 10C R 11C ) nC — wherein R 10C and R 11C are independently selected from hydrogen and methyl and nC is 1 or 2; and L 2C is selected from the group consisting of alkyl, —CONR 7C R 8C , and —SO 2 NR 7C R 8C . According to one embodiment, R 6C and R 5C is independently selected from hydrogen
wherein R 12C and R 13C are independently selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen.
According to another aspect, compounds of Formula 1D are provided
According to one embodiment, R 1D is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 2D is —COR 7D . According to one embodiment, R 3D is substituted or unsubstituted alkyl. According to one embodiment, R 4D is substituted or unsubstituted heteroaryl. According to one embodiment, R 6D and R 5D are hydrogen.
According to an alternative embodiment, R 2D is selected from —COR 7D , —CONR 7D R 8D , and —SO 2 R 7D . According to one embodiment, R 3D is substituted or unsubstituted alkyl group, or substituted or unsubstituted heteroalkyl. According to one embodiment, R 4D is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. According to one embodiment, R 5D and R 6D are independently selected from hydrogen, and alkyl. According to one embodiment, X D is selected from —C(O)N(R 7D )—, —O and —N—R 7D . According to one embodiment, R 1D is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl, R 2D is —COR 7D , R 3D is substituted or unsubstituted alkyl, R 4D is selected from substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl, R 6D and R 5D are hydrogen. According to one embodiment, R 4D is selected from
wherein R 12D and R 13D are independently selected from hydrogen, hydroxyl, sulfhydryl, alkoxy, thioalkoxy, alkyl and halogen.
According to another aspect, the present invention includes pharmaceutical compositions comprising a compound of the present invention or a pharmaceutically acceptable salt thereof. The pharmaceutical compositions of the present invention can be used for treating or preventing a wide variety of conditions or disorders, particularly those disorders mediated by acetylated proteins involved in the regulation of gene expression.
According to another aspect, the present invention includes methods for treating, preventing, delaying the onset of, or slowing the progression of disorders mediated by acetylated proteins involved in the regulation of gene expression, in mammals in need of such treatment. The methods involve administering to a subject a therapeutically effective amount of a compound as provided herein, including a salt thereof, or a pharmaceutical composition that includes such compounds.
DETAILED DESCRIPTION OF THE INVENTION
The scope of the present invention includes all combinations of aspects and embodiments.
The following definitions are meant to clarify, but not limit, the terms defined. If a particular term used herein is not specifically defined, such term should not be considered indefinite. Rather, terms are used within their accepted meanings.
As used throughout this specification, the preferred number of atoms, such as carbon atoms, will be represented by, for example, the phrase “C x -C y alkyl,” which refers to an alkyl group, as herein defined, containing the specified number of carbon atoms. Similar terminology will apply for other preferred terms and ranges as well. Thus, for example, C 1-6 alkyl represents a straight or branched chain hydrocarbon containing one to six carbon atoms.
As used herein the term “alkyl” refers to a straight or branched chain hydrocarbon, which may be optionally substituted, with multiple degrees of substitution being allowed. Examples of “alkyl” as used herein include, but are not limited to, methyl, ethyl, propyl, isopropyl, isobutyl, n-butyl, tert-butyl, isopentyl, and n-pentyl.
As used herein, the term “alkene” refers to an unsaturated hydrocarbon that includes one or more carbon-carbon double bonds. The term “lower alkene” refers to an alkene that includes from five to twenty carbon atoms, such as from two to ten carbon atoms, while the term “upper alkene” refers to an alkene that includes more than twenty carbon atoms, such as from twenty-one to one hundred carbon atoms. The term “substituted alkene” refers to an alkene that has one or more of its hydrogen atoms replaced by one or more substituent groups, such as halogen.
As used herein, the term “alkyne” refers to an unsaturated hydrocarbon that includes one or more carbon-carbon triple bonds. The term “lower alkyne” refers to an alkyne that includes from five to twenty carbon atoms, such as from two to ten carbon atoms, while the term “upper alkyne” refers to an alkyne that includes more than twenty carbon atoms, such as from twenty-one to one hundred carbon atoms. The term “substituted alkyne” refers to an alkyne that has one or more of its hydrogen atoms replaced by one or more substituent groups, such as halogen.
As used herein, the term “cycloalkyl” refers to a fully saturated optionally substituted monocyclic, bicyclic, or bridged hydrocarbon ring, with multiple degrees of substitution being allowed. Preferably, the ring is three to twelve-membered, more preferably, from five- to six-membered. Exemplary “cycloalkyl” groups as used herein include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
As used herein, the term “alkoxy” refers to a group —OR a , where R a is “alkyl” as defined herein.
As used herein, the term “heterocycloalkyl” or “heterocycle” or “heterocyclyl” refers to an optionally substituted mono- or polycyclic ring system, optionally containing one or more degrees of unsaturation, and also containing one or more heteroatoms, which may be optionally substituted, with multiple degrees of substitution being allowed. Exemplary heteroatoms include nitrogen, oxygen, or sulfur atoms, including N-oxides, sulfur oxides, and dioxides. Preferably, the ring is three to twelve-membered, preferably five or six-membered and is either fully saturated or has one or more degrees of unsaturation. Such rings may be optionally fused to one or more of another heterocyclic ring(s) or cycloalkyl ring(s). Examples of “heterocyclic” groups as used herein include, but are not limited to, tetrahydrofuran, pyran, tetrahydropyran, 1,4-dioxane, 1,3-dioxane, piperidine, pyrrolidine, morpholine, tetrahydrothiopyran, and tetrahydrothiophene.
As used herein, the term “aryl” refers to a single benzene ring or fused benzene ring system which may be optionally substituted, with multiple degrees of substitution being allowed. Examples of “aryl” groups as used include, but are not limited to, phenyl, 2-naphthyl, 1-naphthyl, anthracene, and phenanthrene. Preferable aryl rings have five- to ten-members. The term “aryl” also includes a fused benzene ring system, namely where a cyclic hydrocarbon or heterocycle (e.g., a cyclohexane or dioxane ring) or heteroaryl (e.g., pyridine) is fused with an aromatic ring (aryl, such as a benzene ring).
As used herein, the term “heteroaryl” refers to a monocyclic five to seven membered aromatic ring, a fused bicyclic aromatic ring system comprising two of such aromatic rings, which may be optionally substituted, with multiple degrees of substitution being allowed, or to a fused bicyclic ring system namely where a cycloalkyl or heterocycle (e.g., a cyclohexane or dioxane ring) is fused with a heteroaryl ring. Preferably, heteroaryl rings contain five- to ten-members. These heteroaryl rings contain one or more nitrogen, sulfur, and/or oxygen atoms. In certain embodiments, the heteroaryl rings contain one to three nitrogen, one to three oxygen, and one or two sulfur atoms. N-oxides, sulfur oxides, and dioxides are permissible heteroatom substitutions. Examples of “heteroaryl” groups as used herein include, but are not limited to, furan, thiophene, pyrrole, imidazole, pyrazole, triazole, tetrazole, thiazole, oxazole, isoxazole, oxadiazole, thiadiazole, isothiazole, pyridine, pyridazine, pyrazine, pyrimidine, quinoline, isoquinoline, quinoxaline, benzofuran, benzoxazole, benzothiophene, indole, indazole, benzimidazole, imidazopyridine, pyrazolopyridine, and pyrazolopyrimidine.
As used herein the term “halogen” refers to fluorine, chlorine, bromine, or iodine.
As used herein the term “haloalkyl” refers to an alkyl group, as defined herein, that is substituted with at least one halogen. Examples of branched or straight chained “haloalkyl” groups as used herein include, but are not limited to, methyl, ethyl, propyl, isopropyl, n-butyl, and t-butyl substituted independently with one or more halogens, for example, fluoro, chloro, bromo, and iodo. The term “haloalkyl” should be interpreted to include such substituents as perfluoroalkyl groups such as —CF 3 .
As used herein, the term “sulfhydryl” refers to refers to a —SH group.
As used herein, the term “carboxyamido” refers to —NH—C(O)—W, wherein W is hydrogen or an unsubstituted or substituted alkyl, alkene, alkyne, cycloalkyl, aryl, or heterocycle group.
As used herein, the term “amine” is given its ordinary meaning and includes primary, secondary and tertiary amines.
As used herein, the term “amido” refers to a group of the formula —C(O)NR 15 R 16 , wherein R 15 and R 16 are alkyl, cycloalkyl or heterocycle, or R 15 and R 16 can form cycloalkyl or heterocycle. As used herein, the term “sulfamido” refers to the group —SO 2 —NR 15 R 16 .
As used herein, the term “pharmaceutically acceptable” refers to carrier(s), diluent(s), excipient(s) or salt forms of the compounds of the present invention that are compatible with the other ingredients of the formulation and not deleterious to the recipient of the pharmaceutical composition.
As used herein, the term “pharmaceutical composition” refers to a compound of the present invention optionally admixed with one or more pharmaceutically acceptable carriers, diluents, or excipients. Pharmaceutical compositions preferably exhibit a degree of stability to environmental conditions so as to make them suitable for manufacturing and commercialization purposes.
As used herein, the terms “effective amount”, “therapeutic amount”, and “effective dose” refer to an amount of the compound of the present invention sufficient to elicit the desired pharmacological or therapeutic effects, thus resulting in an effective treatment of a disorder. Treatment of a disorder may be manifested by delaying or preventing the onset or progression of the disorder, as well as the onset or progression of symptoms associated with the disorder. Treatment of a disorder may also be manifested by a decrease or elimination of symptoms, reversal of the progression of the disorder, as well as any other contribution to the well being of the patient. The effective dose can vary, depending upon factors such as the condition of the patient, the severity of the symptoms of the disorder, and the manner in which the pharmaceutical composition is administered. Effective doses may be administered as a single dose, or as one or more doses that may be administered over a 24 hours period.
According to one embodiment, the compound is at least one compound selected from Formula I, Formula 1A, Formula 1B, Formula 1C or Formula 1D as provided herein, including those compounds set forth in Tables 1-6 and 10.
According to one embodiment, the compound is at least one compound selected from:
6-chloro-3-cinnamoyl-4-phenylquinolin-2(1H)-one; 6-chloro-3-(3-(2-chloro-6-fluorophenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-chloro-3-(3-(2,4-dichlorophenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-chloro-4-phenyl-3-(3-o-tolylacryloyl)quinolin-2(1H)-one; 6-chloro-3-(3-(2-methoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-chloro-3-(3-(3,4-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-chloro-4-phenyl-3-(3-(thiophen-2-yl)acryloyl)quinolin-2(1H)-one; 6-chloro-3-(3-(4-(dimethylamino)phenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-bromo-3-(3-(2,3-dihydrobenzo[b][1,4]dioxin-6-yl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-bromo-3-(3-(2,5-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one; 6-chloro-3-cinnamoyl-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-4-(pyridin-3-yl)-3-(3-o-tolylacryloyl)quinolin-2(1H)-one; 6-chloro-N-(2-methylbenzyl)-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxamide; 6-chloro-3-cinnamoyl-4-phenyl-1,8-naphthyridin-2(1H)-one; 6-chloro-3-(3-(2-chloro-6-fluorophenyl)acryloyl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(3-(3-fluoro-5-methylpyridin-4-yl)acryloyl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-chloro-3-cinnamoyl-N-(3-methoxyphenyl)-2-oxo-1,2-dihydroquinoline-4-sulfonamide; 6-chloro-3-cinnamoyl-2-oxo-N-(pyridin-3-yl)-1,2-dihydroquinoline-4-sulfonamide; 6-chloro-3-(3-(2-chloro-6-fluorophenyl)but-2-enoyl)-4-phenylquinolin-2(1H)-one; 3-cinnamoyl-6-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(piperidin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(pyrrolidin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-morpholinoquinolin-2(1H)-one; 5-(2-chlorovinyl)-4-(4-ethylpiperazin-1-yl)-3-(2-methyloxazol-4-yl)-6-vinylpyridin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(1H-pyrrol-1-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(1H-pyrazol-1-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(pyrrolidin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(piperidin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-morpholinoquinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(4-methylpiperazin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-2-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(1H-pyrrol-1-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(furan-3-yl)quinolin-2(1H)-one; 6-chloro-3-(3,5-dimethylisoxazol-4-yl)-4-(isoxazol-4-yl)quinolin-2(1H)-one; 6-chloro-3-(isoxazol-4-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(1H-pyrazol-4-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(furan-3-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-4-(pyridin-4-yl)-3-(thiophen-3-yl)quinolin-2(1H)-one; 6-chloro-3-(1H-imidazol-4-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-3-(morpholinosulfonyl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-3-(4-methylpiperazin-1-ylsulfonyl)-4-(pyridin-3-yl)quinolin-2(1H-one; N-(3-cinnamoyl-2-oxo-4-(pyridin-3-yl)-1,2-dihydroquinolin-6-yl)-5-methylisoxazole-3-carboxamide; 6-(3,5-dimethylisoxazol-4-yl)-3-(morpholinosulfonyl)quinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-3-(4-methylpiperazin-1-ylsulfonyl)quinolin-2(1H)-one; 4-(6-(3,5-dimethylisoxazol-4-yl)-2-oxo-1,2-dihydroquinolin-3-yl)-N-ethyl-N-methylbenzamide; 6-(3,5-dimethylisoxazol-4-yl)-3-(2-fluoro-5-(morpholine-4-carbonyl)phenyl)quinolin-2(1H)-one; N-cyclopentyl-3-(6-(3,5-dimethylisoxazol-4-yl)-2-oxo-1,2-dihydroquinolin-3-yl)benzenesulfonamide; 3-(6-(3,5-dimethylisoxazol-4-yl)-2-oxo-1,2-dihydroquinolin-3-yl)-N,N-dimethylbenzenesulfonamide; 3-(6-(3,5-dimethylisoxazol-4-yl)-2-oxo-1,2-dihydroquinolin-3-yl)-N-(1-methylpyrrolidin-3-yl)benzenesulfonamide; 3-(1H-benzo[d]imidazole-2-carbonyl)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 5-(3,5-dimethylisoxazol-4-yl)-3-(2-(pyridin-3-yl)ethylidene)indolin-2-one; 6-(3,5-dimethylisoxazol-4-yl)-1-(pyridin-3-ylmethyl)-1H-benzo[d]imidazol-2(3H)-one; 6-(3-chloroisoxazol-5-yl)-3-(morpholinosulfonyl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 3-(3,5-dimethylisoxazol-4-yl)-6-(morpholinosulfonyl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-(3-chloroisoxazol-5-yl)-3-cinnamoyl-4-phenylquinolin-2(1H)-one; (E)-methyl 5-(3-cinnamoyl-2-oxo-4-(pyridin-3-yl)-1,2-dihydroquinolin-6-yl)-2-methyloxazole-4-carboxylate; 6-(3-chloroisoxazol-5-yl)-3-cinnamoyl-4-(pyridin-3-yl)quinolin-2(1H)-one; 3-cinnamoyl-6-(3,5-dimethylisoxazol-4-yl)-4-(phenylamino)quinolin-2(1H)-one; 3-cinnamoyl-6-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-3-ylamino)quinolin-2(1H)-one; N-(3-benzoyl-2-oxo-1,2-dihydroquinolin-5-yl)-2-methoxybenzenesulfonamide; N-(3-cinnamoyl-2-oxo-1,2-dihydroquinolin-5-yl)pyridine-3-sulfonamide; N-(3-benzoyl-2-oxo-1,2-dihydroquinolin-5-yl)pyridine-3-sulfonamide; N-(3-cinnamoyl-2-oxo-1,2-dihydroquinolin-5-yl)-2-methoxybenzenesulfonamide; 6-(3,5-dimethylisoxazol-4-yl)-3-(morpholine-4-carbonyl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-chloro-3-(3-chloroisoxazol-5-yl)quinolin-2(1H)-one; N-(6-chloro-2-oxo-1,2-dihydroquinolin-3-yl)-5-methylisoxazole-3-carboxamide; 6-(3,5-dimethylisoxazol-4-yl)-3-(morpholine-4-carbonyl)quinolin-2(1H)-one; 6-chloro-4-(4-(2-fluorophenyl)piperazin-1-yl)-3-(2-methyloxazol-4-yl)quinolin-2(1H)-one; 6-chloro-4-(4-(3-fluorophenyl)piperazin-1-yl)-3-(2-methyloxazol-4-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(4-(pyridin-2-yl)piperazin-1-yl)quinolin-2(1H)-one; 6-chloro-3-(2-methyloxazol-4-yl)-4-(4-phenethylpiperazin-1-yl)quinolin-2(1H)-one; 3-bromo-6-chloro-4-hydroxy-1-(4-methoxybenzyl)quinolin-2(1H)-one; 6-chloro-1H-benzo[d][1,3]oxazine-2,4-dione; 1-benzyl-6-chloro-1H-benzo[d][1,3]oxazine-2,4-dione; 6-chloro-1-(4-methoxybenzyl)-1H-benzo[d][1,3]oxazine-2,4-dione; 1-benzyl-6-chloro-3-(3,5-dimethylisoxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl trifluoromethanesulfonate; 3-acetyl-6-bromo-4-phenylquinolin-2(1H)-one; 6-bromo-3-cinnamoyl-4-phenylquinolin-2(1H)-one; 6-chloro-4-hydroxy-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)quinolin-2(1H)-one; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl 4-methylbenzenesulfonate; -chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl benzenesulfonate; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl 4-fluorobenzenesulfonate; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl 4-chlorobenzenesulfonate; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl naphthalene-2-sulfonate; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl quinoline-8-sulfonate; 6-chloro-1-(4-methoxybenzyl)-3-(2-methyloxazol-4-yl)-2-oxo-1,2-dihydroquinolin-4-yl biphenyl-4-sulfonate; N-(4-(2-chlorovinyl)-6-(3,5-dimethylisoxazol-4-yl)-5-hydroxyhexa-1,5-dien-3-yl)-N-(hepta-2,4,6-trienyl)formamide; N1,N3-bis(4-bromophenyl)malonamide; N1,N3-bis(4-(3,5-dimethylisoxazol-4-yl)phenyl)malonamide; 6-(3,5-dimethylisoxazol-4-yl)-4-hydroxyquinolin-2(1H)-one; 4-chloro-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 4-(benzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 4-(2-chlorobenzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-4-morpholinoquinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-4-(piperidin-1-yl)quinolin-2(1H)-one; 4-(benzylamino)-1-(benzylsulfonyl)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; and salts thereof.
The compounds of the present invention may crystallize in more than one form, a characteristic known as polymorphism, and such polymorphic forms (“polymorphs”) are within the scope of the present invention. Polymorphism generally can occur as a response to changes in temperature, pressure, or both. Polymorphism can also result from variations in the crystallization process. Polymorphs can be distinguished by various physical characteristics known in the art such as x-ray diffraction patterns, solubility, and melting point.
Certain of the compounds described herein contain one or more chiral centers, or may otherwise be capable of existing as multiple stereoisomers. The scope of the present invention includes mixtures of stereoisomers as well as purified enantiomers or enantiomerically/diastereomerically enriched mixtures. Also included within the scope of the invention are the individual isomers of the compounds represented by the formulae of the present invention, as well as any wholly or partially equilibrated mixtures thereof. The present invention also includes the individual isomers of the compounds represented by the formulas above as mixtures with isomers thereof in which one or more chiral centers are inverted.
The present invention includes a salt or solvate of the compounds herein described, including combinations thereof such as a solvate of a salt. The compounds of the present invention may exist in solvated, for example hydrated, as well as unsolvated forms, and the present invention encompasses all such forms. The salts of the present invention can be pharmaceutically acceptable salts which includes non-toxic salts of the compounds set forth herein.
Examples of suitable pharmaceutically acceptable salts include inorganic acid addition salts such as chloride, bromide, sulfate, phosphate, and nitrate; organic acid addition salts such as acetate, galactarate, propionate, succinate, lactate, glycolate, malate, tartrate, citrate, maleate, fumarate, methanesulfonate, p-toluenesulfonate, and ascorbate; salts with acidic amino acid such as aspartate and glutamate; alkali metal salts such as sodium salt and potassium salt; alkaline earth metal salts such as magnesium salt and calcium salt; ammonium salt; organic basic salts such as trimethylamine salt, triethylamine salt, pyridine salt, picoline salt, dicyclohexylamine salt, and N,N′-dibenzylethylenediamine salt; and salts with basic amino acid such as lysine salt and arginine salt. The salts may be in some cases hydrates or ethanol solvates.
Although it is possible to administer the compound of the present invention in the form of a bulk active chemical, it is preferred to administer the compound in the form of a pharmaceutical composition or formulation. Thus, pharmaceutical compositions are provided that include one or more compounds of Formula I and/or pharmaceutically acceptable salts thereof and one or more pharmaceutically acceptable carriers, diluents, or excipients. Another aspect of the invention provides a process for the preparation of a pharmaceutical composition including admixing one or more compounds of Formula I and/or pharmaceutically acceptable salts thereof with one or more pharmaceutically acceptable carriers, diluents or excipients.
The manner in which the compounds set forth herein may be administered can vary. According to one embodiment, the compounds can be administered orally. Preferred pharmaceutical compositions may be formulated for oral administration in the form of tablets, capsules, caplets, syrups, solutions, and suspensions. Such oral formulations can be provided in modified release dosage forms such as time-release tablet and capsule formulations. Pharmaceutical compositions can also be administered via injection, namely, intravenously, intramuscularly, subcutaneously, intraperitoneally, intraarterially, intrathecally, and intracerebroventricularly. Intravenous administration is a preferred method of injection. Suitable carriers for injection are well known to those of skill in the art and include 5% dextrose solutions, saline, and phosphate buffered saline.
Pharmaceutical compositions may also be administered using other means, for example, rectal administration. Formulations useful for rectal administration, such as suppositories, are well known to those of skill in the art. The compounds can also be administered by inhalation, for example, in the form of an aerosol; topically, such as, in lotion form; transdermally, such as, using a transdermal patch (for example, by using technology that is commercially available from Novartis and Alza Corporation); by powder injection; or by buccal, sublingual, or intranasal absorption. Pharmaceutical compositions may be formulated in unit dose form, or in multiple or subunit doses.
The administration of the pharmaceutical compositions described herein can be intermittent, or at a gradual, continuous, constant or controlled rate. The pharmaceutical compositions may be administered to a warm-blooded animal, for example, a mammal such as a human being. In addition, the time of day and the number of times per day that the pharmaceutical composition is administered can vary.
The compounds as provided herein may also be used for the preparation of a medicament for the treatment or prevention of a disease or condition mediated by inhibiting bromodomain-containing proteins from binding acetylated proteins.
Methods for treating, preventing, delaying the onset of, or slowing the progression of disorders mediated by acetylated proteins involved in the regulation of gene expression, in mammals in need of such treatment are also provided. The methods involve administering to a subject a therapeutically effective amount of a compound as provided herein, including a salt thereof, or a pharmaceutical composition that includes such compounds.
According to one embodiment, the methods include the administration of at least one compound provided in Tables 1-6 and 10. According to another embodiment, the methods include the administration of at least one of the following compounds:
6-bromo-4-phenyl-3-(6-phenyl-2-thioxo-1,2-dihydropyrimidin-4-yl)quinolin-2(1H)-one; 6-chloro-4-phenyl-3-(6-phenyl-2-thioxo-1,2-dihydropyrimidin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(6-(pyridin-4-yl)-2-thioxo-1,2-dihydropyrimidin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(6-phenyl-2-thioxo-1,2-dihydropyrimidin-4-yl)-4-(pyridin-3-yl)quinolin-2(1H)-one; 6-chloro-3,4-di(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(pyridin-3-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(pyridin-2-yl)-4-(pyridin-4-yl)quinolin-2(1H)-one; 6-chloro-3-(5-(4,4-dimethyl-4,5-dihydrooxazol-2-yl)pyridin-3-yl)quinolin-2(1H)-one; 2,5-dimethoxy-N-((2-methoxynaphthalen-1-yl)methyl)aniline; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)propionamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)acetamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)benzamide; 3-(1H-benzo[d]imidazol-2-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 3-(4H-1,2,4-triazol-3-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 6-chloro-4-phenyl-3-(tosylmethyl)quinolin-2(1H)-one; 3-(4-allyl-5-(thiophen-2-yl)-4H-1,2,4-triazol-3-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 6-chloro-3-(4-(4-methoxyphenyl)-6-oxo-1,6-dihydropyrimidin-2-ylthio)-4-phenylquinolin-2(1H)-one; 4-phenyl-3-(pyridin-2-ylthio)quinolin-2(1H)-one; 3-(4-amino-6-oxo-1,6-dihydropyrimidin-2-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 4-(2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-2H-benzo[b][1,4]oxazin-3(4H)-one; 3-(4-ethyl-5-(morpholinomethyl)-4H-1,2,4-triazol-3-ylthio)-4-phenylquinolin-2(1H)-one; 6-chloro-4-phenylquinolin-2(1H)-one; 6-bromo-3-(5-(4-methoxyphenyl)-4,5-dihydroisoxazol-3-yl)-4-phenylquinolin-2(1H)-one; 6-chloro-3-(5-methoxy-1H-benzo[d]imidazol-2-ylthio)-4-phenylquinolin-2(1H)-one; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-2-chlorobenzamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-3-chlorobenzamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)benzenesulfonamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-4-methylbenzenesulfonamide; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-3-methoxypropanamide; 4-methyl-N-(6-methyl-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)benzenesulfonamide; N-((6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)methyl)-4-methylbenzenesulfonamide; 6-chloro-3-(1-(methylsulfonyl)-5-phenyl-4,5-dihydro-1H-pyrazol-3-yl)-4-phenylquinolin-2(1H)-one; 6-chloro-3-(6-oxo-4-propyl-1,6-dihydropyrimidin-2-ylthio)-4-phenylquinolin-2(1H)-one; 6-chloro-3-(5-methoxy-1H-benzo[d]imidazol-2-ylthio)-4-phenylquinolin-2(1H)-one; 3-(5-benzyl-6-methyl-4-oxo-4,5-dihydropyrimidin-2-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; ethyl 2-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)acetate; 4-methyl-N-((6-methyl-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)methyl)benzenesulfonamide; 6-chloro-4-phenyl-3-(phenylsulfonyl)quinolin-2(1H)-one; N-(6-bromo-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-2-(diethylamino)acetamide; 2-(6-methyl-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)acetic acid; 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl morpholine-4-carbodithioate; 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl diethylcarbamodithioate; 6-chloro-3-(1-methyl-1H-imidazol-2-ylthio)-4-phenylquinolin-2(1H)-one; 3-(benzo[d]thiazol-2-ylthio)-7-chloro-4-phenylquinolin-2(1H)-one; 3-(5-amino-1,3,4-thiadiazol-2-ylthio)-7-chloro-4-phenylquinolin-2(1H)-one; 7-chloro-3-(3-(methylthio)-1,2,4-thiadiazol-5-ylthio)-4-phenylquinolin-2(1H)-one; 1-(6-chloro-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-N-(3-(diethylamino)propyl)piperidine-3-carboxamide; 3-(6-chloro-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)-N-methyl-5-phenyl-4,5-dihydro-1H-pyrazole-1-carbothioamide; 3-acetyl-6-bromo-4-phenylquinolin-2(1H)-one; 6-chloro-3-(5-methyl-1,3,4-thiadiazol-2-ylthio)-4-phenylquinolin-2(1H)-one; 6-chloro-4-phenyl-3-(4-propoxypyrimidin-2-ylthio)quinolin-2(1H)-one; 3-(4-amino-5-p-tolyl-4H-1,2,4-triazol-3-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 3-(4-amino-6-oxo-1,6-dihydropyrimidin-2-ylthio)-6-chloro-4-phenylquinolin-2(1H)-one; 6-chloro-3-(1-methyl-1H-tetrazol-5-ylthio)-4-phenylquinolin-2(1H)-one; 1-(6-chloro-2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)quinoxalin-2(1H)-one; 3-(4-amino-6-oxo-1,6-dihydropyrimidin-2-ylthio)-4-phenylquinolin-2(1H)-one; 5-(2-methoxybenzyl)-5-methyl-3-(2-oxo-4-phenyl-1,2-dihydroquinolin-3-yl)imidazolidine-2,4-dione; 6-bromo-4-phenyl-3-(2,2,2-trifluoroacetyl)quinolin-2(1H)-one; 4-phenyl-3-(quinazolin-4-yloxy)quinolin-2(1H)-one; 3-(4-methyl-5-(trifluoromethyl)-4H-1,2,4-triazol-3-ylthio)-4-phenylquinolin-2(1H)-one; 3-(3-fluorophenoxy)-4-phenylquinolin-2(1H)-one; 3-(5-(4-fluorophenyl)-2H-tetrazol-2-yl)-4-phenylquinolin-2(1H)-one; 2-(6-(4-chlorophenyl)-8-methoxy-1-methyl-4H-benzo[f][1,2,4]triazolo[4,3-a][1,4]diazepin-4-yl)-N-ethylacetamide; tert-butyl 2-(4-(4-chlorophenyl)-2,3,9-trimethyl-6H-thieno[3,2-f][1,2,4]triazolo[4,3-a][1,4]diazepin-6-yl)acetate; 2-methoxy-N-(3-methyl-2-oxo-1,2,3,4-tetrahydroquinazolin-6-yl)benzenesulfonamide. N1,N3-bis(4-bromophenyl)malonamide; N1,N3-bis(4-(3,5-dimethylisoxazol-4-yl)phenyl)malonamide; 6-(3,5-dimethylisoxazol-4-yl)-4-hydroxyquinolin-2(1H)-one; 4-chloro-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 4-(benzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 4-(2-chlorobenzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-4-morpholinoquinolin-2(1H)-one; 6-(3,5-dimethylisoxazol-4-yl)-4-(piperidin-1-yl)quinolin-2(1H)-one; or 4-(benzylamino)-1-(benzylsulfonyl)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one.
The compounds as provided herein may be used in the treatment of a variety of disorders and conditions and, as such, may be used in combination with a variety of other suitable therapeutic agents useful in the treatment or prophylaxis of those disorders or conditions. Thus, one embodiment of the present invention includes the administration of the compound of the present invention in combination with other therapeutic compounds. Such a combination of pharmaceutically active agents may be administered together or separately and, when administered separately, administration may occur simultaneously or sequentially, in any order. The amounts of the compounds or agents and the relative timings of administration will be selected in order to achieve the desired therapeutic effect. The administration in combination of a compound of the present invention with other treatment agents may be in combination by administration concomitantly in: (1) a unitary pharmaceutical composition including both compounds; or (2) separate pharmaceutical compositions each including one of the compounds. Alternatively, the combination may be administered separately in a sequential manner wherein one treatment agent is administered first and the other second. Such sequential administration may be close in time or remote in time.
Another aspect of the present invention includes combination therapy comprising administering to the subject a therapeutically or prophylactically effective amount of the compound of the present invention and one or more other therapy including chemotherapy, radiation therapy, gene therapy, or immunotherapy.
The compounds of the present invention can be used for the prevention or treatment of various conditions or disorders mediated by inhibiting bromodomain-containing proteins from binding acetylated proteins. The compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of various types of cancer, inflammation, obesity, metabolic, cardiovascular, neurodegenerative, psychiatric and infectious diseases. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of systemic or tissue inflammation, inflammatory responses to infection or hypoxia, cellular activation and proliferation, lipid metabolism, fibrosis and viral infections. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of a variety of chronic autoimmune and inflammatory conditions such as rheumatoid arthritis, osteoarthritis, acute gout, psoriasis, systemic lupus erythematosus, multiple sclerosis, inflammatory bowel disease (Crohn's disease and Ulcerative colitis), asthma, chronic obstructive airways disease, pneumonitis, myocarditis, pericarditis, myositis, eczema, dermatitis, alopecia, vitiligo, bullous skin diseases, nephritis, vasculitis, atherosclerosis, depression, retinitis, uveitis, scleritis, hepatitis, pancreatitis, primary biliary cirrhosis, sclerosing cholangitis, Addison's disease, hypophysitis, thyroiditis, type I diabetes and acute rejection of transplanted organs. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of a wide variety of acute inflammatory conditions such as acute gout, giant cell arteritis, nephritis including lupus nephritis, vasculitis with organ involvement such as glomerulonephritis, vasculitis including giant cell arteritis, Wegener's granulomatosis, Polyarteritis nodosa, Behcet's disease, Kawasaki disease, Takayasu's Arteritis, vasculitis with organ involvement and acute rejection of transplanted organs. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of diseases or conditions which involve inflammatory responses to infections with bacteria, viruses, fungi, parasites or their toxins, such as sepsis, sepsis syndrome, septic shock, endotoxaemia, systemic inflammatory response syndrome (SIRS), multi-organ dysfunction syndrome, toxic shock syndrome, acute lung injury, ARDS (adult respiratory distress syndrome), acute renal failure, fulminant hepatitis, burns, acute pancreatitis, post-surgical syndromes, sarcoidosis, Herxheimer reactions, encephalitis, myelitis, meningitis, malaria and SIRS associated with viral infections such as influenza, herpes zoster, herpes simplex and coronavirus. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of conditions associated with ischaemia-reperfusion injury such as myocardial infarction, cerebro-vascular ischaemia (stroke), acute coronary syndromes, renal reperfusion injury, organ transplantation, coronary artery bypass grafting, cardio-pulmonary bypass procedures, pulmonary, renal, hepatic, gastro-intestinal or peripheral limb embolism. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of disorders of lipid metabolism via the regulation of APO-A1 such as hypercholesterolemia, atherosclerosis and Alzheimer's disease. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of fibrotic conditions such as idiopathic pulmonary fibrosis, renal fibrosis, post-operative stricture, keloid formation, scleroderma and cardiac fibrosis. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of viral infections such as herpes virus, human papilloma virus, adenovirus and poxvirus and other DNA viruses. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of diseases associated with systemic inflammatory response syndrome include sepsis, burns, pancreatitis, major trauma, haemorrhage and ischaemia. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of SIRS, the onset of shock, multi-organ dysfunction syndrome, which includes the onset of acute lung injury, ARDS, acute renal, hepatic, cardiac and gastro-intestinal injury and mortality. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of sepsis, sepsis syndrome, septic shock and endotoxaemia, acute or chronic pancreatitis, herpes simplex infections and reactivations, cold sores, herpes zoster infections and reactivations, chickenpox, shingles, human papilloma virus, cervical neoplasia, adenovirus infections, including acute respiratory disease, poxvirus infections such as cowpox and smallpox and African swine fever virus and for the treatment of Human papilloma virus infections of skin or cervical epithelia. According to one embodiment, the compounds and their pharmaceutical compositions are particularly useful in the treatment or prevention of various forms of cancer, leukemias and lymphomas including acute myeloid leukemia, Burkitt's lymphoma, multiple myeloma, T-cell lymphoblastic leukemia and other hemotological cancers that involve translocations of mixed-lineage leukemia gene (MLL); solid tumors such as hepatocellular carcinoma, glioblastoma, neuroblastoma, NUT midline carcinoma, sarcoma, breast, colorectal, lung, pancreatic and prostate cancer; osteoarthritis and rheumatoid arthritis; Alzheimer's disease; and HIV infection.
The present invention also provides a method for the synthesis of compounds useful as intermediates in the preparation of compounds of the present invention along with methods for their preparation. The compounds can be prepared according to the methods described below using readily available starting materials and reagents. In these reactions, variants may be employed which are themselves known to those of ordinary skill in this art but are not described in detail here. Those skilled in the art of organic synthesis will appreciate that there exist multiple means of producing compounds of the present invention. Illustrative synthetic methods, including those directed to specific, selected compounds noted in Tables 1, 2, 3, 4, 5, and 6 are set forth herein.
TABLE 1
Compound
Structure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
TABLE 2
Compounds of Formula 1A
Formula 1A
R 1A
R 2A
R 3A
R 4A
R 5A
R 6A
L 1A
Position, L 2A
L 3A
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OH
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—OMe
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
—
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
Ph
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
Ph
H
Ph
—NHCOCH 3
H
—CH 2 —
3, —CH 2 CH 2 —
CH 2
Ph
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
Ph
H
Ph
—NHCOCH 3
H
—CH 2 CH 2 —
3, —CH 2 CH 2 —
CH 2
TABLE 3
Formula 1B
R 1B
R 2B
R 3B
R 4B
R 5B
X B
Y B
L B
H
—CH 3
—CH 3
—OH
═O
—O—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—O—
—CH 2 —
H
—CH 3
—CH 3
—OH
═O
—N(CH) 3 —
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—N(CH) 3 —
—CH 2 —
H
—CH 3
—CH 3
—OH
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—N(CH 3 )CO—
—CH 2 —
H
—CH 3
—CH 3
—OCH 3
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CON(CH 3 )—
═O
—N(CH 3 )CO—
—CH 2 —
—CH 2 CH 2 OH
—CH 3
—CH 3
—OH
═O
—O—
—CH 2 CH 2 —
—CH 2 CH 2 OCH 3
—CH 3
—CH 3
—CONH 2
═O
—O—
—CH 2 —
—CH 2 CONH 2
—CH 3
—CH 3
—OH
═O
—N(CH) 3 —
—CH 2 CH 2 —
—CH 2 CH 2 OH
—CH 3
—CH 3
—CONH 2
═O
—N(CH) 3 —
—CH 2 —
—CH 2 CH 2 OCH 3
—CH 3
—CH 3
—OH
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
—CH 2 CONH 2
—CH 3
—CH 3
—CONH 2
═O
—N(CH 3 )CO—
—CH 2 —
—CH 2 CH 2 OH
—CH 3
—CH 3
—OCH 3
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
—CH 2 CONH 2
—CH 3
—CH 3
—CON(CH 3 )—
═O
—N(CH 3 )CO—
—CH 2 —
H
—CH 3
—CH 3
—OH
═O
—O—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—O—
—CH 2 —
H
—CH 3
—CH 3
—OH
═O
—N(CH) 3 —
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—N(CH) 3 —
—CH 2 —
H
—CH 3
—CH 3
—OH
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CONH 2
═O
—N(CH 3 )CO—
—CH 2 —
H
—CH 3
—CH 3
—OCH 3
═O
—N(CH 3 )CO—
—CH 2 CH 2 —
H
—CH 3
—CH 3
—CON(CH 3 )—
═O
—N(CH 3 )CO—
—CH 2 —
—CH 2 CH 2 OH
—CH 3
—CH 3
—OH
═O
—O—
—CH 2 CH 2 —
TABLE 4
Formula 1C
Position,
Position,
R 1C
R 2C
R 3C
R 4C
R 5C
R 6C
L 1C
L 2C
H
H
H
H
3,
—CH 2 —
bond
CH 3
H
H
H
3,
—CH 2 —
bond
H
H
H
2, CH 3
3,
—CH 2 —
bond
CH 3
H
H
2, CH 3
3,
—CH 2 —
bond
H
H
H
H
3,
—CH 2 —
—CH 2 —
CH 3
H
H
H
3,
—CH 2 —
—CH 2 —
H
H
H
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
H
H
3,
—CH 2 —
bond
CH 3
H
H
H
3,
—CH 2 —
bond
H
H
H
2, CH 3
3,
—CH 2 —
bond
CH 3
H
H
2, CH 3
3,
—CH 2 —
bond
H
H
H
H
3,
—CH 2 —
—CH 2 —
CH 3
H
H
H
3,
—CH 2 —
—CH 2 —
H
H
H
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
H
H
3,
—CH 2 —
bond
CH 3
CH 3
H
H
3,
—CH 2 —
bond
H
CH 3
H
2, CH 3
3,
—CH 2 —
bond
CH 3
CH 3
H
2, CH 3
3,
—CH 2 —
bond
H
CH 3
H
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
H
3,
—CH 2 —
—CH 2 —
H
CH 3
H
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2, CH 3
3,
—CH 2 —
—CH 2 —
H
CH 3
H
H
3,
—CH 2 —
bond
CH 3
CH 3
H
H
3,
—CH 2 —
bond
H
CH 3
H
2, CH 3
3,
—CH 2 —
bond
CH 3
CH 3
H
2, CH 3
3,
—CH 2 —
bond
H
CH 3
H
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
H
3,
—CH 2 —
—CH 2 —
H
CH 3
H
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
H
2,
3,
—CH 2 —
bond
CH 3
H
H
2,
3,
—CH 2 —
bond
H
H
H
2, Ph
3,
—CH 2 —
bond
CH 3
H
H
2, Ph
3,
—CH 2 —
bond
H
H
H
2,
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2,
3,
—CH 2 —
—CH 2 —
H
H
H
2, Ph
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2, Ph
3,
—CH 2 —
—CH 2 —
H
H
H
2,
3,
—CH 2 —
bond
CH 3
H
H
2,
3,
—CH 2 —
bond
H
H
H
2, Ph
3,
—CH 2 —
bond
CH 3
H
H
2, Ph
3,
—CH 2 —
bond
H
H
H
2,
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2,
3,
—CH 2 —
—CH 2 —
H
H
H
2, Ph
3,
—CH 2 —
—CH 2 —
CH 3
H
H
2, Ph
3,
—CH 2 —
—CH 2 —
H
H
H
2,
3,
—CH 2 —
bond
CH 3
CH 3
H
2,
3,
—CH 2 —
bond
H
CH 3
H
2, Ph
3,
—CH 2 —
bond
CH 3
CH 3
H
2, Ph
3,
—CH 2 —
bond
H
CH 3
H
2,
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2,
3,
—CH 2 —
—CH 2 —
H
CH 3
H
2, Ph
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2, Ph
3,
—CH 2 —
—CH 2 —
H
CH 3
H
2,
3,
—CH 2 —
bond
CH 3
CH 3
H
2,
3,
—CH 2 —
bond
H
CH 3
H
2, Ph
3,
—CH 2 —
bond
CH 3
CH 3
H
2, Ph
3,
—CH 2 —
bond
H
CH 3
H
2,
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2,
3,
—CH 2 —
—CH 2 —
H
CH 3
H
2, Ph
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
H
2, Ph
3,
—CH 2 —
—CH 2 —
H
H
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
H
3,
—CH 2 —
—CH 2 —
H
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
H
3,
—CH 2 —
—CH 2 —
H
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
H
3,
—CH 2 —
—CH 2 —
H
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
H
3,
—CH 2 —
—CH 2 —
H
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
H
3,
—CH 2 —
—CH 2 —
H
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
CH 3
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
CH 3
H
Ph
2, CH 3
3,
—CH 2 —
—CH 2 —
H
H
H
H
3,
—CH 2 —
—CH 2 —
CH 3
H
H
H
3,
—CH 2 —
—CH 2 —
H
H
H
H
3,
—CH 2 —
bond
H
H
H
H
3,
—CH 2 —
bond
H
H
H
H
3,
—CH 2 —
bond
H
H
H
H
3,
—CH 2 —
bond
TABLE 5
Formula 1C
R 1C —L 1C —N—R 2C
R 3C
—L 2C —R 4C
Position, R 5C
Position, R 6C
H
H
H
3,
H
H
H
3,
H
H
H
3,
TABLE 6
Formula 1D
R 1D
R 2D
R 3D
R 4D
R 5D
R 6D
X D
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
-COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—CH 2 —
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—CH 2 —
—COCH 3
—CH 2 CONH 2
H
H
—CH 2 —
—COCH 3
—CH 2 CONH 2
H
H
—CH 2 —
—COCH 3
—CH 2 CH 2 OH
H
H
—NH—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—NH—
—COCH 3
—CH 2 CONH 2
H
H
—NH—
—COCH 3
—CH 2 CONH 2
H
H
—NH—
—COCH 3
—CH 2 CH 2 OH
H
H
—NH—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—CH 2 —
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—CH 2 —
—COCH 3
—CH 2 CONH 2
H
H
—CH 2 —
—COCH 3
—CH 2 CONH 2
H
H
—CH 2 —
—COCH 3
—CH 2 CH 2 OH
H
H
—NH—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—NH—
—COCH 3
—CH 2 CONH 2
H
H
—NH—
—COCH 3
—CH 2 CONH 2
H
H
—NH—
—COCH 3
—CH 2 CH 2 OH
H
H
—NH—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CH 2 OH
H
H
—O—
—COCH 3
—CH 2 CH 2 OCH 3
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
—COCH 3
—CH 2 CONH 2
H
H
—O—
EXAMPLE 1
(Compounds 21-41 of Table 1)
Compounds 21-41 set forth in Table 1 may be prepared according the synthetic scheme set forth below. Those skilled in the art of organic synthesis will recognize that other substituents may be introduced to the three position (e.g., (—NH—R—R)) and four position according to the scheme.
EXAMPLE 2
Synthetic Scheme—Formula 1A
Compounds of Formula 1A may be prepared according to the synthetic scheme set forth below.
Benzotriazole 1 can be reacted with 2-oxoacetic acid and Cbz-NH2 to get compound 2 which can be coupled with an aniline derivative 3 in presence of a coupling reagent to obtain compound 4. Compound 5 can be obtained by treatment of compound 4 with ammonia or ammonia equivalent. An alkylation of compound 5 will provide compound 6 and subsequent treatment of compound 6 with Lawesson reagent can provide compound 7. Reaction of compound 7 with hydrazine can provide the hydrazine derivative 8 which can be treated with desired carboxylic acid to get the compound 9. Deprotection of the Cbz group followed by appropriate derivatization will provide the targeted compound of the Formula 1A.
EXAMPLE 3
Synthetic Scheme
The targeted compound of Formula 1A can be prepared by reacting compounds 1, 3, 5, 7 with appropriate side chains having a reacting group as shown below.
EXAMPLE 4
Synthetic Scheme
The compound 1 can be prepared according to the scheme of Example 2. The treatment of compound 1 with 1,1,1-triethoxyethane will give compound 2 which can be further reacted with carbon monoxide using the palladium catalyst to obtain a carboxylic acid ester derivative 3. The coupling of compound 4 with 2-aminoethanol will provide desired compound 5 of Formula 1A.
EXAMPLE 5
Synthetic Scheme
Benzotriazole 1 can be reacted with 2-oxoacetic acid and Cbz-NH2 to get compound 2 which can be coupled with an aniline derivative 3 in presence of a coupling reagent 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide to obtain compound 4. Compound 5 can be obtained by treatment of compound 4 with ammonia in methanol or ammonia acetate. Treatment of compound 4 with Lawesson reagent can provide compound 5 and subsequent reaction of compound 7 with hydrazine can provide the hydrazine derivative 6 which can be treated with 2-(3,5-dimethylisoxazol-4-yl)acetic acid to get the compound 7. The cyclization of compound 7 in presence of mixture of acetic acid and acetic anhydride will provide compound 8 of Formula 1A.
EXAMPLE 6
Synthetic Scheme
The deprotection of the silyl protecting group using TBAF will provide the free phenolic derivative which then can be treated with 2-chloroacetamide in presence of triethylamine to provide compound 3 of the Formula 1A.
Additionally compound 2 also can be reacted with the (2-bromoethoxy)(tert-butyl)dimethylsilane in presence of triethylamine to get compound 5. The deprotection of the silyl protecting group will provide the desired compound 6 of Formula 1A.
EXAMPLE 7
Synthetic Scheme—Formula 1B
Compounds of Formula 1B may be prepared according to the synthetic scheme set forth below.
The substituted isoxazole boronic acid can be reacted with 3-iodo or 3-bromo aniline derivatives 2 using Suzuki coupling conditions to give the corresponding amino compounds. Compound 2 may be reacted with diethyl ethoxymethylenemalonate at appropriate temperature with heating conditions to get compound 4. Hydrolysis of compound 4 will provide compound 5 and subsequent decaboxylation will yield compound 6. The nitration of compound 6 will provide corresponding nitro derivative 7 that can be treated with POCl3 to get the chloro compound 8. The chloro compound then can be treated with appropriate amine to produce compound 9 and subsequent protection of the amine will provide compound 10. The alkylation of compound 10 with halide or reductive alkylation using aldehyde will provide compound 11. The deprotection of the protecting group on compound 10 and then cyclization using di-tert-butyl dicarbonate will produce desired compounds of Formula 1B.
EXAMPLE 8
Synthetic Scheme
The deprotection of compound 1 will provide compound 2 which can be then reacted with an appropriate side chain with to yield desired compound 3 of Formula 1B.
EXAMPLE 9
Synthetic Scheme—Formula 1C
Compounds of Formula 1C may be prepared according to the synthetic scheme set forth below.
The reaction of 4-hydroxyquinolin-2(1H)-one derivative 1 with POCl3 will produce the corresponding dichloro compound 2 and subsequent treatment of compound 2 with aqueous HCl generate compound 3. The alkylation of compound 3 with an appropriate amine will produce the corresponding amino derivative 4 which can be further derivatized to yield compounds of Formula 1C.
EXAMPLE 10
Synthetic Scheme
The reaction of 4-bromoaniline with diethyl malonate under heating conditions will produce compound 3 which can be then treated with (3,5-dimethylisoxazol-4-yl)boronic acid under Suzuki reaction conditions to yield compound 4. The compound 4 can be cyclized to produce 6-(3,5-dimethylisoxazol-4-yl)-4-hydroxyquinolin-2(1H)-one by heating with polyphosphoric acid. Further reaction of 5 with POCl3 will yield the dichloro compound 6 and treatment of 6 with aqueous HCl will give compound 7. The reaction of compound 7 with benzylamine will provide the desired compound 8 of the Formula 1C.
EXAMPLE 11
Synthetic Scheme—Formula 1D
Compounds of Formula 1D may be prepared according to the synthetic scheme set forth below.
The reduction of a substituted nitrobenzene derivative may give the corresponding amino compounds. Compound 2 may be then reacted with diethyl ethoxymethylenemalonate at appropriate temperature with heating conditions to get compound 3. Hydrolysis of compound 3 will provide compound 4 and subsequent decaboxylation will yield compound 5. The reaction of compound 7 with POCl3 may yield the chloro compound 6. The chloro compound then can be treated with appropriate amine to produce compound 7 and subsequent derivatization of 7 can produce compound 8. Deprotection of the compound 8 followed by an appropriate derivatization will provide compound 10 of Formula 1D.
EXAMPLE 12
Synthetic Scheme
2-lodo-4-nitrophenol can be reacted with p-methoxybenzoyl chloride to produce PMB protected derivative 2 which than can be treated with (3,5-dimethylisoxazol-4-yl)boronic acid under Suzuki reaction conditions to yield compound 3. After reduction of nitro compound 3 to amino derivative 4, it can be treated with diethyl ethoxymethylenemalonate at appropriate temperature with heating conditions to get compound 5. Hydrolysis of the ester derivative 5 will provide compound 6 and subsequent decaboxylation will yield compound 7. The compound 7 can be treated with POCl3 to get the chloro compound 8. The chloro compound then can be treated with pyridin-2-ylmethanamine to produce compound 9 and subsequent acylation with acetyl chloride of the amine will provide compound 10. The deprotection of the protecting group of phenol of compound 10 will provide the phenolic compound 11 which can be further derivatized using appropriate alkyl halides to produce corresponding compounds 12 and 13 of Formula 1D.
EXAMPLE 13
6-chloro-3-(3-(2-methoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (Compound 5—Table 1)
(2-amino-5-chlorophenyl)(phenyl)methanone (10 g) was treated with EAA at 180° C. in a sealed tube for five hours to yield 3-acetyl-6-chloro-4-phenylquinolin-2(1H-one (4.5 g). A portion of the 3-acetyl-6-chloro-4-phenylquinolin-2(1H)-one (200 mg) was subsequently treated with 2-methoxybenzaldehyde and NaOH (25 equiv) in water and ethanol at room temperature for 16 hours to yield 6-chloro-3-(3-(2-methoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (60 mg)(LCMS (m/z)=415.10).
EXAMPLE 14
6-chloro-3-(3-(3,4-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (Compound 6—Table 1)
3-acetyl-6-chloro-4-phenylquinolin-2(1H)-one (200 mg)(see Example 1) was treated with 3,4-dimethoxybenzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-3-(3-(3,4-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (55 mg) (LCMS (m/z)=445.11).
EXAMPLE 15
6-chloro-4-phenyl-3-(3-(thiophen-2-yl)acryloyl)quinolin-2(1H)-one (Compound 7—Table 1)
3-acetyl-6-chloro-4-phenylquinolin-2(1H)-one (200 mg)(see Example 1) was treated with thiophene-2-carbaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-4-phenyl-3-(3-(thiophen-2-yl)acryloyl)quinolin-2(1H)-one (55 mg) (LCMS (m/z)=391.04).
EXAMPLE 16
6-chloro-3-(3-(4-(dimethylamino)phenyl)acryloyl)-4-phenylquinolin-2(1H)-one (Compound 8—Table 1)
3-acetyl-6-chloro-4-phenylquinolin-2(1H)-one (200 mg) was treated with 4-(dimethylamino)benzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-3-(3-(4-(dimethylamino)phenyl)acryloyl)-4-phenylquinolin-2(1H)-one (40 mg) (LCMS (m/z)=428.13).
EXAMPLE 17
6-bromo-3-(3-(2,3-dihydrobenzo[b][1,4]dioxin-6-yl)acryloyl)-4-phenylquinolin-2(1H)-one (Compound 9—Table 1)
(2-aminophenyl)(phenyl)methanone (500 mg) was reacted with KBr, ammonium molbedate, and sodium per borate in AcOH at 0° C. for 16 hours to yield (2-amino-5-bromophenyl)(phenyl)methanone (80 mg). A portion of the (2-amino-5-bromophenyl)(phenyl)methanone (200 mg) was treated with EAA at 180° C. in a sealed tube for 10 hours and subsequently washed to yield 3-acetyl-6-bromo-4-phenylquinolin-2(1H)-one (80 mg). A portion of the 3-acetyl-6-bromo-4-phenylquinolin-2(1H)-one (300 mg) was treated with 2,3-dihydrobenzo[b][1,4]dioxine-6-carbaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-bromo-3-(3-(2,3-dihydrobenzo[b][1,4]dioxin-6-yl)acryloyl)-4-phenylquinolin-2(1H)-one (120 mg).
EXAMPLE 18
6-bromo-3-(3-(2,5-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (Compound 10—Table 1)
3-acetyl-6-bromo-4-phenylquinolin-2(1H)-one (200 mg)(see Example 5) was treated with 2,5-dimethoxybenzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-bromo-3-(3-(2,5-dimethoxyphenyl)acryloyl)-4-phenylquinolin-2(1H)-one (55 mg) (LCMS (m/z)=489.06).
EXAMPLE 19
6-chloro-3-cinnamoyl-4-(pyridin-4-yl)quinolin-2(1H)-one (Compound 11—Table 1)
4-chloroaniline (2 g) was treated with isonicotinonitrile in the presence of BCl 3 and AlCl 3 in DCM at 0° C. to 45° C. for 16 hours to yield (2-amino-5-chlorophenyl)(pyridin-4-yl)methanone (300 mg). A portion of the (2-amino-5-chlorophenyl)(pyridin-4-yl)methanone (200 mg) was treated with EAA at 180° C. in a sealed tube for 6 hours to yield 3-acetyl-6-chloro-4-(pyridin-4-yl)quinolin-2(1H)-one (60 mg). A portion of the 3-acetyl-6-chloro-4-(pyridin-4-yl)quinolin-2(1H)-one (200 mg) was treated with benzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-3-cinnamoyl-4-(pyridin-4-yl)quinolin-2(1H)-one (55 mg) (LCMS (m/z)=386.08).
EXAMPLE 20
6-chloro-4-(pyridin-3-yl)-3-(3-o-tolylacryloyl)quinolin-2(1H)-one (Compound 12—Table 1)
3-acetyl-6-chloro-4-(pyridin-4-yl)quinolin-2(1H)-one (200 mg)(see Example 7) was treated with 2-methylbenzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-4-(pyridin-3-yl)-3-(3-o-tolylacryloyl)quinolin-2(1H)-one (100 mg).
EXAMPLE 21
6-chloro-N-(2-methylbenzyl)-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxamide (Compound 13—Table 1)
(2-amino-5-chlorophenyl)(phenyl)methanone (1 g) was treated with diethyl malonate and piperidine at 180° C. in a sealed tube for six hours to yield ethyl 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxylate (400 mg). A portion of the obtained ethyl 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxylate (380 mg) was treated with aqueous NaOH at room temperature for four hours. The resulting mixture was then heated to 100° C. for twelve hours to yield 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxylic acid (200 mg). The obtained 6-chloro-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxylic acid (200 mg) was reacted with COCl 2 in a CCl 4 reflux for three hours. The reaction mixture was concentrated and dissolved in acetone and added to a solution of o-tolylmethanamine and TEA in acetone at 0° C. and stirred at room temperature for three hours to yield 6-chloro-N-(2-methylbenzyl)-2-oxo-4-phenyl-1,2-dihydroquinoline-3-carboxamide (60 mg) (LCMS (m/z)=402.11).
EXAMPLE 22
6-chloro-3-cinnamoyl-4-phenyl-1,8-naphthyridin-2(1H)-one (Compound 14—Table 1)
5-chloropyridin-2-amine (20 g) was treated with pivaloyl chloride/TEA in DCM at 0° C. for two hours to yield N-(5-chloropyridin-2-yl)pivalamide (15 g). A portion of the obtained N-(5-chloropyridin-2-yl)pivalamide (10 g) was treated with t-butyl lithium, N-methoxy-N-methylbenzamide in THF at −78° C. for three hours. The reaction mixture was allowed to warm up to room temperature, stirred for three hours and crystallized to yield N-(3-benzoyl-5-chloropyridin-2-yl)pivalamide (4.5 g). The obtained N-(3-benzoyl-5-chloropyridin-2-yl)pivalamide (4.5 g) was reacted with 3N HCl in 1, 4 dioxane at reflux temperature for five hours to yield (2-amino-5-chloropyridin-3-yl)(phenyl)methanone (2.5 g). A portion of the (2-amino-5-chloropyridin-3-yl)(phenyl)methanone (2.0 g) was treated with EAA at 170° C. overnight to yield 3-acetyl-6-chloro-4-phenyl-1,8-naphthyridin-2(1H)-one (400 mg). A portion of the obtained 3-acetyl-6-chloro-4-phenyl-1,8-naphthyridin-2(1H)-one (350 mg) was reacted with benzaldehyde and aqueous NaOH in ethanol at room temperature for eight hours to yield 6-chloro-3-cinnamoyl-4-phenyl-1,8-naphthyridin-2(1H)-one (100 mg).
EXAMPLE 23
6-chloro-3-(3-(2-chloro-6-fluorophenyl)acryloyl)-4-(pyridin-4-yl)quinolin-2(1H)-one (Compound 15—Table 1)
3-acetyl-6-chloro-4-(pyridin-4-yl)quinolin-2(1H)-one (200 mg)(see Example 7) was treated with 3,4-dimethoxybenzaldehyde and NaOH in water and ethanol at room temperature for 16 hours to yield 6-chloro-3-(3-(2-chloro-6-fluorophenyl)acryloyl)-4-(pyridin-4-yl)quinolin-2(1H)-one (100 mg) (LCMS (m/z)=439.3).
EXAMPLE 24
6-chloro-3-(3-(3-fluoro-5-methylpyridin-4-yl)acryloyl)-4-(pyridin-3-yl)quinolin-2(1H)-one (Compound 16—Table 1)
3-fluoro-5-methylpyridine (1.6 g) was treated with freshly prepared LDA and methyl formate at −78° C. for five hours to yield 3-fluoro-5-methylisonicotinaldehyde (700 mg). 3-acetyl-6-chloro-4-(pyridin-3-yl)quinolin-2(1H)-one (250 mg) was reacted with 3-fluoro-5-methylisonicotinaldehyde (3 equivalents) in aqueous NaOH and ethanol at room temperature for 14 hours to yield 6-chloro-3-(3-(3-fluoro-5-methylpyridin-4-yl)acryloyl)-4-(pyridin-3-yl)quinolin-2(1H)-one (50 mg) (LCMS (m/z)=420.1).
EXAMPLE 25
6-chloro-3-(3-(2-chloro-6-fluorophenyl)but-2-enoyl)-4-phenylquinolin-2(1H)-one (Compound 19—Table 1)
(2-amino-5-chlorophenyl)(phenyl)methanone (2 g) was converted to 3-acetyl-6-chloro-4-phenylquinolin-2(1H)-one (800 mg) which, in turn, was converted to 6-chloro-3-(3-(2-chloro-6-fluorophenyl)but-2-enoyl)-4-phenylquinolin-2(1H)-one (225 mg).
EXAMPLE 26
3-cinnamoyl-6-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-3-yl)quinolin-2(1H)-one (Compound 20—Table 1)
4-bromoaniline (40 mg) was treated with isonicotinonitrile in the presence of BCl 3 /AlCl 3 in DCM at 0° C. to 45° C. for 16 hours to yield (2-amino-5-bromophenyl)(pyridin-3-yl)methanone (7 g). A portion of the obtained (2-amino-5-bromophenyl)(pyridin-3-yl)methanone (100 mg) was reacted with EAA in ethanol at 180° C. in a sealed tube for 12 hours to yield 3-acetyl-6-bromo-4-(pyridin-3-yl)quinolin-2(1H)-one (20 mg). The aforementioned reaction was repeated to yield additional 3-acetyl-6-bromo-4-(pyridin-3-yl)quinolin-2(1H)-one. A portion of the obtained 3-acetyl-6-bromo-4-(pyridin-3-yl)quinolin-2(1H)-one (400 mg) was treated with benzaldehyde and NaOH (aqueous) in ethanol at room temperature for 16 hours to yield 6-bromo-3-cinnamoyl-4-(pyridin-3-yl)quinolin-2(1H)-one (130 mg). A portion of the 6-bromo-3-cinnamoyl-4-(pyridin-3-yl)quinolin-2(1H)-one 940 mg) was treated with 3,5-dimethylisoxazol-4-ylboronic acid, Pd(dppf) 2 Cl 2 , N-methyldicyclohexyl amine, NaOH, in THF at 70° C. for 16 hours to yield 3-cinnamoyl-6-(3,5-dimethylisoxazol-4-yl)-4-(pyridin-3-yl)quinolin-2(1H)-one (6 mg) (LCMS (m/z)=448.04).
EXAMPLE 27
N1,N3-bis(4-bromophenyl)malonamide
4-Bromoaniline (20 mmol) and diethylmalonate (10 mmol) was heated to 150° C. for 20 hr. Reaction was cooled and diluted with ethanol and filtered to give the desired product as a grey solid (1.10 g). δ H (DMSO-d 6 , 400 MHz) 10.32 (s, 2 H, 2×NH 2 ), 7.58 (d, 4 H, J=9.6, Ar), 7.51 (d, 4 H, J=9.6, Ar), 3.48 (s, 2 H, CH 2 ); δ C (DMSO-d 6 , 100 MHz) 165.9, 138.7, 132.0, 121.4, 115.4, 46.4.
EXAMPLE 28
N1,N3-bis(4-(3,5-dimethylisoxazol-4-yl)phenyl)malonamide
N1,N3-bis(4-bromophenyl)malonamide (0.50 mmol) and isoxazole boronic acid (1.08 mmol) were dissolved in toluene/EtOH (8 mL/8:2). 2M Na 2 CO 3 (735 uL) and palladium tetrakis (113 mg) were added and heated to 90° C. for 5 hr. Reaction was cooled, partitioned between EtOAc and H 2 O. The organic portion was washed with H 2 O, sat. NaCl and dried over Na 2 SO 4 . Column chromatography gave the desired product as a yellow solid (117 mg). δ H (CDCl 3 , 400 MHz) 9.25 (s, 2 H, 2×NH2), 7.66 (d, 4 H, J=8.6, Ar), 7.23 (d, 4 H, J=8.6, Ar), 3.61 (s, 2 H, CH 2 ), 2.39 (s, 3 H, Me), 2.56 (s, 3 H, Me).
EXAMPLE 29
6-(3,5-dimethylisoxazol-4-yl)-4-hydroxyquinolin-2(1H)-one
N1,N3-bis(4-(3,5-dimethylisoxazol-4-yl)phenyl)malonamide (117 mg) was treated with polyphosphoric acid (5 eq. by weight) and heated to 140° C. for 5 hr. Reaction was cooled, diluted with H 2 O and filtered to give the desired product as a white solid (65 mg). δ H (DMSO-d 6 , 400 MHz) 11.43 (br s, 1 H, OH), 11.30 (s, 1 H, NH), 7.70 (s, 1 H, Ar), 7.51 (dd, 1 H, J=8.4, 1.6, Ar), 7.35 (d, 1 H, J=8.4, Ar), 5.77 (s, 1 H, CH), 2.40 (s, 3 H, Me), 2.22 (s, 3 H, Me).
EXAMPLE 30
4-chloro-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one
6-(3,5-dimethylisoxazol-4-yl)-4-hydroxyquinolin-2(1H)-one (40 mg) was treated with NEt 3 (65 uL), POCl 3 (0.5 mL) and heated to 65° C. for 3 hr. Reaction was cooled, partitioned between EtOAc and H 2 O. The organic portion was washed with H 2 O, sat. NaCl and dried over Na 2 SO 4 . Column chromatography gave the desired intermediate as a brown solid. The solid was dissolved in dioxane (2 mL) and 6M HCl (2 mL) was added and refluxed for 4 hr. Reaction was cooled, diluted with H 2 O, neutralized to pH 9 with solid K 2 CO 3 and filtered to give the desired product as a cream solid (34 mg). δ H (DMSO-d 6 , 400 MHz) 12.15 (s, 1 H, NH), 7.78 (s, 1 H, Ar), 7.67 (d, 1 H, J=8.4, Ar), 7.48 (d, 1 H, J=8.4, Ar), 6.89 (s, 1 H, CH), 2.42 (s, 3 H, Me), 2.24 (s, 3 H, Me).
EXAMPLE 31
4-(benzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one
4-chloro-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one was heated to 120° C. in a 1:1 mixture of DMSO and benzylamine. Reaction was cooled, partitioned between EtOAc and H 2 O. The organic portion was washed with H 2 O, sat. NaCl and dried over Na 2 SO 4 . Column chromatography gave the desired product as a cream solid (10 mg) after lyophilization. δ H (DMSO-d 6 , 400 MHz) 10.86 (s, 1 H, NH), 7.99 (s, 1 H, Ar), 7.71 (t, 1 H, J=5.2, NH), 7.56 (d, 1 H, J=8.8, Ar), 7.40-7.21 (m, 6 H, Ar), 5.16 (s, 1 H, CH), 4.46 (d, 2 H, J=5.2, CH 2 ), 2.42 (s, 3 H, Me), 2.26 (s, 3 H, Me).
EXAMPLE 32
4-(2-chlorobenzylamino)-6-(3,5-dimethylisoxazol-4-yl)quinolin-2(1H)-one
A similar procedure as set forth in Example 16 gave the desired product as a cream solid (15 mg). δ H (DMSO-d 6 , 400 MHz) 10.94 (s, 1 H, NH), 8.01 (s, 1 H, Ar), 7.18 (t, 1 H, J=5.6, NH), 7.53-7.47 (m, 2 H, Ar), 7.39-7.30 (m, 4 H, Ar), 5.06 (s, 1 H, CH), 4.52 (d, 2 H, J=5.6, CH 2 ), 2.44 (s, 3 H, Me), 2.28 (s, 3 H, Me).
EXAMPLE 33
6-(3,5-dimethylisoxazol-4-yl)-4-morpholinoquinolin-2(1H)-one
A similar procedure as set forth in Example 16 gave the desired product as a white solid (12mg). δ H (DMSO-d 6 , 400 MHz) 11.51 (s, 1 H, NH), 7.60 (s, 1 H, Ar), 7.54 (d, 1 H, J=8.8, Ar), 7.40 (d, 1 H, J=8.8, Ar), 5.94 (s, 1 H, CH), 3.88-3.80 (m, 4 H, Ar), 3.12-3.05 (m, 4 H, Ar), 2.43 (s, 3 H, Me), 2.25 (s, 3 H, Me).
EXAMPLE 34
6-(3,5-dimethylisoxazol-4-yl)-4-(piperidin-1-yl)quinolin-2(1H)-one
A similar procedure as set forth in Example 16 gave the desired product as a cream solid (6 mg). δ H (DMSO-d 6 , 400 MHz) δ H (DMSO-d 6 , 400 MHz) 11.43 (s, 1 H, NH), 7.55-7.50 (m, 2 H, Ar), 7.38 (d, 1 H, J=8.4, CH 2 ), 5.87 (s, 1 H, CH), 3.20-3.01 (m, 4 H, Ar), 2.44 (s, 3 H, Me), 2.26 (s, 3 H, Me), 1.79-1.70 (m, 4 H, Ar), 1.67-1.58 (m, 2 H, Ar).
BIOLOGICAL ASSAYS
EXAMPLE 35
In Vitro Cell Viability
MV4-11 acute myeloid leukemia cells (American Type Culture Collection, Manassas, Va.) were added to 96-well clear bottom assay plates containing RPMI-1640 medium supplemented with 10% fetal bovine serum (FBS) at approximately 30,000 cells/well and incubated for 24 hours at 37° C. with 5% CO 2 and 95% humidity. Control wells containing no cells were included to measure background fluorescence signal. Test compounds were dissolved at 10-20 μM and diluted two-fold in DMSO to produce a working stock of compound solutions. Aliquots of the working stock solutions were subsequently diluted 100-fold in basal RPMI-1640 medium which was then further diluted 10-fold to the assay plate containing the cells to provide 10 test concentrations ranging from 0.04 μM-20 μM. Following a 72-hour incubation period, viability of the cells was determined by the AlamarBlue® assay (Life Technologies, Carlsbad, Calif.) following the manufacturer's protocol. Prior to generation of dose response curves, the data were background subtracted using the no cell control values (mean+/−standard deviation) and fluorescence values versus Log 10 concentration of test compounds were plotted using GraphPad Prism. The resulting sigmoidal curve was then fit to the graph and IC 50 values were calculated using a 4 parameter (4PL) algorithm using the following equation: 4(PL)F(x)=(A−D)/(1+(x/c) B +D, where A=lower asymptote (baseline response), D=upper asymptote (maximum response), C=drug concentration that provokes a response halfway between A and D, B=slope of the curve. The results for selected compounds are set forth in Table 7.
TABLE 7
Compound
In Vitro Cell Viability (IC 50 )
(Table 1)
MV4-11 Cells (AML)
MM1.S Cells (Multiple Myeloma)
1
0.11
μM
5
1.49
μM
2.53
μM
6
3.57
μM
31.9
μM
7
2.3
μM
8
10.31
μM
9
5.52
μM
10
1.75
μM
3
μM
11
0.97
μM
4.21
μM
12
1.04
μM
2.44
μM
13
4.73
μM
3.1
μM
14
0.71
μM
14.1
μM
15
1.18
μM
16
0.4
μM
21
8.6
μM
22
1.8
μM
81
3
μM
127
5.45
μM
147
0.22
μM
148
0.25
μM
EXAMPLE 36
Gene Expression Change of MYC Oncogene
Approximately 1×10 6 MV4-11 were exposed to either DMSO as vehicle control or test compounds at 10 μM for one hour in RPMI medium supplemented with 10% FBS. Total RNA was prepared from the exposed cells using RNeasy® Mini Kit (Qiagen, Venlo, Netherlands) and reverse transcription was performed with QScript™ cDNA SuperMix (Quanta BioSciences, Gaithersburg, Md.) following manufacturers' protocols to yield complementary DNA (cDNA). Quantitative polymerase chain reaction was performed on MX3000 7500 Real-Time PCR system (Agilent Technologies, Santa Clara, Calif.) using cDNA derived from approximately 50 ng of total RNA and PerfeCTa® SYBR® Green FastMix® (Quanta BioSciences) with a thermal profile consisting of denaturation at 95° C. for 10 min followed by 40 cycles of denaturation at 95° C. for 10 seconds and annealing/elongation at 60° C. for 30 seconds. The expression of MYC gene was detected by using the forward primer 5′-CTG GTG CTC CAT GAG GAG A-3′ and reverse primer 5′-CCT GCC TCT TTT CCA CAG AA-3′ while the expression of GAPDH gene was measured with GAPDH PerfeCTa® Reference Gene Assay primers (Quanta BioSciences). Critical threshold (CT) values were obtained with MX Pro software (Agilent Technologies) and the gene expression fold changes were calculated for both MYC and GAPDH genes compared to vehicle control assuming that 1 CT value change corresponds to two-fold difference in gene expressions. MYC gene expression fold changes were then divided by the values for GAPDH gene in order to account for sample-to-sample loading differences. The results for selected compounds are set forth in Table 8.
TABLE 8
Compound
Gene Expression Change of MYC Oncogene (in vitro)
(Table 1)
MV4-11 Cells (AML) - Fold Change
1
−1.4/−1.3
2
−1.4
3
−1.4
4
−1.4
5
−1.6
6
−1.7
7
−1.3
8
−1.3
10
−1.3
11
−3.0
12
−2.8
13
−1.3
14
−3.0
15
−2.3
21
−1.2
22
−1.1
23
−1.0
24
−1.2
70
−1.2
71
−1.1
72
−1.3
73
−1.5
74
−1.0
75
−1.5
76
−1.3
77
−1.2
78
−1.5
79
−1.1
80
−1.3
81
−1.9
82
−1.2
90
−3.0
91
−1.3
92
−1.5
93
−1.6
94
−1.2
95
−1.4
96
−1.3
97
−1.5
98
−1.5
99
−1.4
100
−1.0
101
−1.5
102
−1.1
143
−1.2
144
−1.6/−1.7
145
−1.6/−1.6
EXAMPLE 37
Amplified Luminescent Proximity Homogeneous Assay (ALPHA)
The interactions between test compounds and BRD4 protein containing both bromodomain 1 and bromodomain 2 were measured with human BRD4 protein with N-terminal His tag (BPS Bioscience, San Diego, Calif.) using AlphaScreen® assay at room temperature. A 9 μl reaction mixture in BRD Assay Buffer (BPS Bioscience) containing 25 nM BRD4 and test compounds at various concentrations were incubated for 30 minutes followed by additional 30-minute incubation with 1 μl of 20 μM histone H4 peptide (residue 1-21) in the presence of 5% DMSO. Test compounds (see Table 4) were assayed at 10 μM or 31.6 μM for screening purpose, while 8 different concentrations (10 nM-10 μM) were used for IC 50 measurements. After the incubation, 20 μl of BRD Detection Buffer (BPS Bioscience) containing 10 μg/ml Glutathione Acceptor beads and 10 μg/ml Streptavidin Donor beads (PerkinElmer, Waltham, Mass.) was added and the mixture was incubated for 50 minutes in darkroom. Binding measurements were taken in duplicate at each concentration using EnSpire® Alpha Multimode Plate Reader Model 2390 (PerkinElmer). The AlphaScreen data were analyzed using Graphpad Prism (La Jolla, Calif.). In the absence of the compound, the AlphaScreen signal (A t ) in each data set was defined as 100% activity. In the absence of the histone H4 peptide ligand, the AlphaScreen signal (A b ) in each data set was defined as 0% activity. The percent activity in the presence of each compound was calculated according to the following equation: % activity=[(A−A b )/(A t −A b )]×100, where A=the AlphaScreen signal in the presence of compound; A b =the AlphaScreen signal in the absence of the histone peptide ligand; and A t =the AlphaScreen signal in the absence of the compound. The percent inhibition was calculated according to the following equation: % inhibition=100−% activity.
The inhibitory effects of select compounds from Table 1 are shown in Table 9.
TABLE 9
Compound
BRD4-BD1-BD2
(Table 1)
IC 50
% Inhibition
1
2.43
μM
87%
83
442
nM
99%
84
372
nM
98%
85
876
nM
99%
86
670
nM
99%
87
139
nM
99%
88
864
nM
98%
89
586
nM
99%
90
11.2
μM
62%
97
5.8
μM
59%
98
6.7
μM
64%
121
7.3
μM
68%
122
26.8
μM
65%
124
17.3
μM
50%
126
23.6
μM
50%
128
16.3
μM
64%
132
3.7
μM
92%
143
99%
144
0.049
μM
>90%
145
1.44
μM
72%
EXAMPLE 38
Amplified Luminescent Proximity Homogeneous Assay (ALPHA)
Assays were performed by AlphaScreening technology using a recombinant BRD4-BD1-BD2 and BET Ligand. The AlphaScreening signal from the assay was correlated with the amount of BET Ligand binding to the bromodomain. The compounds were diluted in 50% DMSO and 1 μl of the dilution was added to a 10 μl reaction so that the final concentration of DMSO is 5% in all of reactions. All reactions were conducted at room temperature. The 9 μl reaction mixture in BRD Assay Buffer contains 2.5 nM BRD4-BD1-BD2 and the indicated amount of the inhibitor, and the reaction mixture were incubated for 30 min followed by additional 30 min incubation after the addition of 1 μl of BET Ligand (Table 2.3.1). For the negative control (blank), 1 μl of the assay buffer was added instead of the BET Ligand. After the 30 min incubation with the BET Ligand, 20 μl of BRD Detection buffer containing 10 μg/ml Glutathione acceptor beads and 10 μg/ml Streptavidin Donor beads was added and the final 30 μl mixture was incubated for 50 min in a dark room.
AlphaScreening signal was measured using EnSpire Alpha 2390 Multilabel reader (Perkin Elmer). Binding experiments were performed in duplicate at each concentration. The AlphaScreening data were analyzed using the computer software, Graphpad Prism. In the absence of the compound, the AlphaScreening signal (A t ) in each data set was defined as 100% activity. In the absence of the BET Ligand, the AlphaScreening signal (A b ) in each data set was defined as 0% activity. The percent activity in the presence of each compound was calculated according to the following equation: % activity=[(A−A b )/(A t −A b )]×100, where A=the AlphaScreening signal in the presence of the compound, A b =the AlphaScreening signal in the absence of the BET Ligand, and A t =the AlphaScreening signal in the absence of the compound. The percent inhibition was calculated for certain compounds according to the following equation: % inhibition=100−% activity.
The inhibitory effects of select compounds are shown in Table 10.
TABLE 10
% inhibition
Compound Structure
at 10 μM
50
51
62
65
70
71
74
82
85
98
98
99
99
99
99
99
99
The specific pharmacological responses observed may vary according to and depending on the particular active compound selected or whether there are present pharmaceutical carriers, as well as the type of formulation and mode of administration employed, and such expected variations or differences in the results are contemplated in accordance with practice of the present invention.
Although specific embodiments of the present invention are herein illustrated and described in detail, the invention is not limited thereto. The above detailed descriptions are provided as exemplary of the present invention and should not be construed as constituting any limitation of the invention. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the invention are intended to be included with the scope of the appended claims.
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The present invention relates to compounds that bind to and otherwise modulate the activity of bromodomain-containing proteins, to processes for preparing these compounds, to pharmaceutical compositions containing these compounds, and to methods of using these compounds for treating a wide variety of conditions and disorders.
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FIELD OF THE INVENTION
[0001] The field of the invention is valves with a failsafe mode of closure for oilfield use, primarily in sub-sea applications and more particularly, in the preferred embodiment, which compensate for a rise in internal pressure around the gate when opening and allow internal line pressure to assist in valve closure.
BACKGROUND OF THE INVENTION
[0002] Valves used in sub-sea drilling applications have had actuators with fail-safe closure provisions. Generally, the force required to return the actuator piston and the valve to a fail safe position, which, in most cases were the fail closed position is from the spring force and the actuator stem force. The spring force is normally relatively low in comparison to the total force required for fail-safe operation. The actuator stem force is a primary fail-safe force presented a net area of the stem cross-sectional area that was exposed internally to the valve body. Generally a spring or springs were used to return an actuating piston and the valve gate to a fail-safe position, which, in most cases was the closed position. In some designs, the valve actuator stem presented a net area exposed to internal valve pressure, which, in the absence of hydraulic pressure on the actuating piston provided a net force to move the gate to its fail-safe position. These large unbalanced forces were needed to overcome gate drag due to internal pressures in the valve body forcing the gate laterally. The return spring would also act on the actuating piston to urge the gate to the fail-safe position.
[0003] In drilling applications a condition could exist where the valve body is full of an incompressible fluid like drilling mud. When trying to stroke the gate from a closed to an open position, the stem connecting the gate and the actuating piston would enter the valve body. If the valve body was full of an incompressible fluid, the internal pressure could rise to the point that the maximum working pressure of the valve body could be exceeded. Additionally, further movement of the gate could be stalled as the pressure buildup around the gate could rise to the level where the hydraulic system acting on the actuating piston could not overcome the built up internal pressure from the surrounding incompressible fluid. To compensate for this effect, a balancing stem was attached to the lower end of the gate, to minimize or eliminate this pressure buildup that would otherwise occur as the valve is actuated to open. However, the addition of the balancing stem attached to the gate solved one problem but created another. Since the gate was essentially in pressure balance from internal valve pressure a net unbalanced force was no longer available to overcome gate drag when a fail-safe operation was required. Normally, the return springs could only put out a few thousand pounds of force to assist in the fail-safe movement, but to overcome gate drag forces well in excess of 25,000 pounds would be needed. The solution to the problem was to design an auxiliary pressurized accumulator, which could take the place of the force formerly provided by internal pressure acting on a net area of the gate assembly to drive it to the fail-safe position. The accumulators were large and heavy and their required size and weight increased with the sub-sea depth of the application. They also presented safety concerns in that their pressure had to be released to equalize with the sub-sea pressure before being brought to the surface. They also presented safety concerns in that their pressure had to be vented prior to actuator disassembly to avoid injury to maintenance personnel.
[0004] Various designs of sub-sea drilling gate valves have been attempted, some with the pressure balanced feature, as shown in U.S. Pat. Nos.: 4,809,733; 4,311,297; 4,230,299; 4,489,918; Re 29,322; 4,281,819; 6,125,874; and Re 30,115. Of these, the latter two are of most interest as they provide a way to use the surrounding seabed pressure to urge a balancing piston against the gate to make the valve fail-safe. However, even these two latter references do not provide the ability to compensate for a buildup in internal pressure around the gate during opening while at the same time having a provision to allow a net internal pressure to act on an unbalanced gate to achieve a fail-safe position. In the present invention large accumulators are eliminated or minimized. A compensating piston, which is biased toward the gate but not connected to it, is used in the preferred embodiment. A self contained, charged, pressure chamber acts on the compensating piston. An easy retrofit of existing valves is also possible. These and other advantages of the present invention as well as additional features will be more readily appreciated by those skilled in the art from reading the description of the preferred embodiment, which appears below.
SUMMARY OF THE INVENTION
[0005] A fail-safe gate valve for sub-sea use features a floating, pressure biased compensating piston whose movement prevents internal pressure buildup from opening movement of the gate. A pre-charged fluid chamber provides the bias on the balancing piston. Using unequal piston diameters reduces the charge pressure. The balancing piston is not connected to the gate so that internal pressures can be employed to act on a net area, which biases the gate toward its fail-safe position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a sectional view of a prior art valve using a balancing stem attached to the gate and a single control line to the surface;
[0007] [0007]FIG. 2 is a sectional view of the valve of FIG. 1, using a dual control line system;
[0008] [0008]FIG. 3 is a sectional view of the valve of the present invention, in the closed position;
[0009] [0009]FIG. 4 is the view of FIG. 3 showing downward gate movement prior to the onset of flow through the valve;
[0010] [0010]FIG. 5 is the view of FIG. 4 with flow through the valve just beginning;
[0011] [0011]FIG. 6 is the view of FIG. 5 with the valve fully open; and
[0012] [0012]FIG. 7 is an alternative embodiment as to the placement of the compensating piston.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] [0013]FIGS. 1 and 2 show, respectively, a single and dual control line actuation system for a sub-sea gate valve. The valve 10 has a body 12 and an inlet 14 and an outlet 16 . Located in cavity 17 are inlet seat assembly 18 and outlet seat assembly 20 , respectively surrounding inlet 14 and outlet 16 . A gate 22 is moved between the seat assemblies 18 and 20 so as to isolate with seats, the cavity 17 from passages 16 and 19 in gate 22 . An actuator rod 24 is connected to the gate 22 and has a piston 26 near its top end. Piston 26 is sealed at its periphery where it slides against housing 28 . An actuation system comprises an accumulator 30 connected to a diverter valve 32 through control line 40 . Control line 34 runs from the surface to the sub-sea location of diverter valve 32 . Control line 36 runs from housing 28 above piston 26 to control line 40 and to diverter valve 32 . Control line 38 runs from housing 28 below piston 26 to diverter valve 32 .A balance stem 42 is sealed where it extends through opening 44 .
[0014] In operation, pressure from control line 34 is directed to control line 36 via diverter 32 and line 40 while control line 38 is aligned through the diverter valve 32 to dump fluid to the surrounding seawater. The accumulator 30 is pressurized from line 34 , at this time. Piston 26 , actuator rod 24 , gate 22 and balance stem 42 all move in tandem to open the valve 10 . Because of the presence of the connected balance stem there is no internal pressure buildup in the cavity 17 as the valve opens. At the same time because of the balance stem 42 , internal pressure in cavity 17 does not apply a force that will urge the gate 22 in the opposite and fail-safe direction. Upon failure of hydraulic pressure to diverter valve 32 it assumes a position where pressure from control line 38 , coming from the gas charged accumulator 30 , moves the piston 26 upwardly as flow from line 36 is directed through diverter 32 and back to the surface through line 34 . At the time of failure, there is no pressure beyond hydrostatic in line 34 .
[0015] [0015]FIG. 2 illustrates the use of two control lines, which can be alternatively pressurized or vented to urge the gate 22 up or down. The equipment to do that is at the surface. FIG. 2 has the disadvantage of having to run double the amount of control lines potentially thousands of feet sub-sea. The design of FIG. 1 has the disadvantage of large and heavy equipment, which may not fit in confined areas sub-sea or may be difficult to access or to deliver to the location. The cost factor can become significant due to the high pressure ratings involved for the components, such as the accumulator 30 .
[0016] The present invention, in the preferred mode, is illustrated in FIGS. 3 - 7 . The parts that are the same as in FIGS. 1 - 2 will be identically numbered. The differences are the use of a balancing piston 50 , which has a large area 52 in chamber 54 and a small area 56 exposed to cavity 17 . While piston 50 is shown to be solid it can take many shapes. Area 56 can be recessed to create an upwardly facing receptacle to overly a tab (not shown) at the base of gate 22 to guide gate 22 while still performing the same pressure compensation feature and allowing internal pressure to exert an unbalanced force on the gate 22 to urge it to its fail-safe position. Gate 22 is not attached to piston 50 and is not intended to contact piston 50 . As shown in FIG. 3 the piston 50 is in alignment with gate 22 , but such alignment is optional, as shown in FIG. 7. There a passage 58 communicates to chamber 54 and piston 50 is offset and parallel to gate 22 . Chamber 54 has a variable volume cavity 60 , which connects to a reservoir 62 through line 64 . Reservoir 62 has a movable piston 68 , above which is a pre-charge of pressure, preferably nitrogen. The area 52 being larger than the area 56 allows the use of lower pressure in reservoir 62 . Thus, for example if the maximum desired pressure in cavity 17 is 15,000 pounds per square inch (PSI) and the area ratio of areas 52 to 56 is 3 to 1, then the required nitrogen pressure in reservoir 62 is only 5,000 PSI. Piston 50 is biased by the nitrogen against a travel stop and in FIG. 3 is in its uppermost position. Conversely, because piston 50 is inverted in FIG. 7, it is in its lowermost position, as the valve 10 is getting ready to open. FIG. 7 shows a split view of piston 50 in the extremes of its range of motion.
[0017] Comparing FIGS. 3 and 4 it can be seen that as the gate moves downwardly tending to raise the pressure in cavity 17 , the piston 50 moves in a direction to decrease the volume of variable volume cavity 60 , which at the same time increases the volume of cavity 17 to avoid pressure buildup. There is as yet no flow in the FIG. 4 position. The only thing that has occurred is the gate moving down as well as piston 50 so as to avoid pressure buildup beyond the desired pressure in cavity 17 . That target pressure in cavity 17 is based on the area ratios of areas 52 and 56 and the nitrogen pressure initially charged in reservoir 62 . Since the piston 50 is not linked to gate 22 , when it comes time to go to the fail-safe position, there is an unbalanced force on the gate 22 from internal pressure in valve 10 . This force is enhanced by closure spring 66 . Unlike the FIG. 1 design, an accumulator 30 is not needed in the control system. In the event there is low or no pressure in valve 10 when it needs to go into the fail-safe mode, the force of spring 66 is sufficient because there is little or no gate drag force to overcome.
[0018] [0018]FIG. 5 shows the onset of flow through the valve 10 , at which point further displacement of gate 22 does not tend to further raise the pressure in cavity 17 and there is no further displacement of piston 50 into chamber 54 . FIG. 6 shows the wide open position. A variety of control systems, hooked up to actuator housing 28 to make the piston 26 travel down or allow it to be driven up for the fail-safe mode can be used without departing from the invention. Reservoir 62 can be made integral with chamber 54 such as by placing barrier piston 68 in cavity 60 with the nitrogen pressure on the opposite side from piston 50 . The configuration of FIG. 3 is readily amenable to a retrofit on existing valves so as to simplify the attendant control system by elimination of an accumulator 30 and some of the associated control lines. The control system can be no more complicated than a single control line 70 , which can equalize with line 72 for closure of the gate 22 . Normal operation can be nothing more than applying or removing a pressure in line 70 . Provisions can be made in the control system so that spring 66 does not have to close against hydrostatic pressure in line 70 . While those skilled in control system design will appreciate the variety of systems that can be implemented, the system simplification as compared to FIGS. 1 and 2 is due to the piston 50 not being attached to the gate 22 , which lets an unbalanced force act to close the valve from within using internal pressure. Spring 66 also provides an assist to reach the fail-safe condition. If the valve has no internal pressure when the fail-safe position is needed, the spring 66 can push the piston 26 against the minimal gate drag present with no internal pressure. The accumulator of FIG. 1 is no longer needed. For opening, the use of piston 50 biased with nitrogen or other type of pressure from reservoir 62 , if separate or from chamber 54 if reservoir 62 is integral with it, prevents housing overpressure or stalling of gate 22 during the opening procedure.
[0019] In FIG. 1 item 14 is the inlet and 16 is the outlet. This valve is unidirectional, where 14 and 16 cannot be reversed and bi-directional, where 14 and 16 can be reversed. One reservoir 62 can be used to control the cavity 60 pressure to two or more valves. Line 64 would tee or branch to the individual valves, each having its own chamber 54 . The reservoir 62 would be sized with capacity to control any valve individually or to control all valves, if actuated simultaneously. Chamber 54 can be mounted remotely from the individual valve. Separate chambers or one larger common chamber 54 would service all valves. A line could be run from the individual cavities 17 to the common chamber 54 . Chamber 54 and reservoir 62 could be a combined unit or separate structures.
[0020] The above description is illustrative of the preferred embodiment and various alternatives and is not intended to embody the broadest scope of the invention, which is determined from the claims appended below, and properly given their full scope literally and equivalently.
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A fail-safe gate valve for sub-sea use features a floating, pressure biased compensating piston whose movement prevents internal pressure buildup from opening movement of the gate. A pre-charged fluid chamber provides the bias on the balancing piston. Using unequal piston diameters reduces the charge pressure. The balancing piston is not connected to the gate so that internal pressures can be employed to act on a net area, which biases the gate toward its fail-safe position.
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BACKGROUND
The present invention relates to a water soluble, non-toxic, bio-pharmaceutical extracted from sharks liver which stimulates the patient's immune system and which, in turn, inhibits the growth of cancer cells and reduces toxic side effects on patients exposed to radiation used to treat cancer. It is believed the sharks liver extract could also have beneficial effects in conjunction with chemotherapy.
The sharks immune system is different from that of mammals. It does not produce specific antibodies against each microorganism that invades the body. Instead, the shark has a primitive but effective immune system which includes an immunoglobulin molecule (IgM) in the blood circulating through its body. The IgM binds to foreign substances, mainly proteins (antigens), marking those antigens so they can be found and destroyed. This IgM is similar to the IgM which exists in the human fetus but disappears as the fetus matures. "The shark immune system seems to do an extraordinary job of protecting against cancer and other diseases," (Los Angeles Times, Aug. 27, 1990, pp B3).
Recent research has suggested that shark cartilage, because of its ability to inhibit blood-vessel growth, may inhibit tumor growth. To this end Carl A. Luer, of Mote Marine Laboratory in Sarasota, Fla., has identified a group of three proteins recovered from shark cartilage which he believes may be suitable for retarding or reversing tumor growth without the harmful side effects of radiation (Los Angeles Times, Aug. 27, 1990, pp B3).
Samuel Gruber has reported isolating a protein from a sharks skeleton that, when injected in a tumor, causes the tumor to dry up and die. However, side effects make use of the protein on humans impractical (San Francisco Chronicle, Jan. 18, 1989).
Astrid, Johan and Sven Brouhult, and their associates, have reported on the use in cancer patients of preparations, delivered orally in capsules, containing 85% alkoxyglycerol recovered from the oil of the liver of Greenland sharks. When administered prior to radiation, patients with cancer of the uterine cervix showed higher survival rates then if radiation treatment alone is given (Acta Chem. Scand. 24, 2 (1970) pp. 730-732); (Acta Obstet. Gynecol. Scand. 65(1986) pp. 779-785). Others have taught the alcohol extraction of homogenated shark liver to produce a cytotropic heterogeneous molecular lipid or serum separated from shark blood by alcohol extraction to increase immunity or attack cancer cells.
The materials discussed above are recovered from various organs of the shark using different methods of recovery. They constitute oils or lipids, which are not water soluble. As a result, delivery of the active material, either systemically or directly, to the desired site, or absorption into the target tissue, may be difficult.
There have been reports of a physiological saline extract of shark liver being administered to patients in the former Soviet Republic of Georgia and that material has been used to treat patients with prostate cancer. (Modianova, E. A., Gachechiladze, A. B., Kolotygina, J. M. Kasatkina, N. N., Malenkov, A. B., "Antiblastomogenic and Antipromotor Activity of Katreks," Abstracts of Papers, School Seminar; "Regulation of Tissue Homeostasis: Non-toxic Prophylaxis and Therapy of Chronic Pathologies, Tbilisi, 1987: 191-6; Modianova, E. A., "Predisposition of Epithelial Tissues to the Onset of Spontaneous Tumors as a Manifestation of Impairment of the Resistance of the Integrating Tissue System," In: Ibid 116-118; Glinskii, K. V., Ivanova, A. B., Surgova, T. M., Kaz'min, S. D., Vinnitskii, V. B., "A Study of Several Biochemical Characteristics of the Biopreparation Katreks," In: Ibid:32-41).
However, these materials have several negative characteristics including an unacceptable level of impurities, inconsistency of performance and a limited shelf life of less that about two (2) weeks.
Thus, there is a need for a stable, biologically active, non-toxic material that can be readily isolated and administered to the patient for cancer treatment, which stimulates, enhances, and/or modulates the immune system and reduces or eliminates the toxic side effects of radiation, and possibly, chemotherapy, on patients being treated for various forms of cancer.
SUMMARY
These needs are met by the present invention which comprises a water soluble, lyophilized preparation which can be administered once reconstituted or properly compounded, orally, by intravenous injection, intramuscular, transcutaneously or direct deposition at a desired spot within the body for reduction or elimination of malignant tumors or for the prevention or reduction of the deleterious effects of radiation treatment and possibly of chemotherapy on normal cells within the human body.
More particularly, the invention constitutes a method of recovering, and the products recovered by said method, an extract from the liver of sharks which has significant benefit in stimulating the immune system and reduce the negative side effects of radiation. These materials may also have a beneficial effect when used in conjunction with bone marrow transplants which also necessitate the radiative destruction of the patients diseased bone marrow.
DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
FIG. 1 is a schematic diagram of the process for preparing the liver extract embodying features of the invention.
FIG. 2 is a graph showing the survival of mice exposed to 900 cGy irradiation with various protective measures.
FIG. 3 is a graph showing the survival of mice exposed to 800 cGy irradiation, with various protective measures including the lyophilized shark liver extract.
FIG. 4 is a graph showing the survival of mice exposed to 900 cGy irradiation with various protective measures including the lyophilized shark liver extract.
FIG. 5 is a bar graph showing survival rates responsive to delivery times or protective regimes.
DESCRIPTION
A purified aqueous extract of sharks liver was prepared. It was established that these materials show significant immune stimulation, as reflected by natural killer cell assay, and are more immune stimulating in the same assay than Interferon using C57 BL/6 mice tested Chromium labeled YAC lymphoma cells. Using a mice model at the Division of Radiation Oncology at the National Cancer Institute, we have demonstrated significant and comparable radioprotective effects as stem cell factor (SCF), a known radioprotective substance. Further, the extract prepared as described below, should have beneficial effects when administered to a patient in conjunction with high dose radiation therapy in advanced prostatic carcinoma, and is believed to convey properties of angiogenesis inhibition to tumors and immune stimulation involving NK cell activity properties so as to facilitate the organism's ability to reject cells recognized as "not self" by various methods attributed to NK activity.
METHOD OF PREPARATION
FIG. 1 is a schematic diagram showing a method of preparing the shark liver extract. A quantity of shark liver was refrigerated to about 0° C. to 4° C., finely ground, granulated, pulverized, crumbled, milled or otherwise reduced to a powder or slurry to produce subcellular particles of biological material in colloidal suspension and mixed with an equal amount, by weight, of water or physiological saline solution (PSS). Grinding or morselizing was accomplished by processing in a bench top food blender or juicer/processor. The mixture was maintained at 0° C. to 4° C. with stirring and blending for about 20 minutes. Upon spinning the mixture in a centrifuge at 2780 rpm, 0° C. to 4° C. for 6 hours, the mixture separated into three layers comprising a cellular layer, a pink/brown aqueous layer with its water soluble components, and an oil layer. The aqueous layer which contained the desired shark liver extract (SLE) was isolated for further processing. The aqueous layer may be further processed by deaerating, adding more water and centrifuging again to prepare a further purified aqueous layer. The color can be removed by passing the aqueous layer through absorbent materials generally used for that purpose.
The volume of aqueous layer separated out is measured, filtered through a fine filter, preferably a 23μ filter, to remove visible particulate material and generate a clear appearing solution and then flash dried by spraying the liquid into a vacuum chamber at 0° to 4° C. (lyophilization). The resultant powder (lyophilized water soluble SLE) is collected and weighed so that it can be reconstituted to approximately the same volume with a physiologically acceptable diluent for injection. It has generally been found that there is 140 mg of lyophilized material per 5 ml of diluent. Alternatively, the lyophilized material can be encapsulated in an enteric coated gelcap for oral delivery or a suitable material, such as beeswax/glycerol compositions, for forming a body meltable suppository for transrectal or transurethral delivery. The above described process results in a purified, readily administered composition in which the chemical or biological components of shark liver most beneficial for the procedures discussed below are concentrated and non-active materials are removed. The oil layer collected from the centrifuged mixture can also be used in applications previously disclosed for shark liver oil.
In order to demonstrate the efficacy of shark liver extract prepared according to the above described procedures, mice were treated with various materials, all prepared in the same manner. The difference between the material designated "shark" and "heated shark" is that in the heated shark extract was additionally exposed to 100° C. for four (4) minutes following the process set forth above. The figures show the radiation protection effect of Shark Liver Extract before heating (Shark) and after heating (Heated Shark). The controls for comparison are: Stem Cell Factor (SCF), Chicken Liver Extract (Chicken), and Phosphate Buffer Saline (PBS). The chicken liver extract was derived from chicken liver treated in a manner similar to the SLE. The SCF has known radiation protective properties. The Phosphate Buffer is the carrier, which has no known immune or protective properties.
FIGS. 2-5 are graphical representations of the results obtained. In a first instance (FIG. 2), two differently treated shark liver extracts are compared with controls in mice irradiated at 900 cGy. In each instance, the extract or controls were reconstituted to the original (prelypholized) concentration and 0.2 ml were administered to the mice intraperitoneal or subcutaneously at 20 and 4 hours prior to radiation exposure. FIGS. 3 and 4 compare the effect of lyophilized shark liver extract when the mice are exposed to 800 or 900 cGy under the same protocol. FIG. 5 is a bar chart comparing the survival rate of mice exposed to 900 cGy after treatment with the shark liver extract(S), heated shark liver extract (HS), PBS, SCF and chicken liver extract (CL) under two different delivery regimes for the extract, namely 5 days and 3 days prior to radiation (5 d/3 d) or 20 hours and 4 hours prior to radiation (20 h/4 h). While the SCF results in an 80% survival rate at the 20h/4h, the shark liver extract, with or without heating, shows a survival rate of 50% and 60% which is significantly greater than the PBS control or chicken liver extract.
Table 1 shows the effect of Shark Liver Extract (0.2 ml) on stimulating NK cell activities in mice.
TABLE 1______________________________________EFFECT OF HAWAIIAN WHITE-TIPPED SHARK LIVEREXTRACT TREATMENT ON NK CELL ACTIVITY OF MICE% CYTOTOXICITY, EFFECTOR: TARGET RATIO TREATMENT WITHSPLEEN °CELLS LIVER EXTRACT 200:1 100:1 50:1 25:1______________________________________Normal -- 28.8 18.3 16.0 8.3Extract Treated 0.2 ml 52.2 46.3 25.7 13.7Extract treated 0.1 ml 34.8 21.8 10.7 8.5______________________________________
To generate this data, °C.57BL/6 mice were inoculated i.p. with 0.1 and 0.2 ml of shark liver extract. Two days later, spleens of these mice were harvested and simple cell suspensions were prepared and the NK cell activity was tested against 51 Cr-labeled YAC-1 lymphoma cells. The extract contained 22 mg of protein per ml.
Results of this assay show that treatment of mice with 0.2 ml of shark liver extract resulted in substantial stimulation of NK cell activity. Treatment with 0.1 ml of the extract was not sufficient to significantly increase NK cell activity of the treated mice indicating a dose responsive relationship in the ability of SLE to stimulate immune response in NK cells carrying the 51 Cr labeled YAC-1 lymphoma cells.
Based on the animal studies, it is believed that the solubilized lyophilized form of the shark liver extract can be incorporated into a standardized rectal suppository form which, upon placement within the required pretreatment time period, would confer radiation protection to the rectal/pelvic region during the course of radiation therapy for stage BII or C prostatic carcinoma without altering the expected response of the malignant tissue within the prostate gland to a delivered dose of radiation, thus diminishing the chance of radiation produced cystitis or proctitis developing. Typical carriers used in standardized rectal suppositories include beeswax/glycerol. The proper treatment protocol is based on the test results in animals of radiation protection when given 20 hours and 4 hours before delivery of high dose radiation. The 800 and 900 cGy studies suggest that higher dosage of radiation with better tumor eradication could be achieved with fewer side effects by this method. Secondly, using lyophilized shark liver extract delivered prior to, during, and following courses of treatment for advanced prostate cancer with the chemotherapeutic agent Suramin, patients with hormonally unresponsive advanced carcinoma of the prostate and who have documented rising levels of PSA after having undergone MAB (maximum androgen blockade), that is patients who have undergone orchiectomy and are on Flutamide or are on LH/RH inhibitors with Flutamide, will show improved treatment effects and reduced side effects from the chemotherapy treatment when compared to those not receiving SLE or receiving a placebo treatment.
Although the present invention has been described in considerable detail with reference to certain preferred versions and uses thereof, other versions and uses are possible. For example, while Hawaiian white-tipped shark liver was used, other types of shark liver can be used, and it is not believed that the specific type of shark used will give a different effect. Other suitable shark species include juvenile nurse sharks, horned shark, lemon shark, tiger shark, mako, black tip and sand sharks. However, deep sea sharks are preferred as they are believed to have less environmental toxins than bottom feeding or scavenger sharks. Similar effects may be obtained from the livers of skates and rays which occupy the same taxonomic subclass, called elastobranchs. Further, instead of using water in the above procedures, a saline or physiological solution is believed to be a suitable replacement. The lyophilization product prepared as described above has been shown to have a longer shelf life (i.e., up to 6 months) and to be more consistent in the results obtain than any of the other biological products derive from sharks discussed above.
Further, while use of the shark liver extract embodying features of the invention was described for use in the treatment of prostate cancer using radiation, it would be recognized that the invention has benefit for use in conjunction with other cancer treatments, for treating other cancers, or for use in disease states resulting from a compromised immune system. Also, while the process is directed to recovering a water soluble shark liver extract, the other layers separated by the centrifuge, particularly the oil layer, can be processed in a similar manner to provide a dry non-water soluble shark liver extract. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A water soluble, non-toxic, purified, biological preparation extracted from sharks liver which inhibits the growth of cancer cells by stimulating the patient's immune system and reduces toxic effects on patients exposed to radiation used to treat cancer. The water soluble material can be administered orally, transrectally, transcutaneously or by direct deposition at a desired spot within the body for reduction or elimination of malignant tumors or for the prevention or reduction of the deleterious effects of radiation treatment on normal cells within the human body. The shark liver extract is produced by grinding the liver, extracting the ground material with water, removing the non-water soluble components and lyophilizing the water soluble components to produce a powdered substance suitable for delivery to the patient, said substance having an extended shelf life.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application 10050693.3 filed Oct. 13, 2000, herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a tube feeding device for a work station of a cheese-producing textile machine equipped with an arrangement for transferring an empty tube from a tube reservoir into a tube transfer position for placement on a pivotably seated creel.
BACKGROUND OF THE INVENTION
It is known to provide cheese-producing textile machines with traveling service units, also known as cheese changers, which can be moved along the work stations of these textile machines and can be positioned at the individual work stations when needed. Similarly, it is also known to provide such machines with separate changing devices, which are arranged stationarily at the work stations.
For example, a traveling service unit which can be moved along the work stations, can be positioned at the respective work station when needed thereat to replace a finished cheese with an empty tube, is described, for example, in German Patent Publication DE 37 26 508 A1.
This known movable service unit has a multitude of manipulating devices, which are controlled in accordance with a preset program during a change cycle.
Among other things, the service unit has a tube ejection arm which, when needed, transfers the finished cheese to a special conveying device extending over the length of the machine, as well as a tube gripper, which removes an empty tube from a tube reservoir forming part of the work station, and places the empty tube into the creel of the respective work station. In this case, the tube gripper has individual gripper fingers, whose initial position can be manually adjusted in accordance with the tube format to be manipulated.
A comparable service unit is also described in European Patent Publication EP 0 126 352 B1.
This known service unit is provided with a tube feeder arranged on a pivotably seated intermediate frame, which is also quite elaborate. Depending on whether the tube feeder is required to handle cylindrical or conical empty tubes, the intermediate frame can be pivoted into a first or a second operating position. In accordance with European Patent Publication EP 0 126 352 B1, tube holders are also located on the output side of an empty tube reservoir, which can be manually set in accordance with the respective tube diameter.
Since the structural design of such complex operating units as a whole is relatively elaborate and complicated, the manufacture of such units also becomes quite costly.
Therefore various attempts have been made in the past to replace these movable, relatively complicated service units by stationary, simply constructed changing devices at each one of the work stations of a textile machine.
Other textile machines are described in German Patent Publications DE 21 57 304 B and DE 21 21 426 B, for example, each of whose work stations have a creel, which can be pivoted between a winding position and a cheese delivery position.
Moreover, an empty tube reservoir is assigned to the individual work stations, whose outlet can be positioned within the pivot range of the creel in such a way that, after having delivered the finished cheese, the creel can be automatically provided with a fresh empty tube.
A comparable device is also known from European Patent Publication EP 0 157 654 B1.
With this bobbin-winding machine, the individual work stations are also each equipped with a creel which is pivotable between a winding position, a cheese delivery position and an empty tube pickup position.
Each work station is also assigned its own tube reservoir, which can be acted upon by means of a pivot drive mechanism such that the tube at the front in the tube reservoir can be brought exactly to the level of the empty tube pickup position of the creel and can be picked up thereat by the closing creel.
A textile machine with stationary changing devices at each work station, as well as an associated empty tube reservoir, is also represented and described in German Patent Publication DE 195 28 983 A1 embodied in a false twist machine.
However, all of the above described changing devices have the serious flaw that they are only designed for a defined tube format.
Thus the empty tube reservoirs are each designed and arranged such that the empty tube feeding position of the empty tube reservoir corresponds with the empty tube pickup position of the creel only at a defined tube diameter. When changing the tube format, extensive manual adjustment or retrofitting work is respectively required, if this is even possible at all with the known devices.
SUMMARY OF THE INVENTION
In view of the above mentioned known machines and devices, it is an object of the present invention to provide a more simplified and cost-effective device for the introduction of empty tubes, even of different format, into the creels of the work stations of a cheese-producing textile machine.
In accordance with the present invention, this object is attained by means of a tube feeding device for a work station of a cheese-producing textile machine having an arrangement for transferring an empty tube from a storage position in a tube reservoir into a tube transfer position for presentation to a pivotably seated creel between rotatable tube receiving plates thereof. Briefly summarized, the tube feeding device comprises a tube gripper configured to be automatically adjustable to the diameter and the shape of an empty tube for displacing a central longitudinal axis of the empty tube during a tube transfer operation independently of the shape or the diameter of the empty tube such that, in the tube transfer position of the tube transferring arrangement, the central longitudinal axis of the empty tube coincides with a common axis of rotation of the tube receiving plates of the creel.
Briefly summarized, the tube feeding device comprises a tube gripper configured to be automatically adjustable to the diameter and the shape of an empty tube for displacing a central longitudinal axis of the empty tube during a tube transfer operation independently of the shape or the diameter of the empty tube such that, in the tube transfer position of the tube transferring arrangement, the central longitudinal axis of the empty tube coincides with a common axis of rotation of the tube receiving plates of the creel.
The tube feeding device in accordance with the present invention has the particular advantage that such a tube feeding device makes it possible without problems to transfer empty tubes of any arbitrary diameter or of different shapes (cylindrical or conical) to a creel or to change the tube format, without any prior adjustment work being necessary.
Thus, the tube feeding device in accordance with the present invention picks up the respective empty tube with is tube gripper from a preferably stationary tube reservoir, which is a part of the winding head, and conveys it into a tube transfer position, in which it can be taken over by the creel. In the course of this transport, the center longitudinal axis of the empty tube is automatically aligned such that, in the tube transfer position of the tube feeding device, it exactly coincides with the axis of rotation of the tube receiving plate positioned thereat. The empty tube can subsequently be securely grasped between the rotatably seated tube receiving plates when the creel is closed.
In a preferred embodiment, the tube gripper has a pressure application piston, which is seated to be vertically displaceable and is functionally connected with the gripper finger pairs. The gripper finger pairs are themselves fixed on connecting brackets to be rotatable to a limited extent. In this case, the functional coupling of the pressure application piston, or of a pressure application plate tiltably arranged on the pressure application piston, with the gripper finger pairs results in every movement of this pressure application piston and/or plate to lead to a comparable, but oppositely directed movement of the gripper finger pairs.
According to another feature of the invention, the pressure application piston is slidingly guided in a hollow body, for example a cylindrical one, and is cushioned by a spring element. Thus, the spring element acts on the pressure application piston to urge it in an extending direction.
A drive arm of a control linkage which, for example, can be acted upon by the creel of the respective work station, acts on the hollow body, which itself is displaceably seated in an appropriate receiving bore of a base body of the tube gripper.
The hollow body, and also the pressure application piston, can be displaced without problems in the direction toward the empty tube via the drive arm. In the process, the pressure application plate arranged on the pressure application piston is placed on the empty tube by means of the spring force of the spring element between the pressure application piston and the hollow body, and thereby fixes it securely in place.
In an advantageous embodiment, a pressure application plate is arranged on the pressure application piston and is tiltable in respect to the center longitudinal axis of the empty tube and is connected at its end with the gripper finger pairs by means of respective tongue-like pushers. The pressure application plate is automatically matched to the position of the surface of the empty tube, and in the process exactly controls the associated gripper finger pairs automatically via the tongue-like pushers.
According to a further feature of the invention, each of the pushers has an elongated slot guide, which limits the displacement of a carriage- like connecting element. The connecting elements are each connected via control linkages with one of the gripper finger pairs. Thus, the position of the gripper finger pairs is defined by the position of the connecting elements, or by the position of the tongue-like pushers, which in turn are connected to the pressure application plate of the pressure application piston.
Such a direct mechanical coupling of the pressure application piston, or its pressure application plate, with the associated gripper finger pairs constitutes a cost-effective and dependable control arrangement, which makes possible in a simple manner the exact positioning of the center longitudinal axis of an empty tube, independently of the shape and diameter of the picked-up empty tube.
In a preferred embodiment, the connecting elements slide on guide rails formed on the base body. Thus, not only the height position of the connecting elements is dependably preset, but horizontal displacement of the connecting elements is dependably prevented by the guide rails.
It is further preferred that the connecting elements, and therefore the gripper finger pairs, can be fixed in a special basic position by special holding plates, so that a problem-free transfer of an empty tube from the tube reservoir to the tube feeding device is assured.
To this end, the holding plates each have an angled guide slot, which extends over a collar-like shoulder on the connecting elements.
In a first embodiment, the base body of the tube gripper is displaceably seated on a base frame of the tube feeding device.
More specifically, a drive arm of a control linkage preferably acts on the base body of the tube gripper and makes possible a spatial displacement of the tube gripper, as well as its defined actuation.
In this case, the control linkage has, among other things, a control arm which can be acted upon by the pivotably seated creel. It is possible by means of such an embodiment of the tube feeding device to operate the tube gripper by the pivot drive mechanism of the associated creel.
Thus, with the above described design, the tube feeding device requires no drive mechanism of its own.
In an alternative embodiment, a drive mechanism, preferably an electric drive mechanism, is arranged in the area of the base frame. Here, an electric motor is connected with the tube gripper, for example by means of an above described, slightly modified control linkage, and can displace as well as operate the tube gripper.
By the use of such an electric drive mechanism arranged on the base frame of the tube feeding device, it is possible to further accelerate the changing procedure, in particular the introduction of the empty tube into the creel.
In this case, the tube feeding device in accordance with the invention is either stationarily fixed in place at each one of the work stations of a cheese-producing textile machine or is designed as a movable service unit which can be positioned at the appropriate work station when required.
Such an embodiment leads to a textile machine having a large degree of efficiency, since a possible defect of one of the tube feeding devices only impairs the respective work station, while all of the other work stations remain unaffected. Moreover, a textile machine with stationary tube feeding devices at each work station has an inherently high degree of efficiency, since it is possible to immediately initiate the changing process at each work station. If necessary, changing processes can also take place simultaneously at several work stations.
An embodiment wherein the tube feeding device is a part of a traveling service unit has the particular advantage that, as a whole, it is more cost-effective when employing the tube feeding device because it is possible by means of advance planning and control to minimize possibly occurring losses of efficiency. In particular, a tube feeding device embodied in this manner requires considerably less time for supplying a work station than, for example, a mobile cheese-changing unit employed up to now.
Further details, features and advantages of the present invention will be understood from an exemplary embodiment described herein with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a cheese-producing textile machine with stationary tube feeding devices at the individual work stations, in accordance with the present invention;
FIG. 2 is another front view, similar to FIG. 1, wherein a tube feeding device in accordance with the present invention is embodied as a traveling service unit which can be moved along the work stations;
FIG. 3 is a side view of a tube feeding device, whose tube gripper is parked in a tube transfer position,
FIG. 4 is another side view of the tube feeding device of FIG. 3, showing the tube gripper in a tube transfer position;
FIG. 5 is a front view of the tube gripper of FIGS. 3 and 4 as viewed from the direction X in FIG. 4;
FIG. 5 a is a front view of the tube gripper in accordance with FIG. 5, but with a conical empty tube;
FIG. 6 is a further enlarged side view of the tube gripper in the tube transfer position of FIG. 4, wherein the representation of the holding plates has been omitted for reasons of clarity;
FIG. 7 is a side view of the base body of the tube gripper, partially in cross-section; and
FIG. 8 is a side view of a tube feeding device in accordance with a further alternative embodiment of a tube feeding device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A cheese-producing textile machine, in the exemplary embodiment an automatic cheese winder, is represented in a front view in FIGS. 1 and 2 and is identified as a whole by the reference numeral 1 . Customarily, such automatic cheese winders 1 have a plurality of identical work stations 2 , which are arranged between end frames 5 and 6 . Here, the work stations 2 are arranged in alignment adjacent each other and, when required, are accessible from a service path extending along a front side of the textile machine 1 .
The cheese winder 1 operates in a known manner, which therefore need not be explained in detail, to rewind spinning cops 9 into large-volume cheeses 11 on these work stations, also called winding heads 2 . In the course of the rewinding process, each spinning cops 9 is disposed in an unwinding position 10 located at each respective winding head 2 along a transverse conveying path of travel through the winding head (not represented).
As indicated in FIGS. 1 and 2, the winding heads 2 are supplied and emptied via a bobbin and tube conveying system 3 . The spinning cops 9 , and the emptied cop tubes 4 once unwound, are supported in vertical orientation on tube conveying plates 8 while being circulated through this bobbin and tube conveying system 3 , of which only the tube return path 7 is represented in FIGS. 1 and 2.
Since the spinning cops are not only rewound, but the yam is also checked during the rewinding process and, if required, cleaned, each winding head 2 has a number of special yarn monitoring and processing devices, which are known per se and are therefore not explained in detail.
Therefore, the schematic representation of the individual winding heads 2 is limited in FIG. 1 to the indication of the end product, a so-called cheese 11 , a cheese drive roller 17 and a stationary tube feeding device 12 in accordance with the present invention, which is arranged with its base frame 20 on a crossbar 21 extending above the winding devices.
Each winding head 2 furthermore has its own dedicated winding head tube storage reservoir 13 for receiving a number of empty cheese tubes 14 required for producing a cheese 11 .
As indicated in FIG. 1, each winding head 2 moreover has its own winding head computer 15 which is connected, for example by means of a bus system (not represented) with a central information system 16 of the textile machine.
The textile machine 1 represented in FIG. 2 differs from the textile machine in accordance with FIG. 1 only by the design of the tube feeding device 12 of the present invention.
In the embodiment of FIG. 2, the automatic winder 1 is provided with only a single tube feeding device 12 , in the form of a movable service unit 18 , in place of a plurality of stationary tube feeding devices 12 associated respectively with the individual winding heads 2 . This service unit 18 is supported by a wheeled running gear 63 affixed to the base frame 20 and rollably mounted on a track 64 extending above the winding heads 2 of the textile machine 1 .
In this embodiment, the service unit 18 is preferably connected via a bus line (not represented) with the central information system 16 of the textile machine 1 and can be actuated by the latter in accordance with the requirements at the individual work stations 2 .
FIG. 3 shows a lateral view of a tube feeding device 12 in accordance with the invention.
As shown in FIG. 3, the tube feeding device 12 essentially comprises a base frame 20 which, in accordance with the embodiment in FIG. 1, is rigidly fixed in place on a crossbar 21 of the automatic cheese winder 1 , a tube reservoir 13 fastened to the base frame 20 , as well as a tube gripper 24 , which is movably attached to the base frame 20 .
More specifically, the base frame 20 has an elongated guide slot 22 for the displaceable seating of the base body 31 of the tube gripper 24 .
Furthermore, a control linkage, identified as a whole by the reference numeral 23 , is arranged on the base frame 20 . The control linkage 23 comprises in detail a control arm 25 with a pivot shaft 26 , a drive arm 28 rotatably seated on a pivot shaft 27 , as well as an intermediate linkage 29 inserted between the control arm 25 and the drive arm 28 . A spring element 30 , preferably an extension spring, also acts on the drive arm 28 .
As can be seen in FIG. 3, the base body 31 of the tube gripper 24 is conducted by means of sliding rollers 32 or the like within the elongated guide slot 22 of the base frame 20 .
Moreover, sealing brackets 33 , 34 , which support the pivot shafts 37 , 38 of the gripper finger pairs 35 , 36 , are formed on the side of the base body 31 opposite the slide rollers 32 . The gripper finger pairs 35 , 36 are seated on these pivot shafts 37 , 38 , to be rotatable to a limited extent and are connected via control linkages 39 , or 40 , with special connecting elements 41 , 42 on the base body 20 .
Each of the connecting elements 41 , 42 slides on a respective guide rail 48 , 49 , formed on the base body 31 , and has a collar-like shoulder 47 over which extends an elongated receiver slot 60 in a respective tongue-like slide 43 , 44 , and a guide 65 in a respective one of the support plates 45 , 46 .
As can be seen in particular in FIG. 7, the base body 31 has a receiving bore 50 , which is open toward the bottom and is preferably slit longitudinally at 52 . A hollow body 51 is displaceable seated in this receiving bore 50 , and has a connecting bracket 53 which passes outwardly from the receiving bore 50 and is connected with the drive arm 28 of the control linkage 23 . Moreover, a pressure application piston 54 , on which a spring element 55 acts, is displaceably seated inside the hollow body 51 . On its end, the pressure application piston 54 has a pressure application plate 56 , which is seated to be tiltable in the direction of the longitudinal axis 57 of the tubes 14 , and to which the tongue-like slides 43 , 44 , are connected.
Actuation of the tube feeding device 12 takes place either via the creel 19 , which acts on the control arm 25 of the control linkage 23 , as represented by the embodiment of FIG. 3, or via a separate drive mechanism 62 which is attached to the base frame 20 of the tube feeding device 12 , as represented by the embodiment of FIG. 8 .
The drive mechanism 62 is preferably in the form of an electric motor and serves to actuate the displacement of the tube gripper 24 inside the base frame 20 , as well as the functionally correct actuation of the tube gripper 24 . It is of course also possible to provide several drive mechanisms for the displacement and actuation of the tube gripper 24 in place of a common drive 62 .
Thus, the base frame can have a drive mechanism for moving the tube gripper 24 inside the base frame 20 , and a further, separate drive mechanism for actuating the tube gripper 24 .
However, this embodiment variation is not represented in the drawings.
The operation of the device of the present invention will thus be understood, with reference to the exemplary embodiment in accordance with FIG. 1 .
When a cheese 11 at one of the winding heads 2 of the textile machine 1 has reached its prescribed preselected size (e.g., a preselected diameter or preselected yam length), which is detected by the associated winding head computer 15 , the respective winding head 2 is stopped and the yarn being unwound from the spinning cop 9 onto the cheese 11 is made ready in a known manner for producing a new cheese.
Thereafter the creel 19 is pivoted from its winding position into a tube transfer position by means of an appropriate drive mechanism (not represented), and the finished cheese 11 is transferred to a cheese conveying arrangement (not represented) extending behind the winding heads 2 over the length of the machine.
At this time, the tube gripper 24 of the tube feeding device 12 is disposed in the tube receiving position I, which is represented in FIG. 3 .
More specifically, a fresh empty tube 14 is kept ready within the inwardly pivoted pairs of gripper finger 35 , 36 .
As indicated in FIG. 3, the gripper finger pairs 35 , 36 are fixed in place in this position by the support plates 45 , 46 . More specifically, limit stops at the connecting bracket 53 of the hollow body 51 act in the direction F on the angled rear sides 68 of the support plates 45 , 46 . In this manner, the support plates 45 , 46 are pivoted around their pivot point 59 such that the shoulder 47 of the connecting brackets 41 , 42 , on which the control linkages 39 , 40 of the gripper finger pairs 35 , 36 are hinged, is fixed in the angled portion of the support plate guide 65 .
After the cheese 11 has been transferred onto the cheese conveying arrangement, the creel 19 is pivoted back into its winding position and in the process acts on the control arm 25 of the control linkage 23 in the direction E.
This pivoting movement of the control arm 25 is transferred via the intermediate linkage 29 to the drive arm 28 , which thereupon is pivoted downwardly in the direction G. The downwardly pivoting drive arm 28 is connected to the connecting bracket 53 of the hollow body 51 , and thereby displaces this hollow body 51 , and in turn the pressure application piston 54 seated in a cushioned manner in the hollow body 51 , downwardly until the hollow body 51 and the connecting bracket 53 reach the end position represented in FIG. 4, whereupon the support plates 45 , 46 are released and then pivot in the direction H around their pivot point 59 .
In the course of lowering the hollow body 51 , the pressure application plate 56 , which is tiltably arranged on the end of the pressure application piston 54 , engages the empty tube 14 . Thus, the spring element 55 arranged inside the hollow body 51 acts on the empty tube 14 via the pressure application piston 54 , and the pressure application plate 56 thereon, and in turn also acts via the empty tube 14 on the gripper finger pairs 35 , 36 .
Because of the force of this action, the gripper finger pairs 35 , 36 pivot downwardly and in the process lift the connecting element 41 , 42 via the control linkage 39 , 40 . Here, the displacement path of the connecting elements is limited by the slides 43 , 44 , or by their elongated receiver slots 60 .
Thus, in the course of the displacement of the tube gripper 24 from its tube receiving position I into its tube transfer position II, in which the base body 31 of the tube gripper 28 is displaced in the direction V in the elongated guide slot 22 of the base frame 20 , the shoulder 47 of the connecting elements 41 , 42 rests against the upper edge of the elongated receiver slot 60 of the tongue-like slides 43 , 44 , such as is represented by way of example in FIGS. 5 and 5 a . In the process, the empty tube 14 is placed in a position in which its center longitudinal axis 57 exactly coincides with the axis of rotation 61 of the tube receiving plates 58 of the creel 19 , which at this time has also been pivoted into the tube transfer position II.
Thereupon, the empty tube 14 can be gripped without problems by closing the creel 19 , and after the yarn being unwound from the spinning cop 9 and being kept in readiness at the winding device, as previously indicated, has been fixed in place on the empty tube 14 , or has been clamped between the empty tube 14 and one of the tube receiving plates 58 of the creel 19 , the tube 14 can be lowered onto the cheese drive roller 17 .
The pairs of fingers 35 , 36 open against the spring force of the spring element 55 in the course of this lowering movement of the empty tube 14 onto the cheese drive roller 17 , whereby the control arm 25 of the control linkage 23 is removed from contact with the creel 19 in the course of the pivoting of the creel 19 into its winding position. Thereupon, the tube gripper 24 moves back into its initial, or base position represented in FIG. 3, which also represents the tube receiving position I, under the influence of the spring element 30 .
In the course of pivoting into this tube receiving position I, the drive sleeves 66 , which are arranged in the area of the pivot shaft 37 and are hinged on the gripper fingers, engage the closing and transfer elements 67 , which are pivotably arranged on the tube reservoir 13 . In the process, the closing and transfer elements 67 are pivoted in a manner such that the front one of the empty tubes 14 stored in the tube reservoir 13 is transferred to the gripper finger pairs 35 , 36 .
Thereupon, the tube change cycle is terminated and the tube feeding device 12 is ready for another tube transfer.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A tube feeding device ( 12 ) for a work station ( 2 ) of a cheese-producing textile machine ( 1 ) with an arrangement for transferring an empty tube ( 14 ) stored in a tube reservoir ( 13 ) into a tube transfer position (II) in which the empty tube ( 14 ) can be accepted by a pivotably seated creel ( 19 ). The tube feeding device ( 12 ) has a tube gripper ( 24 ) which is automatically adjustable to the diameter and the shape of an empty tube ( 14 ) for displacing the central longitudinal axis ( 57 ) of the empty tube ( 14 ) during the tube transfer operation independently of the shape or the diameter of the empty tube ( 14 ) so as to coincide with the common axis of rotation ( 61 ) of tube receiving plates ( 58 ) of the creel ( 19 ) in the tube transfer position (II).
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BACKGROUND OF THE INVENTION
The present invention relates to improved curable organosilicone resin coating compositions having low solvent content. More particularly, the present invention relates to compositions comprising a conventional hydroxyl functional organosiloxane resin copolymer, wherein part or all of the solvent ordinarily present in coating compositions of the resin copolymer is replaced with a reactive liquid silicone resin having an increased flash point.
Silicone resins having trifunctional siloxy units and difunctional siloxy units are well known in the art and have been used extensively in the formulation of paints, varnishes, molding compounds and encapsulating compositions. Typically, these resins contain residual hydroxyl functionality, and occasionally residual alkoxy functionality, which may be condensed by means of heat and/or catalysis in order to cure the resins. Resins of this type are generally utilized in the form of solutions in organic solvents since they are often solids, or, at best, very viscous liquids at ordinary temperatures.
Thus, for example, U.S. Pat. No. 3,846,358 to Roedel discloses a process for producing a solid silicone resin by a complex sequence comprising partially hydrolyzing and alkoxylating an organohalosiloxane mixture with an alcohol and water, adding more alcohol, removing the acid formed by distillation adjusting the acidity of the intermediate, adding additional water and alcohol and finally adjusting the solids content.
In U.S. Pat. No. 4,160,858, Roedel discloses a similar process for producing a solventless silicone resin having a viscosity of 200 to 5,000 cP at 25° C. wherein an alkali metal hydroxide is emPloyed to reduce the acidity and excess alcohol and water are stripped off in a final step.
Silicone resins may also be prepared directly from alkoxysilanes and polysiloxanes, as shown in U.S. Pat. No. 4,113,665 to Law et al. which teaches binder compositions for chemically resistant coatings. These binder resins are formed by reacting a trialkoxysilane with an aliphatic polyol and/or a silicone intermediate having hydroxyl or alkoxy terminal groups and a molecular weight of about 500 to 2,000 in the presence of an aqueous acidic solution.
Solventless silicone coating compositions are disclosed by Saad et al. in U.S. Pat. No. 4,780,338. In this invention, a silicone resin containing hydroxy, alkoxy or acyloxy functionality is blended with a diorganopolysiloxane fluid having functional groups which react with the alkoxy or acyloxy groups of the silicone resin and a condensation catalyst to cure the composition.
GB No. 2,067,212 A to Toray Silicone Company discloses room temperature curing silicone resins comprising hydroxy-functional organopolysiloxane resin, low molecular weight hydroxyl-terminated diorganopolysiloxane and an organosilane having 2 or 3 hydrolyzable groups, or a partial hydrolysis product thereof. These compositions can be cured using tin or titanate catalysts.
The use of various acids and bases as catalysts in the polymerization of silanol-terminated siloxanes is known in the art. In this regard, perfluoroalkyl sulfonic acids, inter alia, have been utilized to promote the condensation of silanol-functional siloxanes to form high molecular weight fluids, gums and copolymers. In U.S. Pat. No. 4,508,887, Kohl discloses a method for preparing a polyorganosiloxane by reacting an inert medium mixture of at least one hydroxyl-containing organosiloxane in the presence of a catalytically effective amount of a catalyst consisting essentially of an amine salt of an acid and an unreacted acid selected from fluorinated alkanesulfonic acids or sulfuric acid.
Such acids have also found utility as catalysts during the partial hydrolysis of chlorosilane mixtures. German Laid Open Publication DT 2,345,923 Al to Bayer AG discloses chlorine-functional fluids and resins prepared by the partial hydrolysis of various chlorosilanes in the presence of perfluoroalkyl sulfonic acids.
U.S. Pat. No. 4,585,705 to Broderick et al. discloses a release coating composition comprising a conventional hydroxyl functional siloxane resin containing methyl, phenyl, phenylmethyl and diphenyl siloxane units, the reactive diluent methyltrimethoxysilane, a fluid polysiloxane "slip" component and a curing catalyst. The conventional hydroxyl functional siloxane resins are generally solids and must be dissolved in an inert solvent in order to be effectively aPplied as a coating composition. Thus, the above cited patent to Broderick et al. advanced the art in that a reactive solvent replaced some, or all, of the usual inert solvent. In this way, a 100% reactive coating composition could be obtained. However, an inherent limitation of such a composition remains: the volatility of the methyltrimethoxysilane is actually greater than some of the conventional solvents it replaces (methyltrimethoxysilane has a closed cup flash point of about 47° F.). Thus, the hazards related to fire and explosion are not relieved by the inclusion of the above noted reactive diluent. Moreover, when curing the compositions of the Broderick et al. patent at elevated temperatures, a considerable amount of the methyltrimethoxysilane has been found to volatilize, even though it is intended to react with the other components. This evaporation of reactive diluent not only wastes a costly component, but contributes to total volatile organic compounds (VOC) emission, counter to current trends in air quality standards.
SUMMARY OF THE INVENTION
The difficulties noted with respect to the reactive diluent employed by Broderick et al., cited supra, have been overcome by the present invention by replacing all or part of the solvents, used in conjunction with conventional resins in coating applications, with a reactive liquid silicone resin having reduced volatility relative to the above mentioned methyltrimethoxysilane. None of the above recited references teaches the preparation of the reactive silicone coating compositions of the present invention. These compositions are particularly suitable in modern coating applications since they result in compositions having low VOC emissions. Moreover, it has been discovered that modification of conventional resins according to the present invention often results in improved flexibility of the conventional resins. The present invention therefore relates to a solventless silicone coating composition comprising
(A) 100 parts by weight of a hydroxyl functional organosiloxane resin copolymer comprised of at least two units selected from the group consisting of MeSiO 3/2 units, Me 2 SiO 2/2 units, PhMeSiO 2/2 units, PhSiO 3/2 units, Ph 2 SiO 2/2 units and PrSiO 3/2 units, in which Me denotes a methyl radical, Ph denotes a phenyl radical and Pr denotes a Propyl radical, said resin copolymer having 0.5 to 6 weight percent residual hydroxyl radicals attached to the silicon atoms thereof, a total molar organic group to silicon ratio of 1 to 1.7 and a total molar phenyl group to silicon ratio of 0.35 to 0.85; and
(B) from about 1 to 100 parts by weight of a liquid silicone resin composition prepared by a process comprising
(I) reacting a mixture consisting essentially of
(i) a phenylsilane having the general formula
PhSi(OR).sub.3
wherein R is selected from the group consisting of methyl, ethyl, Propyl and acetyl radicals and Ph denotes a phenyl radical,
(ii) a polydimethylsiloxane and
(iii) an equilibrating amount of an acid catalyst having the formula
ZSO.sub.3 H
wherein Z is a perfluoroalkYl group having 1 to 10 carbon atoms molar ratio of said polYdimethylsiloxane (ii) to said phenylsilane (i) being between about 1:9 and about 9:1,
(II) hydrolyzing the reaction product formed in step (I) with sufficient water to provide from about 0.5 to about 1 mole of residual -OR functionality per 100 parts by weight of said liquid silicone resin and
(III) neutralizing said acid catalyst (iii).
DETAILED DESCRIPTION OF THE INVENTION
The solventless silicone coating composition of the present invention comprises a homogeneous mixture of (A) a hydroxyl functional organosiloxane resin copolYmer and (B) a liquid silicone resin.
The hydroxyl functional organosiloxane resin copolymer (A) is selected from conventional resins comprising at least two units selected from the group consisting of MeSiO 3/2 units, Me 2 SIO 2/2 units, PhMeSiO 2/2 units, PhSiO 3/2 units, Ph 2 SIO 2/2 units and PrSiO 3/2 units, wherein Me, Ph and Pr hereinafter denote methyl, phenyl and propyl radicals, respectively. For the purposes of the present invention, the conventional resin has from 0.5 to 6 weight percent residual hydroxyl radicals attached to the silicon atoms thereof, a total molar organic group to silicon ratio of 1 to 1.7 and a total molar phenyl group to silicon ratio of 0.35 to 0.85.
Resins suitablY employed a comPonent (A) are well known in the art and many are available commercially. They are typically prepared by hydrolyzing the respective chlorosilanes in an aromatic solvent, such as toluene and xylene. These resins are typically solids and thus require the presence of a solvent in order to be used as coating compositions. Generally, the solvent employed in their preparation is retained to some extent for this purpose.
The liquid silicone resin (B) is a reaction product prepared by hydrolyzing, and then neutralizing, an equilibrated mixture of (i) a phenylsilane and (ii) a polydimethylsiloxane, the equilibration reaction being facilitated by a strong acid catalyst (iii).
Component (i) of liquid silicone resin (B) may be represented by the formula
PhSi(OR).sub.3
wherein R is selected from the grouP consisting of methyl, ethyl, propyl and acetyl radicals. It is preferred that R is either a methyl or ethyl radical and it is particularlY preferred that component (i) is phenyltrimethoxysilane.
The polydimethylsiloxane (ii) of liquid silicone resin (B) may be a linear polydimethylsiloxane. The selection of terminal groups for the linear polydimethylsiloxane is not critical for the purpose of the present invention provided that an inert terminal group, such as trimethylsilyl, is not employed when the degree of polymerization of the polydimethylsiloxane is less than about 200. Thus, generic examples of suitable terminal groups include trialkylsilyl, alkoxydialkylsilyl, aryldialkylsilyl and hydroxydialkylsilyl groups. Specific terminal groups which may be used include Me 3 Si-, MeO(Me 2 )Si-, and HO(Me 2 )Si-. Preferably, the end group is HO(Me 2 )Si-.
Although comPonent (ii) is described as a polydimethylsiloxane, up to about 10 mole percent of siloxane units containing alkyl groups having 2 to 8 carbon atoms, phenyl groups or trifluoropropyl groups may be copolymerized with the dimethylsiloxane units to still be within the scope of this invention. Thus, copolymers of dimethylsiloxane units with phenylmethylsiloxane, methylhexylsiloxane or methyltrifluoropropylsiloxane units are specific examples of this component. It is preferred that when component (ii) is a linear polydimethylsiloxane, that it be the dimethyl homopolymer.
Alternatively, and preferably, polydimethylsiloxane (ii) is selected from at least one polydimethylcyclosiloxane having the formula
(Me.sub.2 SiO).sub.x
wherein x is an integer between 3 and about 10, inclusive. For the purposes of the present invention, this preferred polydimethylsiloxane is a mixture of such cyclic siloxanes.
Component iii of the liquid silicone resin (B) is a strong acid capable of efficiently redistributing (i.e., equilibrating) siloxane bonds. It has been observed that weak acids, such as phosphoric or acetic, do not redistribute siloxane bonds and therefore do not produce the liquid silicone resins of the present invention. Suitable acids are represented by the general formula
ZSO.sub.3 H
wherein Z is a perfluoroalkyl group having 1 to about 10 carbon atoms. Examples of suitable acid catalysts include perfluoromethane sulfonic acid, perfluoroethane sulfonic acid, perfluorohexane sulfonic acid, perfluorooctane sulfonic acid and perfluorodecane sulfonic acid. It is preferred that component (iii) is perfluoromethane sulfonic acid.
In order to prepare the liquid silicone resin (B), phenylsilane (i) and olydimethylsiloxane (ii) are mixed in a mole ratio of 1:9 to 9:1 and reacted in the presence of an equilibrating amount of catalyst (iii). The reaction is carried out under an inert atmosphere, such as nitrogen or argon, and the preferred mole ratio of components (i) to component (ii) is 1:2 to 2:1. The term "equilibrating amount" as used herein denotes a sufficient amount of acid catalyst (iii) to efficiently rearrange the siloxane bonds of reactants (i) and (ii) so as to provide a substantially equilibrated product of reaction within 3-5 hours at temperatures between about 60 and 80° C. This amount may readily be determined by those skilled in the art by following the disappearance of the reactants using, e.g., gas chromatography, the acid in the sample being neutralized before each such determination. Thus, for example, when the catalyst is the preferred perfluoromethane sulfonic acid, it is employed at about 0.04 to 0.1 weight percent of the total of components (i) and (ii). This amount of perfluoromethane sulfonic acid is sufficient to equilibrate the above mentioned components within about 4 hours at 70° C.
After equilibration of components (i) and (ii) is attained, the reaction product is hydrolyzed with sufficient water to provide from about 0.5 to about 1 mole of residual--OR functionality per 100 parts by weight of liquid silicone resin (B). As should be apparent to the skilled artisan, the molar units and weight units must, of course, be consistent (e.g., gram-moles and grams, respectively). The basic reactions relied upon to calculate the amounts of water to be used in the hydrolysis step are: (1) the hydrolysis of the--OR groups on the above described equilibrated product to form silanol groups; and (2) condensation of the silanol groups to form siloxane bonds. The net effect of these reactions, assuming the complete condensation of all silanol groups formed, requires the employment of one half mole of water for the hydrolysis of each mole of--OR groups. Using this assumption, in combination with the above mentioned range of the ratio of the polydimethylsiloxane to the phenylsilane, one skilled in the art can readily calculate the approximate amounts of the ingredients to be used in forming the liquid silicone resin compositions having from about 0.5 to about 1 mole of residual--OR functionality per 100 parts by weight of said liquid silicone resin. In practice, it has been found that, when R is methyl, the calculated (i.e., theoretical methoxy content is usually close to the analytically determined value thereof. Preferably, when R is methyl, the final liquid silicone resin according to the present invention has from about 0.5 to 0.65 moles of residual methoxy functionality per 100 parts by weight; of the liquid silicone resin (B), a value of about 0.58 being most preferred. The hydrolysis step may be carried out at temperatures between about I8 and 70° C., but preferably below the boiling point of the alcohol (e.g., MeOH) or acetic acid formed during the hydrolysis. This reaction should be carried out for at least one hour, whereupon the reactants are referably heated to reflux and the alcohol or acetic acid formed is removed by distillation.
Finally, the acid catalyst is neutralized and the product stripped under vacuum to remove the remaining alcohol, or acetic acid, byproduct as well as other impurities. The product is then cooled and filtered.
It has been noted that the actual amount cf residual --OR functionality left on the liquid silicone resin has been found to be critical in formulating the compositions of the Present invention. For example, when less than about 0.5 moles of residual--OR functionality per 100 parts by weight of the liquid silicone resin remains (e.g., corresponding to approximately 15 weight percent methoxy the compositions tend to gel upon storage under ordinary conditions. On the other hand, when the--OR content is above about 1 moles of residual--OR functionality per 100 parts by weight of said liquid silicone resin (e.g., corresPonding to 30 weight percent methoxy), the liquid silicone resins have such a low molecular weight that they tend to evaporate at the elevated temperatures often employed in curing the compositions of the present invention.
In order to prepare the organosilicone resin coating compositions of the present invention, from about 1 to 100 parts by weight of liquid silicone resin (B) are uniformly mixed with 100 parts by weight of hydroxyl functional organosiloxane resin copolymer (A). The mixing may be carried out at ordinary temperatures provided a homogeneous solution or dispersion results. Since most of the hydroxyl functional organosiloxane resin copolymers are solids at ordinary temperatures, it is often necessary to first dissolve component (A) in a suitable solvent, such as toluene, xylene, naphtha, and isobutylisobutyrate, before blending with the liquid silicone resin (B). Indeed, the solvent already present in many of the commercial hydroxyl functional organosiloxane resin copolymers is generally sufficient for this purpose. The solvent may be removed by a vacuum strip operation to provide a 100% reactive composition if it is judged, that its viscosity is low enough for practical coating applications. In some cases, the solid hydroxyl functional organosiloxane resin copolymer (A) may be mixed directly with liquid silicone resin (B) if the combination is heated slightly.
Preferred embodiments of the present invention utilize phenyltrimethoxysilane and a mixture of polydimethylcyclosiloxanes in a mole ratio of about 2:1respectively, for the preparation of the liquid silicone resin (B), trifluoromethane sulfonic acid being the preferred equilibration catalyst. From 10 to 60 parts by weight of this component (B) is then uniformly mixed with 100 parts by weight of one of the hydroxyl functional organosiloxane resin copolymers (A).
Because the liquid silicone resin (B) contains residual alkoxy or acetoxy functionality and the hydroxyl functional organosiloxane resin copolymer (A) contains residual silanol functionality, cure of the coating compositions of the present invention may be hastened by the addition of catalysts known in the art to promote the hydrolysis of the--OR groups and the condensation of--OR and SiOH groups to form a three-dimensional siloxane network. Catalysts suitable for this purpose may be selected from the organotitanates, such as tetraisopropyl titanate and tetrabutyl titanate and organometallic compounds, such as dibutyltin dilaurate, tin octoate, dibutyltin diacetate, zinc octoate, cobalt octoate, cobalt naphthanate and cerium naphthanate. Typically, from about 1 to 10 parts by weight of the catalyst are employed for each 100 parts by weight of the solventless silicone coating composition.
The compositions of the present invention may further be compounded with various fillers, such as titanium dioxide, mica, iron oxide and aluminum flake, pigments, thermal stabilizers, flow agents and other additives commonly employed in the formulation of coating compositions.
In use, the compositions of the present invention may be applied to various substrates by any of the conventional coating techniques, such as spraying, dipping, brushing or by the use of a doctor blade.
The liquid silicone resin compositions of the present invention find utility in the preparation of protective coatings for metal, glass and plastic substrates, corrosion resistant high temperature paints, release coatings for bakeware, binders for masonry water repellant and decorative topcoat for appliances and tanks, inter alia.
EXAMPLES
The following examples are presented to further illustrate the compositions of the present invention, but are not to be construed as limiting the invention, which is delineated in the appended claims. All parts and percentages in the examples are on a weight basis and measured properties were obtained at 25° C. unless indicated to the contrary.
The following materials were employed in the preparation of the illustrative and comparative examples:
LSR 1--A liquid silicone resin was prepared by mixing under a nitrogen purge 78 parts of phenyltrimethoxysilane and 14 parts of a mixture of polycyclosiloxanes having the formula (Me 2 SiO) x , wherein Me hereinafter denotes a methyl radical and x had a value between 3 and 10. The mixture was stirred and 0.05 parts of trifluoromethane sulfonic acid was added. The catalyzed mixture was then slowly heated to 70° C. and stirred at this temperature for about 4 hours. Upon cooling to about 34° C., 6.8 parts of deionized water was added. The resulting exothermic reaction brought the temperature of the mixture to about 70° C.;. Stirring was continued for about another hour without further application of heat. Powdered calcium carbonate (0.3 part was added to neutralize the acid catalyst and a vacuum (about 40 mm Hg) was applied while slowly heating to about 156° C. This temperature was held for about 4 hours to strip off volatiles. The product was cooled and filtered using Celite filter aid. It had a residual methoxy functionality of about 18% (i.e., 0.58 moles --OMe per 100 grams of the LSR 1), a viscosity of about 105 cP and a closed cup flash point of about 150° F.
LSR 2--A liquid silicone resin similar to LSR 1 and prepared in a like manner, wherein the quantities of phenyltrimethoxysilane, polycyclosiloxanes and deionized water were 56, 41 and 2.8 parts, respectively. The resulting liquid resin had a residual methoxy functionality of about 17% (i.e., 0.55 moles--OMe per 100 grams of the LSR 2), a viscosity of about 15 cP and a closed cup flash point of about 99° F.
RESIN 1--A solid silicone resin consisting essentially of MeSiO 3/2 , PhSiO 3/2 , PhMeSiO 2/2 and Ph 2 SiO 2/2 units, wherein Ph hereinafter denotes a phenyl group, in the molar ratio of 45:40:5:10. This resin was PrePared by hydrolyzing the respective chlorosilanes in toluene and had a residual hydroxyl functionality of 5.0%.
RESIN 2--A 50% solids solution in xylene of a silicone resin consisting essentially of MeSiO 3/2 , PhSiO 3/2 , PhMeSiO 2/2 and Ph 2 SiO 2/2 units in the molar ratio of 25:15:50:10. This resin was also prepared by hydrolyzing the respective chlorosilanes and had a residual hydroxyl functionality of 0.5% (on a solids basis).
RESIN 3--A 50% solids solution in xylene/toluene of a silicone resin consisting essentially of MeSiO 3/2 , PhSiO 3/2 , Me 2 SiO 2/2 and Ph 2 SiO 2/2 units in the molar ratio of 25:37:19:19. This resin was also prepared by hydrolyzing the respective chlorosilanes and had a residual hydroxyl functionality of 0.5% (on a solids basis).
TBT=Tetra(n-butyl) titanate catalyst.
CO=A 6% solution of cobalt octoate catalyst in Rule 66 mineral spirits.
ZO=An 8% solution of zinc octoate catalyst in Rule 66 mineral spirits.
The following test methods were utilized in characterizing the materials described infra:
Pencil Hardness--ASTM Test Method D 3363.
Slip Angle--An indication of coefficient of friction, this test basically consisted of placing a cheesecloth-covered weight (500 grams) on the coated panel and tilting the panel. The angle of incline from the horizontal at which this weight started to slide was recorded.
Impact Resistance--ASTM D2794.
T-Bend--ASTM D4145.
The aforementioned ASTM (American Society for Testing and Materials) test methods are well known in the art and said methods are hereby incorPorated by reference
EXAMPLES 1-6
Homogeneous blends consisting of 40% LSR 1 and 60% of RESINS 1, 2 and 3, respectively, were prepared at room temperature to form coating compositions, as indicated in Table 1. To each blend there was added 0.5% ©of CO catalyst and 0.5% TBT catalyst, on a solids basis. These coating compositions were used to dip-coat steel panels, which were subsequently dried at room temperature for ten minutes and then cured at 450° F. for 15 minutes. The cured films, which all had a good appearance, were tested according to the above described methods, as were similarly prepared films of the individual RESINS 1, 2 and 3 (Comparative Examples 4, 5 and 6, respectively).
TABLE 1______________________________________ (Compartive) Example Example 1 2 3 4 5 6______________________________________Coating CompositionParts LSR 1 40 40 40 -- -- --Parts RESIN 1 60 -- -- 100 -- --Parts RESIN 2 -- 60 -- -- 100 --Parts RESIN 3 -- -- 60 -- -- 100Cured Film PropertiesPencil Hardness 5 H B H 7 H 5 B BSlip Angle (Degrees) 3 3 3 3 3 3Impact Resistance Pass Pass Pass Fail Pass Fail______________________________________
The compositions of the present invention not only provided cured coatings which showed some improvement in flexibility (as evidenced by the impact resistance reported in Table 1), but they illustrate systems having reduced solvent content versus conventional silicone resins.
EXAMPLE 7
A flowable, 100% reactive resin system was prepared by dissolving 234 grams of RESIN 1 in 75 grams of acetone at 50° C. To this resin solution, there was added 156 grams of LSR 2 to form a homogeneous mixture. The mixture was then stripped of solvent while still warm under a reduced pressure. The resultant solventless resin had a solids content of about 88% (measured by heating a small sample at 135° C. for 3 hours) and a viscosity of about 32,000 cP.
To 40 grams of the above solventless resin there was added 0.2 grams of ZO and 0.2 grams of TBT catalysts. Draw-downs on steel panels were made using the wire-wound bars indicated in Table 2, whereupon the coatings were allowed to dry at room temperature for 10 minutes and then cured at 500° F. for 20 minutes.
TABLE 2______________________________________ Draw-down Bar Number #3 #18 #24 #32______________________________________Cured Film PropertiesFilm Thickness (Mils) 0.5 1.9 2.5 2.9Pencil Hardness 2 H F F HBImpact Resistance Pass Fail Fail FailT-Bend Pass Pass Fail Fail______________________________________
The resin system of this example is thus well suited for use as a bakeware coating, where the typical coating thickness is in the range of 0.2 mil.
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Curable organosilicone resin coating compositions are disclosed wherein part or all of the solvent ordinarily present in conjunction with a conventional hydroxyl functional organosiloxane resin copolymer is replaced with a reactive liquid silicone resin having an increased flash point and reduced volatility relative to a prior art reactive diluent. The liquid silicone resin employed is a reaction product prepared by hydrolyzing, and the neutralizing, an equilibrated mixture of (i) a phenylsilane and (ii) a polydimethylsiloxane, the equilibration reaction being facilitated by a perfluoroalkane sulfonic acid (iii).
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CROSS-REFERENCES TO RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 11/853,951, filed Sep. 12, 2007, now issued as U.S. Pat. No. 7,667,077, the entirety of which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Grant No. CHE 0314666 awarded by the National Science Foundation.
BACKGROUND OF THE INVENTION
As described, the invention relates generally to the field of chemistry and in particular to the synthesis of a new class of triazapentadiene compounds and compositions formed therefrom.
While triazapentadienes are useful ligands, triazapentadienes with highly fluorinated and other halogenated substituents are rare; perfluorinated compounds have not yet been reported.
SUMMARY OF THE INVENTION
The invention describes a new class of compounds as poly-halogenated triazapentadienes that include fully fluorinated triazapentadienes, chlorinated triazapentadienes and complexed compositions produced therefrom.
The poly-halogenated triazapentadienes disclosed are prepared in high yield, typically as a colorless crystalline solid. The synthesized triazapentadienes are thermally stable and soluble in typical solvents (e.g., toluene, tetrahydrofuran [THF], dichloromethane [CH 2 Cl 2 ], diethyl ether [Et 2 O], hexane, dimethylsulfoxide). The halogen may include fluorine, chlorine, bromine and iodine. The synthesized triazapentadienes and their deprotonated forms (e.g., triazapentadienyl anions) serve as ligands, having, among other things, several metal binding sites for complexation with one or more metal ions. Metal complexed triazapentadienyl fragments may further bind additional molecules, including one or more carbon- or nitrogen-based donor molecules.
In one or more embodiments, described herein are compositions comprising poly-halogenated 1,3,5 triazapentadiene, wherein the composition is thermally stable, electron-poor and accommodates sterically demanding substituents on both 2- and 6-positions of N-aryl groups. Such composition may further coordinate with one or more metal ions. In one form, compositions are metal triazapentadienyl ligands and binds a carbon- or nitrogen-based donor molecule. The compositions may be a ligand for metal coordination chemistry. The compositions are typically weak donors. The compositions inhibit growth of Gram positive and Gram negative bacteria.
In additional embodiments are provided one or more compositions comprising a poly-halogenated 1,3,5 triazapentadiene with electron deficient primary amines, wherein the composition is prepared by a reaction with a tertiary amine as a base. Such compositions may be from a reaction that includes C 6 F 5 NH 2 , C 3 F 7 —CF═N—C 4 F 9 and triethylamine in a molar ratio at or about 2:1:3 or C 6 F 5 NH 2 , CF 3 —CF═N—C 2 F 5 and triethylamine in a molar ratio at or about 2:1:3. Such compositions include [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H, [N{(CF 3 )C(C 6 F 5 )N} 2 ]H, [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H and [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H. The compositions may complex with a metal to form a metal triazapentadienyl. Examples of these include [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(NCCH 3 ), [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO, [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 , [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ), [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ), [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuNCCH 3 , {[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag} n , [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag, [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag, and [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag. Such compositions may be a metal triazapentadienyl adduct that binds a carbon- or nitrogen-containing donor.
Generally, compositions herein include a compounds as described below.
in which R 1 may be an alkyl or aryl groups and R 2 may be a fluoro alkyl group. Such compositions are effective as antibacterial agents.
In further embodiments are provided a ligand for metal coordination chemistry comprising:
wherein R 1 is an alkyl or aryl group and R 2 is a fluoro alkyl group and wherein the composition has coordination centers for complexation with a metal ion. The metal ion is introduced in a solvent. Such solvents may include acetonitrile or tetrahydrofuran. The ligands when complexed are capable of further complexation with a second molecule having one or more donors. Examples include but are not limited to carbon monoxide, ethylene, acetonitrile, and phosphine.
A synthetic pathway for a new class of poly-halogenated triazapentadienes is disclosed herein. Synthesis takes advantage of a reaction with triethylamine as compared with previous unsuccessful and/or highly inefficient (very low yield) synthetic routes that have relied on a reaction with excess primary amines.
Compositions herein are typically obtained by a reaction comprising:
wherein R 1 is an alkyl or aryl group and R 2 is a fluoro alkyl group. R 1 is typically selected from the group consisting of C 6 F 5 , 2-F,6-(CF 3 )C 6 H 3 ; 3,5-(CF 3 ) 2 C 6 H 3 ; 2,6-Cl 2 C 6 H 3 ; CH(Me)Ph; 2,6-(i-Pr) 2 C 6 H 3 and 2,4,6-(Me) 3 C 6 H 2 , wherein Me is methyl, Ph is phenyl. R 2 is typically CF 3 and C 3 F 7 . Products of such a reaction typically produce compositions as described herein in high yield as a colorless crystalline solid. When R 2 is C 3 F 7 , the reaction includes C 6 F 5 NH 2 , C 3 F 7 CF═N—C 4 F 9 (obtained from tri(perfluorobutyl)amine, (C 4 F 9 ) 3 )N, precursor) and triethylamine in a molar ratio at or about 2:1:3. When R 2 is CF 3 , the reaction includes C 6 F 5 NH 2 , CF 3 CF═N—C 2 F 5 (obtained from tri(perfluoroethyl)amine, (C 2 F 5 ) 3 N, precursor) and triethylamine in a molar ratio at or about 2:1:3.
Methods described herein produce compounds that inhibit growth of Gram-positive and Gram-negative bacteria. A suitable method includes providing a composition comprising
as an antibacterial agent. Examples of Grain positive bacteria that are inhibited are Staphylococcus aureus and Pseudomonas aeruginosa . Gram positive bacteria that are inhibited by compounds described herein include Bacillus subtilis and Escherichia coli.
The synthesized triazapentadienes (with and without complexed metals) as described herein inhibit bacterial growth of both Gram positive and Gram-negative bacteria.
Those skilled in the art will further appreciate the above-noted features and advantages of the invention together with other important aspects thereof upon reading the detailed description that follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE FIGURES
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, wherein:
FIGS. 1A-1B depict representative structures for 1,3,5-triazapentadiene molecules described herein;
FIG. 1C depicts a structure from another class of compounds known as 1,5-diazapentadiene;
FIG. 2 depicts a representative triazapentadiene composition as described herein;
FIG. 3 depicts a prior typical synthetic route to form another related class of compounds;
FIG. 4 depicts a synthetic route for forming a triazapentadiene as described herein;
FIG. 5 depicts a metal complexation reaction for triazapentadienes as described herein;
FIG. 6 depicts another metal complexation reaction of a polyhalogenated triazapentadienyl ligand as described herein;
FIG. 7 depicts an X-ray structure of a metal complexed triazapentadiene composition described herein;
FIGS. 8A and 8B depict (A) X-ray structure and (B) ball and stick molecular structure of another metal complexed triazapentadiene composition described herein;
FIG. 9 depicts an X-ray structure of still another metal-complexed triazapentadiene composition described herein;
FIG. 10A depicts an X-ray structure of still another metal complexed triazapentadienes composition described herein;
FIGS. 10B and 10C depict ball and stick molecular structures of complexed triazapentadiene compositions described in FIG. 10A ; and
FIG. 11 depicts a representative structure of a fully-fluorinated triazapentadienyl silver(I) complex described herein.
DETAILED DESCRIPTION OF THE INVENTION
The invention, as defined by the claims, may be better understood by reference to the following detailed description. The description is meant to be read with reference to the figures contained herein. This detailed description relates to examples of the claimed subject matter for illustrative purposes, and is in no way meant to limit the scope of the invention. The specific aspects and embodiments discussed herein are merely illustrative of ways to make and use the invention, and do not limit the scope of the invention.
Described herein poly-halogenated triazapentadienes, including a fully fluorinated triazapentadiene and a highly fluorinated triazapentadiene as depicted in FIGS. 1A and 1B . The new class of compounds described herein are related to a popular class of compounds known as diazapentadienes that may also be fluorinated ( FIG. 1C ). Accordingly, compounds disclosed herein are referred generally as 1,3,5-triazapentadienes as shown in FIG. 2 in which R 1 may be a alkyl or aryl group and R 2 may be a fluoro alkyl group. Examples of R 1 include C 6 F 5 , 2-F,6-(CF 3 )C 6 H 3 ; 3,5-(CF 3 ) 2 C 6 H 3 ; 2,6-Cl 2 C 6 H 3 ; CH(Me)Ph; 2,6-(i-Pr) 2 C 6 H 3 and 2,4,6-(Me) 3 C 6 H 2 , wherein Me is methyl, Ph is phenyl. Examples of R 2 include CF 3 and C 3 F 7 . Such compounds may be halogenated with one or more halogen groups that include fluorine, chlorine, bromine and or iodine.
As a new class of compounds, the poly-fluorinated triazapentadienes, fully fluorinated triazapentadienes and other poly-halogenated triazapentadienes compositions described herein are different from previously disclosed but related compositions, such as 1,5-diazapentadiene.
While a previous synthetic route had been used to form some of the related compounds—a reaction which relied on excess primary amines (FIG. 3 )—such a reaction was unsuited for forming the new class of compounds disclosed herein, which includes triazapentadienes with electron deficient primary amines, and also produced compounds of very low yield.
Triazapentadienes with electron deficient primary amines are prepared herein by a suitable reaction that includes a tertiary amine as the base. A preferred synthetic route is depicted in FIG. 4 , wherein R 1 and R 2 are as described above. In one example, C 6 F 5 NH 2 with C 3 F 7 —CF═N—C 4 F 9 and triethylamine are combined in a molar ratio at or about 2:1:3. In another example, C 6 F 5 NH 2 , CF 3 CF═N—C 2 F 5 (obtained from tri(perfluoroethyl)amine, (C 2 F 5 ) 3 N, precursor) and triethylamine are combined in a molar ratio at or about 2:1:3. Formed compounds include, but are not limited to, [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H and [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H.
Formed triazapentadienyl compositions described herein are thermally stable, usually electron-poor and may have sterically demanding substituents on both 2- and 6-positions of N-aryl groups. Examples of representative formed compounds are shown FIGS. 4-11 .
The synthesized triazapentadienes described herein serve as ligands and form metal complexes with specific coordinated centers. For example, a metal ion, such as copper or silver is introduced in acetonitrile or in tetrahydrofuran (THF). After metal complexation, a metal-complexed triazapentadienyl composition is capable of further complexation with other molecules having one or more donors (e.g., C-, N-, P-based molecules, such as CO, ethylene, acetonitrile, phosphine). A first example of a metal complexation reactions are shown in FIG. 5 . Another example of a metal complexation reaction is shown in FIG. 6 .
In FIG. 5 , the initial triazapentadiene composition, [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H, was first complexed with Cu 2 O as a source for the copper (Cu) ion to form [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 . The metal complex [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 was further reacted with carbon monoxide (CO, at 1 atm) in CH 2 Cl 2 leading to [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(NCCH 3 ) as depicted in FIG. 7 or reacted with ethylene (at 1 atm) in dichloromethane leading to [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) as depicted in FIG. 8 . Selected bond lengths of the structure of FIG. 7 (in Angstroms [Å]) and angles (in degrees) include: Cu—C 1.8333 (17); Cu—N(4) 2.0183 (14); Cu—N(1) 2.0232 (12); Cu—N(3) 2.0499 (12); O—C 1.124 (2), N(1)-Cu—N(3) 91.04 (5); and O—C—Cu 176.68 (16). Selected bond lengths of the structure of FIG. 8 in Å and angles (in degrees) include: Cu—N(3) 1.946 (2); Cu—N(1) 1.955 (2); Cu—C(21) 2.010 (3); Cu—C(22) 2.018 (3); C(21)-C(22) 1.364 (4); N(3)-Cu—N(1) 96.66 (9).
Interestingly, with the composition of FIG. 7 , the acetonitrile remained bonded to the copper (I) in the carbonyl adduct as evident from the spectroscopic and X-ray crystallographic data (vide infra). [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ) was also prepared using a similar route and the complexed composition also retained acetonitrile (see FIG. 9 ).
Referring to FIG. 7 , the copper center is four-coordinate and adopts a pseudo tetrahedral geometry. The triazapentadienyl ligand binds to the metal center in a κ 2 -fashion, Similarly, [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ) also features a four-coordinate copper center (see FIG. 9 ). For [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ), the Cu—C distance and Cu—C—O angle are 1.846 (3) Å and 177.0 (4)°, respectively.
Referring to FIG. 8 , the copper center is three-coordinate and the X-ray structure of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) ( FIG. 8A ) shows the ethylene molecule coordinates to copper(I) in an η 2 -fashion. The 1 H NMR spectrum of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) in C 6 D 6 showed the ethylene signal at δ3.27, which is a significant upfield shift relative to a corresponding peak of free ethylene (δ5.24). With this composition, treatment with excess ethylene led to a disappearance of the bound ethylene signal, indicating fast exchange with free ethylene on the NMR timescale. The ethylene carbon signal of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) in 13 C{ 1 H}NMR spectrum is observed at δ86.1. A corresponding peak in free ethylene appears at a much higher frequency (δ123.5). The C═C bond distance of the coordinated ethylene (1.364 (4) Å) of FIG. 8 is identical to that found in [HC{(CH 3 )C(2,6-Me 2 C 6 H 3 )N} 2 ]Cu(C 2 H 4 ) (1.365 (3) Å)—a related diazapentadienyl system—and marginally longer as compared to that of free ethylene. The nitrogen to copper distances of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) (1.946 (2), 1.955 (2) Å) were much shorter compared to those observed for the [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(CH 3 CN). This may be primarily a steric effect because the former has a 3-coordinate metal site (vs. 4-coordinate in the latter). The Cu—N distances of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ) are similar to those seen with 3-coordinate [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO.
In another metal complexation example depicted in FIG. 6 , an initial triazapentadiene composition is [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H and reacted as a lithium salt, [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Li, with CuOTf and CO (at 1 atm) in THF. The x-ray structure formed by the reaction of FIG. 10 is a three coordinate metal complex, [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO, that crystallized in the P2 1 /n space group with two chemically similar molecules in an asymmetric unit (the relative orientation of the C 3 F 7 groups is the only key difference between the two, as depicted in FIG. 10C ) and included a trigonal planar copper site.
IR spectra of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(NCCH 3 ) and [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ) show that ν CO bands of the exemplified compositions appear at 2108 and 2119 cm −1 , respectively. A three coordinate [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO had a much higher ν CO at 2128 cm −1 . The acetonitrile ligand appears to reduce acidity at the copper site. Yet, ν CO values of all complexed compositions were high and closer to that of free CO, which is 2143 cm −1 , indicating a presence of acidic copper sites with poor Cu→CO π-backbonding and a weak donating nature of the formed polyfluorinated triazapentadienyl ligands described (see TABLE 1). TABLE 1 illustrates representative structural and spectroscopic parameters for copper-carbonyl compounds described herein. Bond distance data is given for representative compounds based on structural characterization.
TABLE 1
ν CO in cm −1
ν CO in cm −1
Cu—C
Compound
KBr
Nujol
(Å)
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(NCCH 3 )
2108
2107
1.8333
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 )
2119
2118
1.846
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO
2128
2120
1.815
Complexed compositions described herein, such as [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(NCCH 3 ), [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO, and [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ), may be dried under reduced pressure without losing CO or ethylene; [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ) may lose CO under similar conditions to give [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuNCCH 3 . The loss of a ligand (e.g., CO) in the latter compound may be a steric effect of such a bulkier triazapentadienyl composition. CH 2 Cl 2 solutions comprising a complexed composition (e.g., Cu—CO complexed compositions or ethylene complexed compositions) turned green with time when exposed to air. Solid samples of such compositions (e.g., Cu—CO and Cu—C 2 H 4 complexes) may be handled in air for short periods without any apparent decomposition.
Unless otherwise noted, all synthetic manipulations were carried out under an atmosphere of purified nitrogen using standard Schlenk techniques, Solvents were purchased from commercial sources, distilled from conventional drying agents, and were degassed by a freeze-pump-thaw method known to one of ordinary skill in the art. Glassware was oven-dried at 150° C. overnight. NMR spectra were recorded at 25° C. on a 500 and 300 MHz spectrometer ( 1 H, 500.16 MHz or 300.53 MHz; and 19 F: 470.62 MHz or 282.78 MHz). Proton chemical shifts were reported in ppm versus Me 4 Si. 19 F NMR chemical shifts were referenced relative to external CFCl 3 . Melting points were obtained on a suitable melting apparatus and readings were not corrected. Elemental analyses of CHN were performed a suitable analyzer. Pentafluoroaniline, 2-fluoro,6-trifluoromethylaniline, triethylamine, Cu 2 O, (CuOTf) 2 .benzene, carbon monoxide, and ethylene were purchased from commercial sources. Perfluoro-5-aza-4-nonene was synthesized using a published procedure (e.g., Siedle, et al. Inorg. Chem. 2003; 42:932).
For synthesis of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H, perfluoro-5-aza-4-nonene (1.00 g, 2.30 mmol) was added dropwise to a mixture of triethylamine (0.69 mL, 6.90 mmol) and pentafluoroaniline (0.84 g, 4.6 mmol) in ether at 0° C. After addition, the solution was stirred overnight at room temperature. Nitrogen atmosphere was not necessary after this point. The mixture was then filtered; filtrate was collected and washed with 10% HCl and then twice with deionized water. The ether layer was separated and dried over CaCl 2 . The solvent was removed under reduced pressure to obtain a white powder which was recrystallized from CH 2 Cl 2 at −25° C. to obtain colorless crystals of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H in 85% yield. Melting point (Mp) was 104-105° C. 19 F NMR (CDCl 3 ): δ 80.00 (apparent triplet, J=8.4 Hz, 9.8 Hz, CF 3 ), −80.37 (apparent triplet, J=8.4 Hz, 9.8 Hz, CF 3 ), −115.08 (br, α-CF 2 ), −116.72 (s, α-CF 2 ), −124.85 (br, β-CF 2 ), −126.44 (s, β-CF 2 ), −144.82 (d, J=17.2 Hz, o-F), −148.0 (d, J=19.5 Hz, o-F), −149.54 (t, J=20.9 Hz, p-F), −159.44 (t, J=21.8 Hz, p-F), −159.80 (t, J=18.3 Hz, m-F), −162.90 (td, J=21.2 Hz, 6.6 Hz, m-F). 1 H NMR (CDCl 3 ): δ 6.91 (s, 1H, NH). Elemental analysis for C 20 HF 24 N 3 : (a) Calculated: C, 32.50; H, 0.14; N, 5.68; (b) Found: C, 31.98; H, 0.41; N, 5.72.
For synthesis of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(CH 3 CN), [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H (0.50 g, 0.67 mmol) and Cu 2 O (0.05 g, 0.34 mmol) were mixed in acetonitrile and refluxed overnight. The resulting solution was filtered through a bed of a filter agent (e.g., standard supercell); filtrate was collected and solvent removed under reduced pressure to obtain crude [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 as an oil, which was crystallized from hexane-Et 2 O mixture and used directly in the next step. [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 was dissolved in CH 2 Cl 2 and CO was bubbled through the solution followed by stirring for 30 minutes, When solvent was removed under reduced pressure crude [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(CH 3 CN) was obtained which was dissolved in ether and cooled to −25° C. to obtain pale yellow crystals. Yield was 77%. Mp.: 92-94° C. 19 F NMR (CDCl 3 ): δ−162.94 (td, J=24.0 Hz, 6.6 Hz, m-F), −160.00 (t, J=19.5 Hz, m-F), −159.52 (t, J=22.8 Hz, p-F), −149.74 (t, J=20.4 Hz, p-F), −147.99 (d, J=19.5 Hz, o-F), −144.80 (d, J=17.2 Hz, o-F), −126.49 (s, (β-CF 2 ), −124.83 (br, β-CF 2 ), −116.77 (s, α-CF 2 ), −115.12 (br, α-CF 2 ), −80.38 (apparent triplet, J=7.6 Hz, 10.8 Hz, CF 3 ), −80.01 (apparent triplet, J=7.6 Hz, 10.8 Hz, CF 3 ). 1 H NMR (CDCl 3 ): δ 1.87 (s, 3H, CH 3 CN). Elemental analysis for C 23 H 3 CuF 24 N 4 O: (a) Calculated: C, 31.72; H, 0.35; N, 6.43; (b) Found: C, 29.80; H, 0.80; N, 5.19. IR (KBr, cm −1 ): 2108 (CO).
For synthesis of [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ), [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]CuNCCH 3 was prepared as described above, dissolved in CH 2 Cl 2 and ethylene was bubbled into the solution for about 3 minutes. After stirring for 30 minutes, the solvent was removed under vacuum. The resulting residue was dissolved in hexane and cooled to −25° C. to obtain needle shaped crystals. Yield: 92%. Mp: 120-122° C. 19 F NMR (CDCl 3 ): δ−80.23 (t, J=9.8 Hz, CF 3 ), −109.02 (d, J=8.5 Hz, α-CF 2 ), −124.24 (s, β-CF 2 ), −148.32 (d, J=20.7 Hz, o-F), −157.98 (t, J=21.6 Hz, p-F), −161.57 (td, J=21.8 Hz, 5.3 Hz, m-F), 1 H NMR (CDCl 3 ): δ 3.86 (s, 4H, C 2 H 4 ). 1 H NMR(C 6 D 6 ): δ 3.07 (s, 4H, C 2 H 4 ). 1 3C{ 1 H} NMR (CDCl 3 ), selected: δ 86.1 (s, C 2 H 4 ). Elemental analysis for C 22 H 4 F 24 N 3 Cu: (a) Calculated: C, 31.84; H, 0.49; N, 5.06; (b) Found: C, 32.27; H, 0.57; N, 5.26.
For synthesis of [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H, perfluoro-5-aza-4-nonene (1.00 g, 2.31 mmol) was added dropwise to a solution of 2-fluoro,6-trifluoromethylaniline (0.827 g, 4.62 mmol) and triethylamine (1.0 mL, 7.18 mmol) in ether (15 mL) at −5° C. This solution was allowed to warm to room temperature and stirred for 3 days (a precipitate and formation of two phases were observed after 12 hours). Inert atmosphere was not required. The resulting mixture was washed once with 10% HCl and twice with deionized water. The organic layer was separated and dried over CaCl 2 . The solvent was removed under reduced pressure to obtain a yellow oily composition. Pentane was added and cooled to −15° C. to obtain [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H as a white precipitate. It could be recrystallized from CH 2 Cl 2 at −15° C. Yield: 52%, Mp: 77-83° C. 19 F NMR (CDCl 3 ): δ−61.66 and −61.70 (s, 6F, o-CF 3 ), −79.98 (t, J=9.8 Hz, 3F, CF 3 ), −80.43 (t, J=8.7 Hz, 3F, CF 3 ), −115.37 (s, 2F, α-CF 2 ), −119.54 (s, 2F, α-CF 2 ), −124.60 (br, 2F, o-F), −126.34 (s, 4β, —CF 2 ). 1 H NMR (CDCl 3 ): δ 7.51 (apparent doublet, J=2.75 Hz, 2H), 7.36 (m, 2H), 7.13 (m, 2H), 6.55 (s, 1H, NH). Elemental analysis for C 22 H 7 F 22 N 3 : (a) Calculated: C, 36.13; H, 0.96; N, 5.75; (b) Found: C, 35.74; H, 1.00; N, 5.86.
For synthesis of [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 ), [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H (0.500 g, 0.684 mmol) and Cu 2 O (0.059 g, 0.410 mmol) were mixed in acetonitrile (15 mL) and heated overnight at 90° C. The reaction mixture was filtered, and solvent was removed from the filtrate under reduced pressure. A resulting oily product ([N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuNCCH 3 ) was dissolved in about 4 mL of methylene chloride and carbon monoxide was bubbled through for 3 minutes. The mixture was stirred for 4 hours and treated with CO again and cooled to −15° C. The composition crystallized as yellow needles after 24 hours at −15° C. Solvent was removed using a syringe and the composition was dried under a nitrogen/CO stream. CO may lose easily under reduced pressure affording a copper-acetonitrile adduct. Yield 80%. Mp: about 57° C. (dec.). 19 F NMR (CDCl 3 ): δ−59.70 (s, 6F, o-CF 3 ), −80.57 (s, 6F, CF 3 ), −106.53 and −110.17 (AB multiplet, J=277.7 Hz, α-CF 2 ), −106.94 and −109.30 (AB multiplet, J=279.3 Hz, α-CF 2 ), −121.72 and −121.79 (s, 2F, o-F), −123.23 and −123.56 (s, 4F, β-CF 2 ). 1 H NMR (CDCl 3 ): δ 7.52 to 7.10 (br, 6H, m- and p-Ar), 1.98 (s, 3H, NCCH 3 ). 1 H NMR (cyclohexane-d 12 ): δ 7.36 to 6.96 (m, 6H, m- and p-Ar), 1.74 (s, 3H, NCCH 3 ). Elemental analysis for C 25 H 9 F 22 N 4 OCu: (a) Calculated: C, 34.80; H, 1.05; N, 6.49; (b) Found: C, 33.42; H, 1.04; N, 6.38. IR (KBr, cm −1 ): 2119 (CO).
For synthesis of [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO, THF solution of [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H (0.420 g, 0.575 mmol) was treated with n-butyllithium (0.25 mL, 2.5M in hexanes) at −60° C. After 2 hours, the mixture warmed slowly to room temperature. Solvent was removed under reduced pressure to obtain a white solid which was dissolved in CH 2 Cl 2 and added to (CuOTf) 2 .benzene (0.145 g, 0.287 mmol) in CH 2 Cl 2 at room temperature. After stirring for 1 hour, the mixture was treated with CO for 5 minutes and stirred for 2 hours. The mixture was filtered through a bed of celite and the filtrate was concentrated using a CO stream. [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO crystallized as yellow rods from the mixture overnight at 5° C. The composition was dried using a nitrogen stream or may be dried using reduced pressure. Yield 53%. Mp: 65° C. (dec.). 19 F NMR (CDCl 3 ): 6-59.65 and −59.69 (s, 6F, o-CF 3 ), −80.56 (apparent t, J=−11.5 Hz, 8.6 Hz, 6F, CF 3 ), −106.45 and −110.08 (AB multiplet, J=280.7 Hz, α-CF 2 ), −106.88 and −109.23 (AB multiplet, J=279.3 Hz, α-CF 2 ), −121.60 (br peak with a shoulder, 2F, o-F), −123.21 and −123.52 (s, 4F, β-CF 2 ). 1 H NMR (CDCl 3 ): δ 7.68-7.10 (m, m,p-Ar). Elemental analysis for C 23 H 6 F 22 N 3 OCu: (a) calculated: C, 33.61; H, 0.74; N, 5.11; (b) Found: C, 32.70; H, 0.84; N, 5.12. IR (KBr, cm −1 ): 2128 (CO).
When identifying the structure of compositions described herein, a suitable crystal of a sample was covered with a layer of hydrocarbon oil and mounted with paratone-N oil on a cryo-loop, and immediately placed in a low-temperature nitrogen stream. X-ray intensity data were measured at 100(2) K, on a detector system equipped with a cryostream cooler, a graphite monochromator, and a Mo Kα fine-focus sealed tube (λ=0.710 73 Å). Data (in frames) were integrated with suitable software package available to one of ordinary skill in the art. Data were corrected for absorption effects using a multi-scan technique (SADABS). Structures were solved and refined using a suitable software package available to one of ordinary skill in the art. Additional details of data collection and refinement are provided in TABLES 2-5.
TABLE 2
Crystal data/structure refinement for
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(CH 3 CN).
Empirical formula
C23H3CuF24N4O
Formula weight
870.83
Temperature
100(2) K
Wavelength
0.71073 Å
Crystal system
Monoclinic
Space group
P2(1)/c
Unit cell dimensions
a = 10.5092(4) Å
α = 90°
b = 12.5716(5) Å
β = 97.5150(10)°
c = 21.8262 (9) Å
γ = 90°
Volume
2858.9(2) Å 3
Z
4
Density (calculated)
2.023 Mg/m 3
Absorption coefficient
0.950 mm −1
F(000)
1688
Crystal size
0.35 × 0.26 × 0.17 mm 3
Theta range for data collection
2.48 to 28.31°
Index ranges
−13 <= h <= 14, −16 <= k <= 16,
−29 <= l <= 28
Reflections collected
26467
Independent reflections
6973 [R(int) = 0.0166]
Completeness to theta = 28.31°
98.2%
Absorption correction
None
Max. and min. transmission
0.8551 and 0.7320
Refinement method
Full-matrix least squares on F 2
Data/restraints/parameters
6973/0/490
Goodness-of-fit on F 2
1.060
Final R indices [I > 2sigma(I)]
R1 = 0.0300, wR2 = 0.0812
R indices (all data)
R1 = 0.0322 wR2 = 0.0830
Largest diff. peak and hole
0.534 and −0.296 e · Å −3
TABLE 3
Crystal data/structure refinement for
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ).
Empirical formula
C22H4CuF24N3
Formula weight
829.82
Temperature
100(2) K
Wavelength
0.71073 Å
Crystal system
Monoclinic
Space group
P2(1)/c
Unit cell dimensions
a = 11.6782(5) Å
α = 90°
b = 21.1320(8) Å
β = 106.4380(10)°
c = 11.3774 (4) Å
γ = 90°
Volume
2692.99 (18) Å 3
Z
4
Density (calculated)
2.047 Mg/m 3
Absorption coefficient
1.000 mm −1
F(000)
1608
Crystal size
0.27 × 0.06 × 0.04 mm 3
Theta range for data collection
1.82 to 25.36°
Index ranges
−13 <= h <= 14, −25 <= k <= 25,
−13 <= l <= 13
Reflections collected
19960
Independent reflections
4894 [R(int) = 0.0491
Completeness to theta = 25.36°
99.1%
Absorption correction
None
Max. and min. transmission
0.9659 and 0.7762
Refinement method
Full-matrix least-squares on F 2
Data/restraints/parameters
4894/0/467
Goodness-of-fit on F 2
1.023
Final R indices [I > 2sigma(I)]
R1 = 0.0376, wR2 = 0.0928
R indices (all data)
R1 = 0.0497 wR2 = 0.0998
Largest diff. peak and hole
0.649 and −0.485 e · Å −3
TABLE 4
Crystal data/structure refinement for
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(NCCH 3 )
Empirical formula
C25H9CuF22N4O
Formula weight
862.90
Temperature
100(2) K
Wavelength
0.71073 Å
Crystal system
Orthorhombic
Space group
Pna2(1)
Unit cell dimensions
a = 12.6364(7) Å
α = 90°
b = 10.8052 (6) Å
β = 90°
c = 21.8933(12) Å
γ = 90°
Volume
2989.3(3) Å −3
Z
4
Density (calculated)
1.917 Mg/m 3
Absorption coefficient
0.899 mm −1
F(000)
1688
Crystal size
0.48 × 0.41 × 0.36 mm 3
Theta range for data collection
2.10 to 25.98°
Index ranges
−15 <= h <= 15, −13 <= k <= 13,
−26 <= l <= 27
Reflections collected
21561
Independent reflections
5843[R(int) = 0.0473]
Completeness to theta = 25.98°
100.0%
Absorption correction
None
Max. and min. transmission
0.7379 and 0.6722
Refinement method
Full-matrix least-squares on F 2
Data/restraints/parameters
5843/22/407
Goodness-of-fit on F 2
1.056
Final RXZ indices [I > 2sigma(I)]
R1 = 0.0418, wR2 = 0.1023
R indices (all data)
R1 = 0.0469, wR2 = 0.1062
Absolute structure parameter
0.57(2)
Largest diff. peak and hole
0.506 and −0.398e · Å −3
TABLE 5
Crystal data/structure refinement for
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CUCO.
Empirical formula
C23H6CuF22N3O
Formula weight
821.85
Temperature
100(2) K
Wavelength
0.71073 Å
Crystal system
Monoclinic
Space group
P2(1)/n
Unit cell dimensions
a = 24.6256 (16) Å
α = 90°
b = 9.7507(6) Å
β = 113.2780(10)°
c = 25.1455(16) Å
γ = 90°
Volume
5546.4(6) Å 3
Z
8
Density (calculated)
1.968 Mg/m 3
Absorption coefficient
0.962 mm −1
F(000)
3200
Crystal size
0.26 × 0.19 × 0.04 mm 3
Theta range for data collection
1.96 to 25.50°
Index ranges
−29 <= h <= 29, −11 <= k <= 11,
−30 <= l <= 30
Reflections collected
40342
Independent reflections
10323[R(int) = 0.0508]
Completeness to
99.9%
theta = 25.50°
Absorption correction
None
Max. and min. transmission
0.9625 and 0.7893
Refinement method
Full-matrix least-squares on F 2
Data/restraints/parameters
10323/0/901
Goodness-of-fit on F 2
1.023
Final RXZ indices
R1 = 0.0556, wR2 = 0.1461
[I > 2sigma(I)]
R indices (all data)
R1 = 0.0776, wR2 = 0.1626
Absolute structure parameter
0.57(2)
Largest diff. peak and hole
1.770 and −0.673e · Å −3
For [N {(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(CO)(CH 3 CN) and [N {(C 3 F 7 )C(C 6 F 5 )N} 2 ]Cu(C 2 H 4 ), hydrogen atoms of acetonitrile and ethylene units were located from a difference map and included/refined isotropically. All non-hydrogen atoms were refined anisotropically.
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]Cu(CO)(—NCCH 3 ) crystallized in the Pna2(1) space group. One of the aryl groups was disordered over two positions. The ortho-CF 3 group in about 65% of the molecules occupied the carbonyl group side, whereas in the remaining portion of the molecule (about 35%), it occupied the acetonitrile group side. Carbon and fluorine atoms of the disordered aryl ring were refined isotropically. All remaining non-hydrogen atoms were refined anisotropically. Hydrogen atoms were placed at calculated positions and refined using a riding model. The crystals show racemic twinning; refined using suitable commands.
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]CuCO crystallized in the P2 1 /n space group. Crystallization, two chemically similar but crystallographically different molecules were found in the asymmetric unit ( FIG. 10C ). There was minor disorder in few fluorine atom positions of the C 3 F 7 moieties as indicated by residual peaks. All non-hydrogen atoms were refined anisotropically. Hydrogen atoms were placed at calculated positions and refined using a riding model.
Compounds described herein may coordinate with any of a number of metal ions, such as but not limited to silver (Ag), copper, gold, thallium, and alkali metals. An example of a fluorinated triazapentadienyl silver(I) complex described herein is depicted in FIG. 11 . Additional examples include [N{(C 3 F 2 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag and [N{(C 3 F 2 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag.
Reactions for complexation with silver(I) were performed in light-protected flasks. For synthesis of {[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag} n ( FIG. 11 ), [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H (1.0 g, 1.35 mmol), silver(I) oxide (0.19 g, 0.81 mmol) and THF (40 μL) were heated at 70° C. in an oil bath for 12 hours followed by filtering over a bed of diatomite. Solvent was evaporated to dryness to yield the product as a white solid. It was recrystallized from a mixture of acetone-toluene by slow evaporation to obtain transparent crystals as thin squares. Yield: 60%. Mp: 140-150° C. (dec). 19 F NMR (DMSO-d 6 ): δ−79.9 (apparent triplet, J=8.7 Hz, 6F, CF 3 ), −113.3 (s, 4F, α-CF 2 ), −125.3 (s, 4F, β-CF 2 ), −149.0 (d, J=19.5 Hz, 4F, o-Ar), −166.3 (t, J=21.7 Hz, 19.5 Hz, 4F, m-Ar), −167.4 (t, J=23.8 Hz, 21.7 Hz, 2F, p-Ar). Elemental analysis for C 20 F 24 N 3 Ag: (a) Calculated: C, 2839; H, 0.00; N, 4.97; (b) Found: C, 28.28; H, <0.20; N, 5.20.
The new class of fluorinated triazapentadiene compounds with and without metal complexation as described herein were analyzed for antibacterial activity against several bacterial strains (both Gram positive and Gram negative). Methods for antimicrobial analysis included a modified Kirby-Bauer method and a determination of their minimum inhibitory concentrations. In brief, the modified Kirby-Bauer method relied on placement of a filter disk impregnated with a desired compound on a solid growth medium. Bacteria were grown to a confluent lawn and the extent of growth inhibition was measured (e.g., as an extent/percentage of a clear zone on the disk and/or solid medium). The assessment of minimum inhibitory concentration (MIC) was determined by a lowest concentration that visibly inhibited growth of bacteria in culture.
Filter disks were provided as sterile filter paper (about 6 mm in diameter) and spotted with 20 μL of a selected compound. Each compound was initially dissolved in dimethylsulfoxide (DMSO); any subsequent dilutions were also made in DMSO. Each filter was placed on an LB agar plate spread with 100 μL of a bacterial culture that had been grown overnight in suitable LB broth. Plates were incubated overnight at 37° C., after which, the extent of growth inhibition around each filter disk was measured. Bacterial strains included Staphylococcus aureus (ATCC 25923), Pseudomonas aeruginosa PAO1, Bacillus subtilis W168 and Escherichia coli HB101. The former two strains are pathogenic Gram-positive and Gram-negative bacteria, respectively. The latter two strains are non-pathogenic Gram-positive and Gram-negative bacterial strains, respectively.
For MIC assessment, compounds were initially dissolved in DMSO and serial dilutions of soluble compounds were made in LB broth. 4 μL of a 37° C. overnight LB broth culture was inoculated into 2 mL of each dilution in LB (each MIC was eventually bracketed to within two fold up and down of that concentration) and the cultures were incubated overnight (with rapid shaking at 37° C.) before being evaluated for growth or lack thereof visually.
Antimicrobial activity of various compounds described herein are depicted in TABLES 6-15. For the TABLES, the concentrations (μg/ml) were normalized to approximately equal molar concentrations for each row and for each compound. The FW for each compound is: [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag (FW 846.06); [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H (FW 739.20); [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H (FW 731.28); [N{(C 3 F 7 )C(C 6 H 5 )N} 2 ]H (FW 559.30); [N{(C 3 F 7 )C(Mes)N} 2 ]H (FW 643.46); [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H (FW 697.08); [N{(CF 3 )C(C 6 F 5 )N} 2 ]H (FW 697.08); [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag (FW 838.15); [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag (FW 803.94); AgNO 3 (FW 169.9); silver (1) sulfadiazine (FW 357.14). In the tables, NZ is no zone of inhibition and ND is not determined.
TABLE 6
Disk sensitivity test with [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag
Diameter of the zone of growth inhibition
Concentration
(mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.86 × 10 4
5.7 × 10 1
70.0
47.0
27.0
18.0
4.86 × 10 3
5.7 × 10 0
33.0
37.0
16.5
14.0
4.86 × 10 2
5.7 × 10 −1
39.0
38.0
12.0
11.0
4.86 × 10 1
5.7 × 10 −2
21.5
22.0
8.0
8.5
4.86 × 10 0
5.7 × 10 −3
10.0
11.0
7.5
8.0
4.86 × 10 −1
5.7 × 10 −4
6.0 (NZ) b
7.5
6.0 (NZ)
6.0 (NZ)
4.86 × 10 −2
5.7 × 10 −5
6.0 (NZ)
6.0 (NZ)
6.0 (NZ)
6.0 (NZ)
4.86 × 10 −3
5.7 × 10 −6
6.0 (NZ)
6.0 (NZ)
6.0 (NZ)
6.0 (NZ)
TABLE 7
Disk sensitivity test with [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.20 × 10 4
5.7 × 10 1
75.0
71.0
9.0
9.5
4.20 × 10 3
5.7 × 10 0
37.5
39.0
8.0
9.0
4.20 × 10 2
5.7 × 10 −1
40.0
47.0
8.0
9.0
4.20 × 10 1
5.7 × 10 −2
19.0
22.0
8.0
8.5
4.20 × 10 0
5.7 × 10 −3
9.0
10.0
7.0
7.0
4.20 × 10 −1
5.7 × 10 −4
6.0 (NZ)
8.0
ND c
ND
4.20 × 10 −2
5.7 × 10 −5
6.0 (NZ)
6.0 (NZ)
ND
ND
4.20 × 10 −3
5.7 × 10 −6
6.0 (NZ)
6.0 (NZ)
ND
ND
4.20 × 10 −4
5.7 × 10 −7
6.0 (NZ)
6.0 (NZ)
ND
ND
TABLE 8
Disk sensitivity test with [N{(CF 3 )C(C 6 F 5 )N} 2 ]H
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
3.10 × 10 4
5.8 × 10 1
36.5
45.0
10.0
11.0
3.10 × 10 3
5.8 × 10 0
35.0
33.0
9.0
10.0
3.10 × 10 2
5.8 × 10 −1
30.0
31.0
9.5
9.0
3.10 × 10 1
5.8 × 10 −2
13.0
22.0
9.5
8.0
3.10 × 10 0
5.8 × 10 −3
22.0
8.0
9.0
8.5
3.10 × 10 −1
5.8 × 10 −4
9.0
7.5
ND
ND
3.10 × 10 −2
5.8 × 10 −5
ND
6.0 (NZ)
ND
ND
3.10 × 10 −3
5.8 × 10 −6
ND
6.0 (NZ)
ND
ND
TABLE 9
Disk sensitivity test with [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.81 × 10 4
5.7 × 10 1
19.0
115.0
23.5
22.0
4.81 × 10 3
5.7 × 10 0
14.0
131.0
15.0
12.5
4.81 × 10 2
5.7 × 10 −1
9.5
78.0
9.0
10.0
4.81 × 10 1
5.7 × 10 −2
9.0
39.0
6.0 (NZ)
9.0
4.81 × 10 0
5.7 × 10 −3
7.5
10.0
6.0 (NZ)
8.0
4.81 × 10 −1
5.7 × 10 −4
6.0 (NZ)
10.0
ND b
ND
4.81 × 10 −2
5.7 × 10 −5
6.0 (NZ)
9.0
ND
ND
4.81 × 10 −3
5.7 × 10 −6
6.0 (NZ)
9.0
ND
ND
4.81 × 10 −4
5.7 × 10 −7
6.0 (NZ)
7.5
ND
ND
TABLE 10
Disk sensitivity test with [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.20 × 10 4
5.7 × 10 1
47.5
100.0
9.0
9.0
4.20 × 10 3
5.7 × 10 0
36.0
85.0
8.5
8.5
4.20 × 10 2
5.7 × 10 −1
34.0
50.0
8.0
8.0
4.20 × 10 1
5.7 × 10 −2
9.0
30.0
8.0
7.0
4.20 × 10 0
5.7 × 10 −3
8.0
13.5
8.0
7.0
4.20 × 10 −1
5.7 × 10 −4
6.0 (NZ)
7.0
7.0
7.0
4.20 × 10 −2
5.7 × 10 −5
6.0 (NZ)
8.0
6.0 (NZ)
7.0
4.20 × 10 −3
5.7 × 10 −6
ND
8.0
ND
ND
4.20 × 10 −4
5.7 × 10 −7
ND
7.5
ND
ND
TABLE 11
Disk sensitivity test with [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.62 × 10 4
5.7 × 10 1
20.0
19.5
15.0
15.5
4.62 × 10 3
5.7 × 10 0
16.5
21.0
13.5
16.0
4.62 × 10 2
5.7 × 10 −1
15.0
18.0
10.0
11.0
4.62 × 10 1
5.7 × 10 −2
14.5
19.0
7.0
9.0
4.62 × 10 0
5.7 × 10 −3
11.0
12.0
6.0 (NZ)
7.0
4.62 × 10 −1
5.7 × 10 −4
6.0 (NZ)
6.0 (NZ)
ND
ND
4.62 × 10 −2
5.7 × 10 −5
6.0 (NZ)
6.0 (NZ)
ND
ND
TABLE 12
Disk sensitivity test with [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H
Diameter of the zone of growth inhibition
Concentration
(mm)
(μg/ml) a
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
4.00 × 10 4
5.7 × 10 1
13.0
21.0
9.0
9.0
4.00 × 10 3
5.7 × 10 0
20.0
19.0
8.0
8.0
4.00 × 10 2
5.7 × 10 −1
16.0
18.5
8.0
8.0
4.00 × 10 1
5.7 × 10 −2
15.0
19.0
8.0
8.0
4.00 × 10 0
5.7 × 10 −3
7.0
13.0
7.0
6.0 (NZ)
4.00 × 10 −1
5.7 × 10 −4
7.0
8.5
ND
ND
4.00 × 10 −2
5.7 × 10 −5
8.0
7.0
ND
ND
4.00 × 10 −3
5.7 × 10 −6
6.0 (NZ)
7.5
ND
ND
4.00 × 10 −4
5.7 × 10 −7
6.0 (NZ)
6.0 (NZ)
ND
ND
TABLE 13
Disk sensitivity test with [N{(C 3 F 7 )C(Mes)N} 2 ]H
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
3.69 × 10 4
5.7 × 10 1
9.5
9.0
9.0
10.0
3.69 × 10 3
5.7 × 10 0
7.5
8.0
8.5
8.0
3.69 × 10 2
5.7 × 10 −1
6.0 (NZ)
6.0 (NZ)
7.5
7.5
3.69 × 10 1
5.7 × 10 −2
6.0 (NZ)
6.0 (NZ)
7.5
7.0
3.69 × 10 0
5.7 × 10 −3
6.0 (NZ)
6.0 (NZ)
7.0
7.0
TABLE 14
Disk sensitivity test with AgNO 3
Diameter of the zone of growth
Concentration
inhibition (mm)
(μg/ml)
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
1.00 × 10 4
5.9 × 10 −2
10.5
16.0
16.0
15.0
1.00 × 10 3
5.9 × 10 −3
9.0
13.0
12.5
14.0
1.00 × 10 2
5.9 × 10 −4
8.5
13.0
9.5
13.0
1.00 × 10 1
5.9 × 10 −5
7.0
9.5
6.0 (NZ)
8.5
1.00 × 10 0
5.9 × 10 −6
6.0 (NZ)
9.0
6.0 (NZ)
7.0
TABLE 15
Disk sensitivity test with Silver(I) sulfadiazine
Diameter of the zone of growth inhibition
Concentration
(mm)
(μg/ml) a
Concentration (mM)
S . aureus
B . subtilis
P . aeruginosa
E . coli
2.05 × 10 4
5.7 × 10 −2
12.5
12.5
17.0
15.0
2.05 × 10 3
5.7 × 10 −3
11.0
12.0
15.0
11.5
2.05 × 10 2
5.7 × 10 −4
9.5
9.5
7.0
6.0 (NZ)
2.05 × 10 1
5.7 × 10 −5
8.0
9.0
7.0
6.0 (NZ)
2.05 × 10 0
5.7 × 10 −6
6.0 (NZ)
6.0 (NZ)
ND
ND
For antibacterial assessment, DMSO, as a control, was used and a no zone of inhibition was observed for all compounds described herein. Other comparative compounds used were representative conventional compounds currently in use for antibacterial purposes and included AgNO 3 and silver(I) sulfadiazine.
Compounds described herein show remarkably high antimicrobial activity as further evidenced in TABLES 16-18. In TABLES 16-18, the last column reflects antimicrobial efficacy of each compound relative to AgNO 3 , wherein efficacy is assessed on a per mole basis in a comparison with the MIC values. Effective compounds as antimicrobials include the highly fluorinated triazapentadiene [N{(CF 3 )C(C 6 F 5 )N} 2 ]H and [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H and the silver adduct [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag; the fluorinated [N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H and its silver adduct [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag; and the chlorinated compound [N{(C 3 F 7 )C(2,6-Cl 2 Ph)N} 2 ]H and its silver adduct [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag.
TABLE 16
S . aureus
Compound
MIC (μg/ml)
MIC (mM)
Relative to AgNO 3
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag
1.80
2.13 × 10 −3
34.45
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H
1.57
2.12 × 10 −3
34.71
[N{(CF 3 )C(C 6 F 5 )N} 2 ]H
1.46
2.71 × 10 −3
27.16
[N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag
8.78 × 10 −1
1.05 × 10 −3
70.10
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H
1.55
1.06 × 10 −3
34.71
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag
0.853
1.12 × 10 −2
69.43
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H
7.80
2.12 × 10 −3
6.57
[N{(C 3 F 7 )C(Mes)N} 2 ]H
2252.38
3.50
2.10 × 10 −2
AgNO 3
12.50
7.36 × 10 −2
1.00
silver (I) sulfadiazine
16.00
4.48 × 10 −2
1.64
TABLE 17
B . subtilis.
Compound
MIC (μg/ml)
MIC (mM)
Relative to AgNO 3
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag
1.80
2.13 × 10 −3
69.01
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H
1.57
2.12 × 10 −3
69.34
[N{(CF 3 )C(C 6 F 5 )N} 2 ]H
7.29 × 10 −1
1.35 × 10 −3
108.89
[N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag
8.70 × 10 −2
1.04 × 10 −4
1413.46
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H
1.60 × 10 −1
2.19 × 10 −4
671.23
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag
4.27 × 10 −1
5.31 × 10 −4
276.84
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H
4.27 × 10 −1
4.59 × 10 −4
320.26
[N{(C 3 F 7 )C(Mes)N} 2 ]H
1723.64
2.69
5.46 × 10 −2
AgNO 3
25.00
1.47 × 10 −1
1.00
silver (I) sulfadiazine
89.18
2.50 × 10 −1
5.88 × 10 −1
TABLE 18
P aeruginosa.
Compound
MIC (μg/ml)
MIC (mM)
Relative to AgNO 3
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag
23.69
2.80 × 10 −2
6.57 × 10 −1
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H
2643.48
3.58
5.14 × 10 −3
[N{(CF 3 )C(C 6 F 5 )N} 2 ]H
1586.90
2.94
6.26 × 10 −3
[N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag
17.56
2.1 × 10 −2
8.76 × 10 −1
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H
2912.70
3.98
4.62 × 10 −3
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag
72.20
8.98 × 10 −2
2.05 × 10 −1
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H
>16671.80
>23.92
<7.69 × 10 −4
[N{(C 3 F 7 )C(Mes)N} 2 ]H
1402.43
2.18
8.44 × 10 −3
AgNO 3
3.12
1.84 × 10 −2
1.00
silver (I) sulfadiazine
2.00
5.60 × 10 −3
3.29
TABLE 19
E . coli .
Compound
MIC (μg/ml)
MIC (mM)
Relative to AgNO 3
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag
23.69
2.80 × 10 −2
2.10
[N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H
2643.48
3.58
1.65 × 10 −2
[N{(CF 3 )C(C 6 F 5 )N} 2 ]H
396.73
1.10
5.35 × 10 −2
[N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag
8.78
1.00 × 10 −2
5.89
[N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H
2912.70
3.98
1.48 × 10 −2
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag
72.20
8.98 × 10 −2
6.56 × 10 −1
[N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H
>16671.80
>23.92
<2.46 × 10 −3
[N{(C 3 F 7 )C(Mes)N} 2 ]H
1126.88
1.75
3.37 × 10 −2
AgNO 3
10.0
5.89 × 10 −2
1.00
silver (I) sulfadiazine
12.81
3.59 × 10 −2
1.64
TABLES 6-19 illustrate that compounds herein are highly effective at inhibiting growth of Gram-positive bacteria (e.g., S. aureus and B. subtilis ) and serve as suitable antibacterial agents for use, such as medicinal use and/or as an antibacterial additive, due to their thermal stability. Compositions herein were 27-1,400 times more effective than AgNO 3 and approximately 16-2,400 times more effective than a currently used antimicrobial, silver sulfadiazine (TABLES 16-19). The Gram-negative bacteria P. aeruginosa (an opportunistic pathogen) and E. coli (strains of which are pathogenic) were most sensitive to ([N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag, [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag and [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag at relatively equivalent levels.
An additional finding suggests that presence of a halogen on phenyl groups in the triazapentadienes compositions herein may be important for improving antibacterial activity against Gram-positive organisms (e.g., S. aureus and B. subtilis ) because [N{(C 3 F 7 )C(Mes)N} 2 ]H was less effective than other triazapentadienes not containing a halogen on its phenyl groups.
In one or more forms, effective amounts of any one or a number of compositions described herein are provided in an appropriate diluted with or without additional ingredients and provided as an antimicrobial solution. The solution may be provided in a concentrated form and further diluted at a later stage, wherein dilutions were at any concentration desired and may depend on preference and/or suitable effectiveness. In addition, the solution may be provided with a pharmaceutical carrier for medicament purposes. In addition or as an alternative, one or more compositions herein may be provided in an effective amount on a surface to act as a surface repellant/antimicrobial.
An agent may remain in a concentrated form or be provided at its effective amount, which, in some forms, may depend on the microbe of interest. For example, as an antimicrobial agent against certain Gram positive bacteria, a composition such as [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]Ag or [N{(C 3 F 7 )C(C 6 F 5 )N} 2 ]H or [N{(CF 3 )C(C 6 H 5 )N} 2 ]H may (alone or in combination) be provided at a concentration of about or greater than 5.0.times.10 −4 mM and provided at a concentration of about or greater than 5.0.times.10 −3 mM when used against certain Gram negative bacteria (see, e.g., TABLES 6, 7 or 8, respectively). An antimicrobial agent such as [N{(C 3 F 7 )C(2-F,6-CF 3 C 6 H 3 )N} 2 ]Ag or N{(C 3 F 7 )C(2-F,6-(CF 3 )C 6 H 3 )N} 2 ]H may be provided at a concentration of about or greater than 5.0.times.10 −7 mM against certain Gram positive bacteria and at a concentration of about or greater than 5.0.times.10 −3 mM when provided against other Gram negative bacteria (see, e.g., TABLES 9 or 10, respectively). An antimicrobial agent such as [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]Ag may be provided at a concentration of about or greater than 5.0.times.10 −3 mM when provided against certain Gram positive and/or Gram negative bacteria (see, e.g., TABLE 11). An antimicrobial agent such as [N{(C 3 F 7 )C(2,6-Cl 2 C 6 H 3 )N} 2 ]H may be provided at a concentration of about or greater than 5.0.times.10 −6 mM against certain Gram positive bacteria and at a concentration of about or greater than 5.0.times.10 −3 mM when provided against Gram negative bacteria (see, e.g., TABLE 12). An antimicrobial agent such as [N{(C 3 F 7 )C(Mes)N} 2 ]H may be provided at a concentration of about or greater than 5.0 mM against certain Gram positive bacteria and at a concentration of about or greater than 5.0.times.10 −3 mM when provided against Gram negative bacteria (see, e.g., TABLE 13). Effective antibacterial concentrations are similar for many compositions described herein.
When in solution a water dispersible component is typically included. This is preferably a water soluble solvent, such as dimethylsulfoxide, toluene, tetrahydrofuran, dichloromethane, diethyl ether, and hexane. In addition or as alternatives, solvents may include polyethylene glycol 400, hexylene glycol, propylene glycol, polypropylene glycol-10 methylglucose ether, ethoxydiglycol, polyethylene glycol-6 caprylic/capric glyceride, ethylene glycol monobutyl ether, polyethylene glycol-8 caprylic/capric glycerides, 3-methoxy-3-methyl-1-butanol, dimethyl isosorbide and mixtures thereof, as examples.
A formulation of compositions described herein in a solution or pharmaceutical preparations is routine. In one embodiment, a common administration vehicle (e.g., tablet, implants, injectable solution, injectable liposome solution, etc.) will contain at least one compound described herein and other suitable ingredients. Other suitable ingredients may include stabilizing agents (e.g., carriers known in the art such as albumin, a globulin, a gelatin, a protamine or a salt of protamine), immunosuppressive agents (e.g., prednisone, melphalain, prednisolone, cyclophosphamide, cyclosporine, 6-mercaptopurine, methotrexate, azathioprine and i.v. gamma globulin and suitable combinations), tolerance-inducing agents, potentiators (e.g., monensin, ammonium chloride, perhexyline, verapamil, amantadine and chloroquine) and/or side-effect relieving agents, as examples. All of such additives when provided for human use have known efficacious dose ranges, such as disclosed in the Physician's Desk Reference, 41st Ed., Publisher Edward R. Barnhart, N.J. (1987).
As such, poly-halogenated 1,3,5-triazapetadienes are useful ligands for other compounds, including metals and carbon- or nitrogen-based donor molecule. Such compounds with and without metal complexation) are potent antibacterial compounds. Such compounds as described herein provide for disinfectant, antiseptic and/or antimicrobial use for personal, medical, commercial and/or industrial applications. The improved compounds as described are also suitable as ligands for metal coordination chemistry. As described, resulting metal adducts may also serve as active catalysts for one or more chemical processes.
While specific alternatives to steps of the invention have been described herein, additional alternatives not specifically disclosed but known in the art are intended to fall within the scope of the invention. Thus, it is understood that other applications of the present invention will be apparent to those skilled in the art upon reacting the described embodiment and after consideration of the appended claims and drawing.
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A new class of fluorinated or polyhalogenated triazepentadienes are disclosed. The synthesized triazapentadienes are thermally stable, soluble in typical solvents and have several metal binding sites for complexation with metal ions. The compounds are prepared as colorless crystalline solids. Synthesis takes advantage of a reaction with triethylamine. Synthesized triazapentadienes (with and without complexed metals) inhibit bacterial growth of both Gram positive and Gram-negative bacteria.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/973,754 filed 19 Sep. 2007. The disclosure of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to deuterium-enriched satavaptan, pharmaceutical compositions containing the same, and methods of using the same.
BACKGROUND OF THE INVENTION
[0003] Satavaptan, shown below, is a well known novel long-acting orally active vasopressin V 2 -receptor antagonist.
[0000]
[0000] Since satavaptan is a known and useful pharmaceutical, it is desirable to discover novel derivatives thereof. Satavaptan is described in U.S. Pat. No. 5,663,431; the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide deuterium-enriched satavaptan or a pharmaceutically acceptable salt thereof.
[0005] It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0006] It is another object of the present invention to provide a method for treating syndrome of inappropriate antidiuretic hormone secretion, comprising administering to a host in need of such treatment a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0007] It is another object of the present invention to provide a novel deuterium-enriched satavaptan or a pharmaceutically acceptable salt thereof for use in therapy.
[0008] It is another object of the present invention to provide the use of a novel deuterium-enriched satavaptan or a pharmaceutically acceptable salt thereof for the manufacture of a medicament (e.g., for the treatment of syndrome of inappropriate antidiuretic hormone secretion).
[0009] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventor's discovery of the presently claimed deuterium-enriched satavaptan.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Deuterium (D or 2 H) is a stable, non-radioactive isotope of hydrogen and has an atomic weight of 2.0144. Hydrogen naturally occurs as a mixture of the isotopes 1 H (hydrogen or protium), D ( 2 H or deuterium), and T ( 3 H or tritium). The natural abundance of deuterium is 0.015%. One of ordinary skill in the art recognizes that in all chemical compounds with a H atom, the H atom actually represents a mixture of H and D, with about 0.015% being D. Thus, compounds with a level of deuterium that has been enriched to be greater than its natural abundance of 0.015%, should be considered unnatural and, as a result, novel over their non-enriched counterparts.
[0011] All percentages given for the amount of deuterium present are mole percentages.
[0012] It can be quite difficult in the laboratory to achieve 100% deuteration at any one site of a lab scale amount of compound (e.g., milligram or greater). When 100% deuteration is recited or a deuterium atom is specifically shown in a structure, it is assumed that a small percentage of hydrogen may still be present. Deuterium-enriched can be achieved by either exchanging protons with deuterium or by synthesizing the molecule with enriched starting materials.
[0013] The present invention provides deuterium-enriched satavaptan or a pharmaceutically acceptable salt thereof. There are forty-two hydrogen atoms in the satavaptan portion of satavaptan as show by variables R 1 -R 42 in formula I below.
[0000]
[0014] The hydrogens present on satavaptan have different capacities for exchange with deuterium. Hydrogen atom R 1 is easily exchangeable under physiological conditions and, if replaced by a deuterium atom, it is expected that it will readily exchange for a proton after administration to a patient. The remaining hydrogen atoms are not easily exchangeable for deuterium atoms. However, deuterium atoms at the remaining positions may be incorporated by the use of deuterated starting materials or intermediates during the construction of satavaptan.
[0015] The present invention is based on increasing the amount of deuterium present in satavaptan above its natural abundance. This increasing is called enrichment or deuterium-enrichment. If not specifically noted, the percentage of enrichment refers to the percentage of deuterium present in the compound, mixture of compounds, or composition. Examples of the amount of enrichment include from about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 21, 25, 29, 33, 37, 42, 46, 50, 54, 58, 63, 67, 71, 75, 79, 84, 88, 92, 96, to about 100 mol %. Since there are 42 hydrogens in satavaptan, replacement of a single hydrogen atom with deuterium would result in a molecule with about 2% deuterium enrichment. In order to achieve enrichment less than about 2%, but above the natural abundance, only partial deuteration of one site is required. Thus, less than about 2% enrichment would still refer to deuterium-enriched satavaptan.
[0016] With the natural abundance of deuterium being 0.015%, one would expect that for approximately every 6,667 molecules of satavaptan (1/0.00015=6,667), there is one naturally occurring molecule with one deuterium present. Since satavaptan has 42 positions, one would roughly expect that for approximately every 280,014 molecules of satavaptan (42×6,667), all 42 different, naturally occurring, mono-deuterated satavaptans would be present. This approximation is a rough estimate as it doesn't take into account the different exchange rates of the hydrogen atoms on satavaptan. For naturally occurring molecules with more than one deuterium, the numbers become vastly larger. In view of this natural abundance, the present invention, in an embodiment, relates to an amount of an deuterium enriched compound, whereby the enrichment recited will be more than naturally occurring deuterated molecules.
[0017] In view of the natural abundance of deuterium-enriched satavaptan, the present invention also relates to isolated or purified deuterium-enriched satavaptan. The isolated or purified deuterium-enriched satavaptan is a group of molecules whose deuterium levels are above the naturally occurring levels (e.g., 2%). The isolated or purified deuterium-enriched satavaptan can be obtained by techniques known to those of skill in the art (e.g., see the syntheses described below).
[0018] The present invention also relates to compositions comprising deuterium-enriched satavaptan. The compositions require the presence of deuterium-enriched satavaptan which is greater than its natural abundance. For example, the compositions of the present invention can comprise (a) a μg of a deuterium-enriched satavaptan; (b) a mg of a deuterium-enriched satavaptan; and, (c) a gram of a deuterium-enriched satavaptan.
[0019] In an embodiment, the present invention provides an amount of a novel deuterium-enriched satavaptan.
[0020] Examples of amounts include, but are not limited to (a) at least 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, to 1 mole, (b) at least 0.1 moles, and (c) at least 1 mole of the compound. The present amounts also cover lab-scale (e.g., gram scale), kilo-lab scale (e.g., kilogram scale), and industrial or commercial scale (e.g., multi-kilogram or above scale) quantities as these will be more useful in the actual manufacture of a pharmaceutical. Industrial/commercial scale refers to the amount of product that would be produced in a batch that was designed for clinical testing, formulation, sale/distribution to the public, etc.
[0021] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0022] wherein R 1 -R 42 are independently selected from H and D; and the abundance of deuterium in R 1 -R 42 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 10%, (c) at least 14%, (d) at least 19%, (e) at least 24%, (f) at least 29%, (g) at least 33%, (h) at least 38%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 62%, (n) at least 67%, (o) at least 71%, (p) at least 76%, (q) at least 81%, (r) at least 86%, (s) at least 90%, (t) at least 93%, (u) at least 98%, and (v) 100%.
[0023] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0024] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R 10 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0025] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 11 -R 13 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0026] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 43 -R 45 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0027] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 14 -R 15 and R 21 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0028] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 16 -R 20 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0029] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 22 -R 26 and R 39 -R 42 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0030] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 27 -R 30 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0031] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 31 -R 38 and R 21 is at least 13%. The abundance can also be (a) at least 25%, (b) at least 38%, (c) at least 50%, (d) at least 63%, (e) at least 75%, (f) at least 88%, and (g) 100%.
[0032] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0033] wherein R 1 -R 42 are independently selected from H and D; and the abundance of deuterium in R 1 -R 42 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 10%, (c) at least 14%, (d) at least 19%, (e) at least 24%, (f) at least 29%, (g) at least 33%, (h) at least 38%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 62%, (n) at least 67%, (o) at least 71%, (p) at least 76%, (q) at least 81%, (r) at least 86%, (s) at least 90%, (t) at least 93%, (u) at least 98%, and (v) 100%.
[0034] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0035] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R 10 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0036] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 11 -R 13 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0037] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 43 -R 45 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0038] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 14 -R 15 and R 21 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0039] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 16 -R 20 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0040] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 22 -R 26 and R 39 -R 42 is at least 1%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0041] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 27 -R 30 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0042] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 31 -R 38 and R 21 is at least 13%. The abundance can also be (a) at least 25%, (b) at least 38%, (c) at least 50%, (d) at least 63%, (e) at least 75%, (f) at least 88%, and (g) 100%.
[0043] In another embodiment, the present invention provides novel mixture of deuterium enriched compounds of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0044] wherein R 1 -R 42 are independently selected from H and D; and the abundance of deuterium in R 1 -R 42 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 10%, (c) at least 14%, (d) at least 19%, (e) at least 24%, (f) at least 29%, (g) at least 33%, (h) at least 38%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 62%, (n) at least 67%, (o) at least 71%, (p) at least 76%, (q) at least 81%, (r) at least 86%, (s) at least 90%, (t) at least 93%, (u) at least 98%, and (v) 100%.
[0045] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0046] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R 10 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0047] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 11 -R 13 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0048] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 43 -R 45 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0049] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 14 -R 15 and R 21 is at least 33%. The abundance can also be (a) at least 67%, and (b) 100%.
[0050] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 16 -R 20 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0051] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 22 -R 26 and R 39 -R 42 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%, (d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0052] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 27 -R 30 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0053] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 31 -R 38 and R 21 is at least 13%. The abundance can also be (a) at least 25%, (b) at least 38%, (c) at least 50%, (d) at least 63%, (e) at least 75%, (f) at least 88%, and (g) 100%.
[0054] In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0055] In another embodiment, the present invention provides a novel method for treating syndrome of inappropriate antidiuretic hormone secretion comprising: administering to a patient in need thereof a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0056] In another embodiment, the present invention provides an amount of a deuterium-enriched compound of the present invention as described above for use in therapy.
[0057] In another embodiment, the present invention provides the use of an amount of a deuterium-enriched compound of the present invention for the manufacture of a medicament (e.g., for the treatment of syndrome of inappropriate antidiuretic hormone secretion).
[0058] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. This invention encompasses all combinations of preferred aspects of the invention noted herein. It is understood that any and all embodiments of the present invention may be taken in conjunction with any other embodiment or embodiments to describe additional more preferred embodiments. It is also to be understood that each individual element of the preferred embodiments is intended to be taken individually as its own independent preferred embodiment. Furthermore, any element of an embodiment is meant to be combined with any and all other elements from any embodiment to describe an additional embodiment.
DEFINITIONS
[0059] The examples provided in the definitions present in this application are non-inclusive unless otherwise stated. They include but are not limited to the recited examples.
[0060] The compounds of the present invention may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention. All tautomers of shown or described compounds are also considered to be part of the present invention.
[0061] “Host” preferably refers to a human. It also includes other mammals including the equine, porcine, bovine, feline, and canine families.
[0062] “Treating” or “treatment” covers the treatment of a disease-state in a mammal, and includes: (a) preventing the disease-state from occurring in a mammal, in particular, when such mammal is predisposed to the disease-state but has not yet been diagnosed as having it; (b) inhibiting the disease-state, e.g., arresting it development; and/or (c) relieving the disease-state, e.g., causing regression of the disease state until a desired endpoint is reached. Treating also includes the amelioration of a symptom of a disease (e.g., lessen the pain or discomfort), wherein such amelioration may or may not be directly affecting the disease (e.g., cause, transmission, expression, etc.).
[0063] “Therapeutically effective amount” includes an amount of a compound of the present invention that is effective when administered alone or in combination to treat the desired condition or disorder. “Therapeutically effective amount” includes an amount of the combination of compounds claimed that is effective to treat the desired condition or disorder. The combination of compounds is preferably a synergistic combination. Synergy, as described, for example, by Chou and Talalay, Adv. Enzyme Regul. 1984, 22:27-55, occurs when the effect of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at sub-optimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
[0064] “Pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of the basic residues. The pharmaceutically acceptable salts include the conventional quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include, but are not limited to, those derived from inorganic and organic acids selected from 1, 2-ethanedisulfonic, 2-acetoxybenzoic, 2-hydroxyethanesulfonic, acetic, ascorbic, benzenesulfonic, benzoic, bicarbonic, carbonic, citric, edetic, ethane disulfonic, ethane sulfonic, fumaric, glucoheptonic, gluconic, glutamic, glycolic, glycollyarsanilic, hexylresorcinic, hydrabamic, hydrobromic, hydrochloric, hydroiodide, hydroxymaleic, hydroxynaphthoic, isethionic, lactic, lactobionic, lauryl sulfonic, maleic, malic, mandelic, methanesulfonic, napsylic, nitric, oxalic, pamoic, pantothenic, phenylacetic, phosphoric, polygalacturonic, propionic, salicyclic, stearic, subacetic, succinic, sulfamic, sulfanilic, sulfuric, tannic, tartaric, and toluenesulfonic.
EXAMPLES
[0065] Table 1 provides compounds that are representative examples of the present invention. When one of R 1 -R 42 is present, it is selected from H or D.
[0000]
[0066] Table 2 provides compounds that are representative examples of the present invention. Where H is shown, it represents naturally abundant hydrogen.
[0000]
[0067] 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 that as specifically described herein.
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The present application describes deuterium-enriched satavaptan, pharmaceutically acceptable salt forms thereof, and methods of treating using the same.
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FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a liquid container, in particular, a liquid container in the form of an ink container removably mountable in an ink jet recording unit or an ink jet recording apparatus, which records on recording medium by ejecting ink.
[0002] An ink jet recording apparatus which forms an image on recording medium by depositing ink in the form of liquid with the use of an ink jet recording head is widely used as an outputting means for such an information processing apparatus as a copying machine, a facsimileing machine, an electronic typewriter, a printer as an outputting peripheral device for a wordprocessor, a workstation, a personal or host computer, etc., or a portable printer to be connected to an optical disc apparatus, a video apparatus, a digital camera, etc.
[0003] As a system for supplying such an ink jet recording apparatus as those described above with ink, there is a system in which an ink container is inseparably or removably attached to a recording head mounted on a carriage or the like and reciprocally movable (in primary scanning direction), and ink is directly supplied to the recording head from this ink container. Whether an ink jet recording apparatus is structured so that an ink container, is inseparably attached to a recording head, or it is structured so that an ink container is removably attached to a recording head, the positioning of an ink container relative to a recording head, or positioning of a recording head unit, that is, the integral combination of a recording head and an ink container, relative to a relevant member (for example, carriage of serial type recording apparatus, reciprocally movable in primary scanning direction) of the main assembly of a recording apparatus, is one of the most important issues related to recording quality. Further, it is very important, in particular, in the field of an ink jet recording apparatus for personal usage, to provide an ink supplying system for an ink jet recording apparatus which is small in size, simple in terms of the operation for mounting or dismounting an ink container or an ink jet recording head unit, and also, simple in terms of mechanism.
[0004] Thus, the inventors of the present invention have proposed a combination of an ink container and a structure for removably attaching an ink container, as an answer to the above described concerns. According to this proposal, an ink container is provided with a anchoring claw, which projects from one of the end surfaces, and a springy latching lever with an anchoring claw, which projects from the bottom portion of the opposite surface from the surface with the anchoring claw. Further, the holder to which an ink container is attached is provided with an anchoring hole into which the anchoring claw of an ink container fits, and an anchoring hole into which the anchoring claw of the springy latching lever of an ink container fits. The two anchoring holes of the holder are in the opposing two side walls of the holder, one for one. As for the mounting of the ink container, first, the ink container is to be positioned so that the anchoring claw projecting from one end of the ink container fits into the anchoring hole of the holder, and then, the ink container is to be pushed down into the predetermined position in the holder by the other end is to cause the anchoring of the latching lever of the ink container to snap into the anchoring hole of the holder. With the two claws locked in the corresponding anchoring holes, the ink container is prevented from dislodging from the abovementioned predetermined position in the holder.
[0005] Such a removably mountable ink container as the one described above has been known to be provided with a storage means capable of electrically storing the information regarding the ink container itself (for example, color of ink therein), in order to make it possible to control the recording process of an ink jet recording apparatus, based on the information stored in the storage means. The information stored in the storage means is read as the ink container is mounted into the ink jet recording apparatus. In the case of an ink jet recording apparatus structured as described above, the ink container must be connected to the recording head so that not only is an ink passage established between the ink container and recording head, but also, an information exchange channel must be established between the two.
[0006] As one of the means for accomplishing the above described objects, Japanese Laid-open Patent Application 2001-253087 discloses the following structural arrangement: The electrical contacts of an ink container and the electrical contacts of a holder are disposed on the same side so that as the ink container is mounted into the holder, the electrical contacts of both sides come into contact with each other, and also, so that once they are placed in contact with each other, they are kept in contact with each other by the engagements between the anchoring claw, such as the one described above, of the ink container, with the corresponding anchoring hole of the holder, and between the anchoring claw of the latching lever, such as the above described one, of the ink container, and the corresponding anchoring hole of the holder. In the case of this structural arrangement, the electrical contacts of the two sides are automatically connected as the ink container is mounted into the holder, eliminating the need for a mechanism dedicated to the connection, or the need for performing a procedure dedicated for the connection. Therefore, this structural arrangement is advantageous from the standpoint of operational efficiency.
[0007] In comparison, the structural arrangement disclosed in Japanese Laid-open Patent Application 2001-253087 suffers from the following problems. That is, if the latching lever of the ink container and the electrical contacts of the holder are not equal in resiliency, for example, if the contact pressure of the electrical contacts is greater than the force generated by the resiliency of the latching lever, the latching lever is excessively deformed, failing thereby to keep the ink container in the predetermined position in terms of the direction in which the force generated by the latching lever acts on the ink container. Therefore, it is possible that the ink passage on the ink container side and the ink passage on the recording head side become misaligned at the joint, preventing thereby ink from being properly supplied, and/or allowing ink to leak from the joint. It is also possible that the contact pressure between the electrical contacts on the ink container side and holder side will become unstable, failing thereby to remain properly connected in terms of electrical conduction.
[0008] As the solution to the above described problems, it is possible to place the electrical contact portion on the bottom surface of the ink container in the same manner as the one disclosed in Japanese Laid-open Patent Application 2-178050. According to Japanese Laid-open Patent Application 2-178050, the ink jet recording head is integral with an ink container, and is removably mountable in the carriage of the ink jet recording apparatus. Its electrical contacts through which recording signals are transmitted to the recording head from the main assembly of the recording apparatus are attached to the bottom surface of the recording head, and the corresponding surface of the carriage. Thus, as the recording head is mounted into the carriage, the electrical contacts of the recording head come into contact with the electrical contact of the carriage, and then, keep sliding thereon while the recording head is moved (pivotally) into its final position on the carriage. Therefore, the electrical contacts of the recording head and the electrical contacts of the carriage are better connected in terms of electrical conductivity. Thus, it seems reasonable to the adopt the design of the electrical joint between the recording head and carriage disclosed in Japanese Laid-open Patent Application 2-178050 to the design of the electrical joint between an ink container and a recording head, through which the ink container information is electrically transmitted.
[0009] However, electrical contacts are electrically conductive members formed of relatively rigid metallic substance, and therefore, applying a large amount of pressure to electrical contacts, and/or causing electrical contacts to slide on each other while applying a large amount of pressure, in order to ensure that the electrical contacts of an ink container and the electrical contacts of the main assembly remain satisfactorily connected in terms of electrical conductivity is unwise from the standpoint of the prevention of the damage to the electrical contacts and the durability of the electrical contacts. In other words, the amount of the pressure to be applied to the electrical contacts to ensure that the electrical contacts of the ink container are kept satisfactorily connected to the electrical contacts of the main assembly must be optimum, that is, the minimum to be effective. Thus, it is unwise to adopt the technologies disclosed in Japanese Laid-open Patent Application 2-178050 without any modification. In particular, in the case that an ink container is removably attachable to a recording head, there is the possibility that when an ink container is attached or removed, the tip of the ink outlet of the ink container will come into contact with the electrical contacts of the main assembly, and wets them. Further, should ink leak from the joint between the ink outlet of the ink container and the ink inlet of the main assembly during the mounting of the ink container, it is very likely that the ink having leaked from the joint will reach the electrical contacts, because the electrical contacts are attached to the bottom surface of the ink container.
SUMMARY OF THE INVENTION
[0010] Thus, the primary object of the present invention is to improve a liquid container having a liquid outlet and an information storage means of a contact type, in order to make it easier to mount or dismount, simpler in the structure of the mechanism for mounting it, more reliable and accurate in terms of its position relative to a device to which it is connected, smaller in the amount of force necessary to mount it, and also, more reliable in terms of the connection between its liquid outlet and the liquid inlet of a device to which it is connected, and the electrical connection between its information storage means and the information storage means of the device to which it is connected.
[0011] Another object of the present invention is to provide a structural arrangement for a liquid container, which is superior, in terms of leak prevention, to the structural arrangement for a liquid container in accordance with the prior art.
[0012] According to an aspect of the present invention, there is provided a liquid container detachably mountable to a mounting portion of an apparatus, the mounting portion including a first locking portion and a second locking portion, said liquid container including a casing for containing liquid and a supply port for supplying the liquid to an ink jet head, said liquid container comprising a first engaging portion provided at a first side of said casing and engageable with the first locking portion; a second engaging portion provided opposed to a second side of said casing which is opposite said first side, said second engaging portion being engageable with the second locking portion; a supporting member for displaceably supporting said second engaging portion; a contact contactable to a member provided in the mounting portion to permit information display means to display information relating to said liquid container, wherein said supply port is disposed in a third side of said casing which is between said first side and said second side, and said contact is disposed at a corner region between said second side and said third side.
[0013] A liquid container structured described above is mounted, in the following manner, into a predetermined liquid container mount of a device to which the liquid container is to be attached: First, a liquid container anchoring first portion on the external surface of one of the lateral walls of the liquid container is to be engaged with a liquid container anchoring first portion of the liquid container mount, and the liquid container is to be pressed by its opposite wall from the wall having the liquid outlet. As the liquid container is pressed, the liquid container moves into the liquid container mount while rotating about the liquid container anchoring first portion. It is ensured by the resiliency of the latching lever of the liquid container that the liquid container is accurately positioned relative to the liquid container mount and retained there. Providing the latching lever of the liquid container with a liquid container anchoring second portion engageable with the liquid container anchoring portion of the liquid container mount further ensures that the liquid container is accurately positioned relative to the liquid container mount, and makes it easier to mount the liquid container.
[0014] Further, since the liquid container is accurately and reliably positioned relative to the liquid container holder (mount), and the liquid outlet of the liquid container is positioned between the lateral wall of the liquid container, on the external surface of which the liquid container anchoring portion, which serves as the above described rotational center, is located, and the opposite lateral wall of the ink container, the possibility of liquid leakage is minimized by the synergetic coordination of the force generated by the contact pressure between the liquid outlet of the liquid container and the liquid inlet of the liquid container mount side, and the force generated by the resiliency of the latching lever of the liquid container.
[0015] In addition, the electrical contacts of the information storage means are disposed on the corner portion, or the edge, between the lateral wall of the liquid container having the liquid outlet and the lateral wall of the liquid container upon which the force generated by the resiliency of the latching lever acts. Therefore, the electrical contacts of the information storage means come into contact with the electrical contacts on the liquid container holder side immediately before the process for mounting the liquid container in the rotational movement is completed. In other words, the electrical contacts of the liquid container and the electrical contacts of the liquid container holder side are placed in contact with each other by the same action taken to couple the liquid outlet of the liquid container with the ink inlet of the liquid container holder. Therefore, not only are the electrical contacts on both sides are placed in contact with each other in the preferable condition, but also, the amount of force required to mount the liquid container is substantially smaller compared to that required when the liquid container in accordance with the prior art is mounted. Further, the latching lever (supporting member) is structured so that its surface facing the wall of the liquid container holder is tilted in such a manner that the closer a given point of the surface is to the wall of the liquid container having the liquid outlet, the closer the given point of the surface is to the wall of the liquid container having the latching lever, and the liquid container and the liquid container holder are structured so that as the liquid container is mounted into the liquid container holder, the rotational movement of the liquid container about the liquid container anchoring first portion can be utilized as the lever action, in which the liquid outlet is the point of action. Therefore, if the liquid container is released before the liquid container anchoring second portion of the latching lever completely engages with the liquid container anchoring second portion of the liquid container mount (holder), the liquid container is popped upward by the reaction force, informing therefore an operator of the incompletion of the liquid container mounting process, ensuring thereby that the liquid container is completely mounted. Further, the information storage means is disposed on the aforementioned slanted wall, that is, the corner portion, of the liquid container. Therefore, as the liquid container is mounted into the liquid container mount (holder), the information storage means is positioned at a level which is a step higher than the bottom wall, that is, the wall having the liquid outlet, of the liquid container. Therefore, even if liquid leaks through the liquid outlet, the information storage means would be protected from the effects of the leak.
[0016] As described above, the present invention makes it possible to make a liquid container, which has a liquid outlet and an information storage means having electrical contacts, simpler in the mechanism for mounting it into the liquid container mount of a device to which it is attached, simpler in the procedure for mounting it, more reliable and accurate in positioning, smaller in the amount of force necessary to mount it, and better in the state of connection between its liquid outlet and the liquid inlet of a device to which it is attached and the state of contact between the electrical contacts of its information storage means and the electrical contacts of the device to which it is attached.
[0017] Further, the present invention can structure a combination of a liquid container and the liquid container mount of a device to which the liquid container is to be attached, so that its electrical contacts are protected from the liquid leakage from the liquid container.
[0018] These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of the ink container in the first embodiment of the present invention, as seen from the bottom side.
[0020] FIGS. 2( a ) and 2 ( b ) are side and bottom plan views, respectively, of the ink container shown in FIG. 1 .
[0021] FIG. 3 is a schematic sectional view of the ink container shown in FIG. 1 , at plane parallel to the side walls of the container.
[0022] FIG. 4 is a schematic drawing for showing the structure of the ink container mount (holder) of the main assembly of an ink jet recording apparatus, and the procedure for mounting the ink container into the ink container mount (holder).
[0023] FIG. 5 is a perspective view of an example of a recording head unit structured so that the ink container in the first embodiment of the present invention can be removably mountable.
[0024] FIG. 6 is a perspective view of the set of ink containers removably mountable in the recording head unit shown in FIG. 5 .
[0025] FIG. 7 is an external perspective view of an ink jet printer in which a recording head and an ink container are mounted to record.
[0026] FIG. 8 is a perspective view of the ink jet printer shown in FIG. 7 , the main assembly cover of which is open.
[0027] FIG. 9 is a perspective view of a set of ink containers different from the set shown in FIG. 6 .
[0028] FIG. 10 is a perspective view of one of the modified versions of the ink container in the first embodiment.
[0029] FIG. 11 is a perspective view of another modified version of the ink container in the first embodiment.
[0030] FIGS. 12( a )- 12 ( c ) are schematic drawings for describing the another structural arrangement and the procedure for elastically pressing an ink container into the predetermined position in the recording head unit.
[0031] FIG. 13 is a schematic side view of the ink container in another embodiment of the present invention.
[0032] FIG. 14 is a sectional view of the ink container, and the ink container mount (holder) therefor, in another embodiment of the present invention.
[0033] FIG. 15 is a schematic sectional view of one of the modified versions of the ink container mount (holder) in the first embodiment, at a plane parallel to the side walls thereof, showing the structure thereof.
[0034] FIG. 16 is a schematic sectional view of the ink container mount (holder) in another embodiment, at a plane parallel to the side walls thereof, showing the structure thereof.
[0035] FIG. 17 is a sectional view of the ink container according to a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Hereinafter the preferred embodiments of the present invention will be described with reference to the appended drawings.
[0037] In this specification, not only does recording mean a process for forming various kinds of images, whether the images have a meaning or not, or whether or not the images are visible, that is, whether or not the images can be detected by the human eye. In other words, it means the process for forming various kinds of images, including the process of treating recording medium itself.
[0038] The meaning of “recording medium” is not limited to the paper used by an ordinary recording apparatus. That is, it includes a much wider range of medium, for example, fabric, plastic, film, metallic plate, glass, ceramic, lumber, leather, etc. In other words, it means anything on which an image can be formed with the use of ink. Hereafter, “recording medium” may sometimes be referred to as “paper”.
[0039] Further, “ink” or “liquid” should be as widely interpreted as the above described meaning of recording. They include any liquid which can form images, that is, meaningful and meaningless patterns, can treat recording mediums, and/or can treat ink itself or recording medium (for example, improve images in terms of fixation, quality, color development, durability, etc., by solidifying coloring ingredient of ink deposited onto recording medium).
1. First Embodiment
1-1 Ink Container
[0040] FIG. 1 is a perspective view of the ink container in the first embodiment as seen from the bottom side, and FIGS. 2( a ) and 2 ( b ) are side and bottom plan views of the ink container in the first embodiment. FIG. 3 is a sectional view of the ink container, at a plane parallel to the side walls of the ink container. It should be noted here that in the following description of the preferred embodiments of the present invention, the front surface of an ink container means the surface which a user faces to operate the apparatus (to mount or dismount ink container, or the like operation).
[0041] The ink container 1 in this embodiment has a to supporting member (latching lever) 3 attached to the bottom of the front surface. The latching lever 3 is an integral part of the ink container 1 , and is formed of resin. It is formed with the container proper of the ink container 1 . It is structured so that it can be elastically deformed toward the container proper of the ink container 1 as the ink container 1 is mounted into the ink container mount (which hereinafter may sometimes be referred to as holder) of a recording apparatus, or as the like operation is carried out. The ink container mount of a recording apparatus will be described later. The ink container 1 also has first and second projections 5 and 6 , which engage with the counterparts of the ink container holder. The first and second projections 5 and 6 are located on the back and front sides, respectively, of the ink container 1 . In this embodiment, the second projection 6 is an integral part of the latching lever 3 . The ink container 1 is securely anchored to the ink container holder by the engagement between the projections 5 and 6 of the ink container 1 and their counterparts of the ink container holder. The procedure for mounting the ink container 1 into the ink container holder will be described later referring to FIG. 4 .
[0042] The bottom wall of the ink container 1 is provided with an ink outlet 7 through which ink is released. The ink outlet 7 couples with the ink inlet of a recording head as the ink container 1 is mounted into the ink container holder. The recording head will be described later. The corner portion of the ink container 1 where the front and bottom walls of the container 1 meet is shaped as if it were chamfered; the front and bottom walls are connected with a slanted wall 130 , the angle of which is roughly 45°. The angle of this slanted wall is roughly the same as the angle at which the latching lever 3 extends from the bottom of the front surface. To this slanted wall 130 , an information storage medium 104 and a circuit board 100 are attached. The information storage medium 104 stores the information about the ink container itself. The circuit board 100 has multiple contact pads 102 as electrical contacts electrically connectible to the connector of the holder. In the case of the ink container shown in FIG. 3 , the information storage medium 104 was sealed with protective sealant after it was attached to the circuit board 100 .
[0043] Referring to FIGS. 2 and 3 , the external surface of the slanted wall 130 of the ink container 1 , to which contact pad 102 is attached, is one of the surfaces of the ink container 1 which are not suitable as the surface on which the ink container 1 is rested. In other words, the contact pad 102 is attached to the surface of the ink container 1 , which is not suitable as the surface on which the ink container 1 is rested. Therefore, attaching the contact pad 102 to the external surface of the slanted wall 130 is expedient from the standpoint of preventing such a problem as an accidental damage to the contact pad 102 . In addition, providing the ink container 1 with this slanted wall 130 gives the bottom wall of the ink chamber 11 a slanted portion, which will conceivably impel the ink toward the ink outlet 13 , contributing to the minimization of the amount of the ink which fail to be drawn out of the ink chamber 11 .
[0044] In this embodiment, the angle of the slanted wall 130 is 45°. In the case that the ink container 1 is structured so that the ink outlet 7 thereof protrudes outward as shown in FIG. 3 , the slanted wall 130 does not come into contact with the surface of a desk or the like on which the ink container 1 might be placed, whether the ink container 1 is placed on the desk or the like so that the wall having the ink outlet faces downward, or the latching lever 3 faces downward (obviously, this is only hypothetical because it is impossible to place the ink container in this manner because of presence of latching lever 3 ). Further, as will be described later in detail, an angle of 45° is the best angle in that the vertical and horizontal components of the contact pressure between the contact pad 102 and the connector 152 of the holder 150 best balance with each other. The angle of the slanted wall 130 may be varied within a range in which the above described effect can be expected. However, in consideration of practicality, the amount of the deviation is desired to be within n 5°.
[0045] As the ink container 1 is mounted into the ink jet recording apparatus, it becomes possible for the contents (for example, expiration date of ink, amount of ink in container, ink color, etc., usable for controlling various aspects of image forming process related to ink container) of the information storage medium 104 to be transmitted to the ink jet recording apparatus. This information can be used by the ink jet recording apparatus for various purposes. For example, the information regarding the expiration date of the ink container 1 can be used to suggest that a user replace the ink container 1 in order to prevent the recording failure attributable to the discoloration of the ink, and increase in the viscosity of the ink. The information regarding the remaining amount of the ink can be used for informing a user of the insufficiency of the amount of the ink in the ink container, in order to prevent the user from suffering from the inconvenience of the interruption of a recording operation (ink ejection) attributable to ink depletion, during recording. Further, the information regarding the color of the ink in the ink container 1 can be used for preventing unsatisfactory recording by informing a user of the mounting of an ink container containing ink different in color from the intended one. In other words, with such information as the above described in the information storage means being available to the recording apparatus, it is possible to always obtain a high quality recording.
[0046] As the information storage medium 104 , various means can be used, for example, a magnetic medium, an photo-magnetic medium, an electrical storage medium, a mechanical switch as a DIP switch, etc., in other words, any means capable of storing information that can be exchanged between itself and an ink jet recording apparatus by being placed in contact with the contact portion of the ink jet recording apparatus. Further, it may be a flush memory, or an instantly writable magnetic medium. However, when it is desired that not only is the information storage medium 104 capable of providing the recording apparatus with the information, but also, the information from the recording apparatus (for example, the amount of ink remainder, ink usage, etc., estimated based on image formation data) can be written into the information medium 104 , or the information therein can be modified or erased, it is possible to employ an EEPROM (electrically erasable programmable ROM).
[0047] Referring to FIG. 3 , the internal space of the ink container 1 is divided into the ink storage chambers 11 and 12 . The ink storage chamber 11 is on the front side where the cartridge anchoring latching lever 3 and circuit board 100 are located, whereas the ink storage chamber 12 is on the back side, and has the ink outlet 7 . The two ink storage chambers 11 and 12 are connected through a hole 13 . The ink storage chamber 11 is an empty space in which nothing but ink is stored. However, the ink storage chamber 12 is completely filled with an ink absorbent member 15 formed of sponge or the like, or completely packed with fine fiber, or the like, and ink is stored in the ink storage chamber 12 by being absorbed into the ink absorbent member 15 . The ink absorbent member 15 is for generating negative pressure by the amount in the range in which the negative pressure is large enough to prevent ink from leaking from the ink ejecting portion, in coordination with the ink retaining force of the meniscuses formed in the ink ejection nozzles of the recording head, and yet, small enough to allow the recording head to eject ink.
[0048] The structure of the ink container 1 does not need to be limited to the above described one in which the internal space of the ink container 1 is divided into the ink storage chamber completely filled with the ink absorbent member, and the ink storage chamber which is nothing but an empty space. For example, it may be such that virtually the entirety of the internal space of the ink container 1 is completely filled up with the ink absorbent member. Further, instead of employing an ink absorbent member as a negative pressure generating means, ink may be directly filled into a pouch, which is formed of elastic substance such as rubber, the resiliency of which acts in the direction to stretch the pouch wall so that its internal space increases. In such a case, the negative force is generated by the tensile force of the pouch. Further, the ink container 1 may be in the form of an ink pouch, a part of the wall of which is formed of elastic material, and which is directly filled with ink. In this case, the negative pressure is generated by the resiliency of the elastic wall portion of the ink container. Further, the ink container 1 may be a combination of a container proper and a pressure adjustment mechanism (for example, one-way valve which opens as internal pressure of container proper falls below predetermined level). In this case, ink is directly stored in the entirety of the internal space of the container proper, and the internal pressure of the container proper is maintained at a predetermined level by the pressure adjustment mechanism.
[0049] Referring to FIGS. 1 and 3 , the bottom wall of the ink chamber 11 is provided with an ink level detecting portion 17 , which is positioned so that it opposes the ink remainder detection sensor (which will be described later) of the main assembly of the recording apparatus when the ink container 1 is in the main assembly. In this embodiment, the ink remainder amount detection sensor is an optical sensor made up of a combination of a light emitting portion and a light receiving portion. The ink remainder amount detection portion 17 is formed of transparent or semitransparent material. More specifically, it is in the form of a prism, the shape and apex angles, etc., of which are predetermined so that when no ink is in the ink storage chamber 11 , the beam of light emitted from the light emitting portion is accurately reflected to the light receiving portion (which will also be described later).
1-2 Ink Container Mount (Holder)
[0050] FIGS. 4( a )-( c ) are schematic drawings for depicting the ink container mount (holder) of the recording head unit, into which the ink container is mounted, and the procedure for mounting the ink container into the mount (holder).
[0051] Generally, the recording head unit 105 is made up of the holder 150 which removably holds ink containers, and a recording head 105 a located under the bottom wall of the holder 150 . As the ink container 1 is inserted into the holder 150 , the ink container anchoring first and second projections 5 and 6 of the ink container 1 engage with the ink container anchoring portions 155 and 156 , respectively, of the holder 150 which is an integral part of the recording head unit 105 comprising the recording head 105 a. As a result, the ink container 1 is firmly anchored to the holder 150 . At the same time, the ink inlet 107 of the recording head, which is located at the bottom of the holder 150 , couples with the ink outlet 7 of the ink container 1 , creating thereby an ink passage between the recording head 105 a and ink container 1 . Also during the insertion of the ink container 1 into the holder 150 , the connector 152 of the holder 150 comes into contact with the contact pad 102 on the outwardly facing surface of the circuit board 100 , establishing electrical connection between the holder 150 and ink container 1 .
[0052] Next, the process through which the ink container 1 is precisely positioned relative to the holder 150 as the ink container 1 is mounted into the holder 150 will be described. When mounting the ink container 1 into the recording head unit 105 , the ink container 1 is to be inserted into the ink container compartment of the holder 150 from above ( FIG. 4( a )) so that the ink container anchoring first projection 5 on the back surface of the ink container 1 will be inserted into the ink container anchoring first portion 155 , in the form a through hole, on the back wall of the holder 150 , and also, so that the ink container anchoring projection 6 of the latching lever 3 rests on the top edge of the front wall of the holder 150 ( FIG. 4( b )).
[0053] Then, the ink container 1 is to be pressed down by the top front end of the ink container 1 in the direction indicated by an arrow mark P. As the ink container is pressed, the ink container 1 rotates in the direction indicated by an arrow mark R, with the contact point between the ink container anchoring first projection 5 of the ink container 1 and the ink container anchoring first portion 155 of the holder 150 serving as the center of rotation. As a result, the front side of the ink container 1 moves downward faster than the back side of the ink container 1 . While the ink container 1 is downwardly moving as described above, the latching lever 3 on the front side of the ink container 1 , is elastically deformed in the direction indicated by an arrow mark Q, because the front surface of the, ink container anchoring second projection 6 of the latching lever 3 of the ink container 1 remaining in contact with the top front edge of the front wall of the holder 150 , being therefore pressed by the reaction force generated as the ink container 1 is pressed.
[0054] Then, as the top edge of the ink container anchoring second projection 6 of the ink container 1 is moved past the top edge of the front wall of the holder 150 , and brought to the hole 157 located below the top edge of the front wall of the holder 150 , the latching lever 3 elastically deforms in the direction indicated by a arrow mark Q′ due to its own resiliency, snapping into the hole 157 . As a result, the projection 6 becomes locked with the top edge of the hole 157 (top edge of hole 157 constitutes ink container anchoring second portion 156 ). Obviously, the ink container anchoring second portion 156 may be the top edge of the hole of the front wall of the holder 150 as it is in this embodiment, or the front wall of the holder 150 may be provided with a small rib or projection capable of anchoring the projection 6 of the ink container 1 . When the ink container 1 is in the state shown in FIG. 4( c ), the ink container 1 is kept pressured in the horizontal direction (direction indicated by an arrow mark y) by the ink container anchoring second portion 156 , more specifically, the resiliency of the latching lever 3 sandwiched between the container proper of the ink container 1 and the font wall of the holder 150 . As a result, the back wall of the ink container 1 is kept in contact with the back wall of the holder 150 . As for the angles of the back walls of the ink container 1 and holder 150 , the walls have only to be intersectional to the direction in which the ink container 1 is kept pressured by the latching lever 3 . However, from the standpoint of the level of preciseness with which the ink container 1 is positioned relative to the holder 150 , the walls are desired to be perpendicular to the direction in which the ink container 1 is kept pressured by the latching lever 3 . Further, as the ink outlet 7 of the ink container 1 couples with the ink inlet 107 of the recording head 105 a, the elastic ink absorbent member in the ink outlet 7 comes into contact with the ink inlet of the recording head 105 a, being thereby compressed. As a result, the ink container 1 is subjected to the pressure generated by the absorbent member in the ink outlet 7 in the direction indicated by an arrow mark z in FIG. 4( c ), that is, the upward pressure. However, this upward pressure generated by the ink absorbent member is negated by the ink container anchoring first portion 155 in engagement with the ink container anchoring first portion 5 , and the ink container anchoring second portion 156 in engagement with the ink container anchoring second projection 6 . In other words, the state of the ink container 1 shown in FIG. 4( c ) is the state of the ink container 1 at the completion of the mounting of the ink container 1 into the recording head unit 105 . In this state, the ink outlet 7 and ink inlet 107 are in contact with each other, and so are the pad 102 and connector 152 . As described above, during the mounting of the ink container 1 , the above described reactive force acts on the ink container. Therefore, if the ink container 1 is released before the ink container anchoring second portion 6 of the latching lever 3 engages with the ink container anchoring second portion 156 , in other words, before the mounting of the ink container 1 is completed, the ink container 1 will pop up from the holder 150 because of the pressure generated by the ink absorbent member in the direction indicated by the arrow mark z, that is, the direction to push the ink container 1 upward, informing an operator of the incomplete mounting of the ink container 1 , and therefore, ensuring that the ink container 1 is satisfactorily mounted. In addition, the fact that the surface of the ink container anchoring portion 6 , which remains in contact with the top edge of the back wall of the holder 150 , is tilted so that the closer to the bottom wall of the ink container 1 , that is, the wall having the ink outlet 7 , a given point of the surface is, the closer to the container proper the given point of the surface is, also contributes more or less to the upward force which causes the ink container 1 to pop up if the ink container 1 is released before the completion of the mounting of the ink container 1 .
[0055] Also when the ink container 1 is in the state shown in FIG. 4( c ), the ink remainder detection portion 17 , in the form of a prism, of the bottom wall of the ink container 1 opposes the ink remainder amount detection sensor of the main assembly (holder 150 ) of the recording apparatus. Thus, it is possible for the beam of the light emitted from the light emitting portion to enter the ink remainder detecting portion 17 in the form of a prism, be reflected (deflected) by the first surface of the portion 17 , be reflected (deflected) by the second surface of the portion 17 , and then, enter the light receiving portion of the sensor.
[0056] To describe the movement of the ink container 1 , shown in FIG. 4( c ), which occurs during the mounting of the ink container 1 into the recording head unit 105 , compared to the principle of action of a lever, the contact point between the ink container anchoring first portion 5 of the ink container 1 and the ink container anchoring first portion of the holder 150 constitutes the fulcrum, and the point of the front side of the ink container 1 , by which the ink container 1 is pressed by an operator constitutes the force application point. Further, the contact point (area) between the ink outlet 7 and ink inlet 107 constitutes the point of action, which is located between the point of force application and fulcrum, preferably being near the fulcrum so that as the ink container 1 is rotationally moved into the holder 150 , the ink outlet 7 is pressed onto the ink inlet 107 by a substantial amount of force. Generally, the joint portion (opening) of the ink outlet 107 is fitted with a combination of a filter and a relatively flexible and elastic member, such as a piece of absorbent material, a seal, or the like, in order to ensure that ink is allowed to flow from the ink container 1 to the recording head 105 a, and that ink does not leak from the joint between the ink container 1 and recording head 105 a.
[0057] In view of the purpose of mounting the ink container 1 into the recording head unit 105 (holder 150 ), it is desirable to employ such a structural arrangement and an ink container mounting process as those described above for applying a relatively large amount of force in order to elastically deform the portions of the ink container 1 relevant to the formation of the ink passage between the ink container 1 and recording head 105 a, and the prevention of ink leakage from the joint between the ink outlet 7 and ink inlet 107 . Further, after the completion of the mounting of the ink container 1 into the recording head unit 105 , the ink container 1 is prevented from becoming loose from the holder 150 , by the ink container anchoring first portion 5 having engaged with the ink container anchoring first portion 155 , and the ink container anchoring second portion 6 having engaged with the ink container anchoring second portion 156 . Therefore, the aforementioned elastic members remain properly compressed (elastically deformed); for example, the absorbent member in the ink outlet 7 remains optimally compressed by the ink inlet 107 (combination of filter and tip of ink outlet, if tip of ink inlet 107 is fitted with filter), or the sealing member fitted around the tip of the ink inlet 107 remains optimally compressed by the ink outlet 17 (if the tip of the ink inlet 107 is fitted with the sealing member).
[0058] On one hand, the pad 102 and connector 152 are metallic members which are relatively high in rigidity, and highly conductive of electricity, and a high level of electrical conductivity must be established between them. On the other hand, applying an excessive amount of pressure to achieve such a level of conductivity is not desirable from the standpoint of damages and durability. Thus, in this embodiment, the pad 102 and connector 152 are placed as far away as possible from the fulcrum, that is, they are placed in the adjacencies of the front wall of the ink container 1 , in order to optimize the contact pressure between them, that is, make the contact pressure as small as possible without jeopardizing the conductivity.
[0059] More specifically, the contact pad 102 is disposed on the external surface of the slanted wall 130 extending from the farthest point of the bottom wall of the ink container 1 from the ink container anchoring first portion 5 . Therefore, when mounting the ink container 1 into the holder 150 , the contact pad 102 comes into contact with the connector 152 right at the end of the process of mounting of the ink container 1 into the holder 150 .
[0060] With the provision of the above described structural arrangement, the force generated by the contact pressure between the contact pad 102 and connector 152 in the direction of the ink container anchoring first portion 5 (direction of arrow mark y) is a component of the force F generated by the contact pressure between the contact pad 102 and connector 152 in the direction perpendicular to the slanted wall 130 . In other words, the above described structural arrangement can minimize the problem, mentioned in the description of the Japanese Laid-open Patent Application 2001-253087, that is attributable to the relationship between the amount of the resiliency of the latching lever and the amount of the contact pressure between the contact pad 102 and connector 152 ; it virtually eliminates the problem, ensuring that the contact pad 102 and connector 152 are correctly connected to each other in terms of electrical conductivity.
[0061] In addition, according to the above described structural arrangement, the relationship between the positional relationship between the contact pad 102 and the ink container anchoring second portion 6 of the latching lever 3 , and the positional relationship between the connector 152 of the holder 105 and the ink container anchoring second portion, is such that the contact pad 102 comes into contact with the connector 152 immediately before the completion of the process of mounting the ink container 1 into the holder 150 , causing thereby the contact pressure between the contact pad 102 and connector 152 to be generated after the completion of the process (after completion of engagement between ink container anchoring second portion 6 and ink container anchoring second portion 106 of holder 150 ). Therefore, it is extremely unlikely that the ink container 1 will fail to be precisely positioned in the holder 150 as described above, and/or that ink fail to be satisfactorily supplied to the recording head due to the misalignment between the ink outlet 7 of the ink container 1 with the ink inlet 107 of the holder 107 . In addition, the above described structural arrangement ensures that the ink container 1 is precisely positioned relative to the electrical contacts of the connector. Therefore, the contact pressure remains stable, eliminating the possibility that connective failure will occur in terms of electrical conductivity. Further, the above described structural arrangement prevents the ink remainder detecting portion 17 in the form of a prism from deviating in position. Therefore, the possibility is extremely small that the ink remainder amount will not be detected at all or will be incorrectly detected due to the misalignment between the light path and light receiving portion of the ink remainder detecting portion 17 .
[0062] Further, the above described structural arrangement in accordance with the present invention can solve the problems that occur when the structural arrangement disclosed in Japanese Laid-open Patent Application 2-178050 is employed without modifications, that is, the problem that occurs as the information storage medium and/or contact pad is placed on the bottom surface of an ink container, in other words, the problems that during the mounting of an ink container, the ink outlet comes into contact with the connector; and/or that short circuit occurs because of the ink leakage from the ink outlet, or the like. The reason why the abovementioned problems are solved is all because the connector 152 in this embodiment is located at a level which is a step higher from the bottom wall of the holder 150 .
[0063] Moreover, in the case that the information storage medium and/or compact pad is placed on the bottom surface of the ink container, even if they are positioned as far as possible from the first ink container anchoring portion, that is, in the immediate adjacencies of the front wall of the ink container, the electrical contacts of the ink container and the electrical contacts of the holder come into contact with each other, while squarely facing each other, immediately before the completion of the process of mounting the ink container. In this case, therefore, in order to ensure that the satisfactory electrical connection is established between the ink container and holder regardless of the surface conditions of the electrical contacts on both sides, the ink container must be mounted with the application of a substantial amount of pressure, and the application of a large amount of pressure may result in the application of an excessive amount of pressure on the electrical contacts.
[0064] In comparison, in the case of the structural arrangement in this embodiment, strictly in terms the balance between the amount of the reactive force (generated in vertical direction) applied to the pad 102 by the connector 152 , at the contact point between the pad 102 and connector 152 as a certain amount of force is applied to the ink container 1 in order to move the ink container 1 vertically downward, and the amount of the force applied to the ink container 1 , the reactive force to which the pad 102 is subjected is the component of the force generated (in the direction perpendicular to the slanted surface 130 ) by the contact pressure between the connector 152 and pad 102 . Therefore, the amount by which the pressure being applied downward to the ink container 1 increases at the end of the process of mounting the ink container 1 when electrical connection is established between the electrical contacts of the circuit board and the electrical contacts of the holder, is small, and therefore, does not drastically reduce the efficiency with which the ink container 1 is mounted by a user.
[0065] Also, according to the structural arrangement in this embodiment, as the ink container 1 is pressed to be placed into the final position (in which ink container anchoring first and second portion 5 and 6 of ink container engage with ink container anchoring first and second portions 105 and 106 , respectively, of holder 150 ), a component force (which causes pad 102 to slide on connector 152 ) is generated by the pressure applied to the ink container 1 in the direction parallel to the primary flat surface of the circuit board 100 , ensuring that the process for mounting the ink container 1 ends as satisfactory electrical connection is established between the pad 102 and connector 152 .
[0066] Also in the case of the structural arrangement in this embodiment, the contact pressure between the pad 102 and connector 152 does not occur until immediately before the completion of the mounting of the ink container, in other words, until the very end of the precise positioning of the ink container 1 . Therefore, if the operation for mounting the ink container 1 is stopped before the ink container anchoring second projection 6 of the latching lever 3 reaches the hole 157 (ink container anchoring second portion) of the holder 150 , the ink container 1 is popped up by the combination of the component force of the force generated by the resiliency of the latching lever 3 , the slanted surface (of ink container anchoring second projection 6 ) of which is in contact with the top edge of the front wall of the holder 150 , and the reactive force resulting from the pressing of the ink outlet 7 upon the ink inlet 107 . Therefore, should the ink container 1 be incompletely mounted, a user will be informed that the ink container 1 has not been completely mounted.
[0067] As described above, according to this embodiment of the present invention, the ink container 1 is provided with the resilient member (latching lever), which keeps the ink container pressured toward the referential point (ink container anchoring first portion, or contact point between ink container anchoring first portion and corresponding portion of holder) on the back surface of the ink container, and the circuit board having the information storage medium, and/or contact pad, is positioned between the referential point and resilient member, in terms of the horizontal direction. Therefore, the ink container is more precisely positioned relative to the holder, ensuring that the connector and contact pad are precisely positioned relative to each other. Therefore, the electrical contacts of the ink container are reliably connected to the electrical contacts of the holder, in terms of electrical conductivity. This, in turn, makes it possible to minimize the size of the contact pad, making it thereby possible to reduce the size of the circuit board on which the information storage medium is mounted. In other words, it is quite reasonable to say that the structural arrangement in this embodiment is superior to that in accordance with the prior art, in consideration of various factors in the design of the ink container and the holder therefor, for example, the amount of force necessary to be applied to an ink container when mounting the ink container, operability of an ink container, reliability in the state of electrical contact, protection of electrical contacts from ink leak, etc.
[0068] FIG. 17 shows another embodiment. An aspect of the present invention is particularly directed to the position of the contact pad 102 . In this embodiment of the present invention, the information storing medium 104 is disposed at another place, more particularly, at a top side, in use, or at a position facing the supporting member. In such a case, an electrode 103 or lead is extended from the information medium 104 to the contact pad 102 which is located at the position according to the aspect of the present invention.
1-3 Application of Present Invention to Ink Jet Recording Apparatus
[0069] Next, an example of a recording head, and also, an example of an ink jet recording apparatus, in which the ink container in the above described first embodiment is mountable, will be described.
[0070] FIG. 5 is a perspective view of an example of a recording head unit structured so that the ink container in the first embodiment of the present invention is removably mountable, and FIG. 6 is a perspective view of a set of ink containers removably mountable in the recording head unit shown in FIG. 5 . FIG. 7 is an external perspective view of an example of an ink jet recording apparatus in which the recording head unit shown in FIG. 5 and the set of ink containers shown in FIG. 6 are mounted for recording, and FIG. 8 is a perspective view of the ink jet recording apparatus shown in FIG. 7 , the main assembly cover of which is open.
[0071] Generally, the recording head unit 105 is made up of the holder 150 for removably holding four ink containers 1 K, 1 C, 1 M, and 1 Y, which correspond to inks of black, cyan, magenta, and yellow colors, respectively, and the recording head 105 a attached to the underside of the holder 150 to eject the four color inks. As any of the four ink containers is mounted into the holder 150 , the ink outlet 7 of the ink container couples with the ink inlet 107 of the recording head attached to the underside of the recording head unit 105 , creating an ink passage between the ink container and recording head unit 105 .
[0072] As the recording head 105 a, it is possible to employ a recording head in which electrothermal transducing elements are disposed within the nozzles (liquid paths), and the pressure resulting from the change in the phase of ink, that is, the pressure resulting from the bubbling (boiling) of ink, caused by the application of thermal energy generated by applying electrical pulse to the electrothermal transducing elements is used for ink ejection. As for the transmission of the electrical pulses to the electrothermal transducing elements of the recording head 105 a, the electrical contacts (unshown), with which the carriage 205 , which will be described later, is provided for the signal transmission are placed in contact with the electrical contacts portion 157 of the recording head unit 105 , making it possible for recording signals to be transmitted through the wiring 158 to the circuit of the recording head 105 a for driving the electrothermal transducing elements of the recording head unit 105 . Designated by a referential number 159 is a set of wires extending from the electrical contacts 157 to the connector 152 .
[0073] The four ink containers of the ink container set are virtually the same, except that they are different in the color of the inks they store, and also, that the ink container 1 K for storing black ink is larger in the widthwise dimension than the other three. More specifically, each ink container has a latching lever 3 having an ink container anchoring second portion (rib) 6 attached to the front surface of the ink container 1 , an ink outlet 7 with which the bottom wall of the ink container 1 is provided, an ink remainder amount detecting portion 17 , in the form of a prism, with which the bottom wall of the ink container 1 is provided, a circuit board 100 and/or contact pad attached to the external surface of the slanted wall 130 connecting the bottom and front wall of the ink container 1 , and an ink container anchoring first portion (projection, or rib) 5 projecting from the rear wall of the ink container. These ink containers 1 K, 1 C, 1 M, and 1 Y are removably and independently mountable in the holder 150 .
[0074] FIG. 7 is an external perspective view of the ink jet printer 200 in which the above described ink containers are mounted for recording. FIG. 8 is an external perspective view of the ink jet printer 20 , shown in FIG. 7 , the main assembly cover of which is open.
[0075] Referring to FIG. 7 , the printer 200 in this embodiment comprises a recording unit 105 , ink containers 1 , a main assembly, a delivery tray 203 , and an automatic sheet feeding apparatus 202 . The main assembly comprises: the carriage 205 on which the recording unit 105 and ink containers 1 are mounted; mechanism for reciprocally moving the carriage, for recording; a main assembly cover 201 ; and various portions of external casing, which cover the mechanism for reciprocally moving the carriage. It also comprise a display panel, which is visible whether the main assembly cover is open or closed, and a control panel 213 having a power switch and a reset switch.
[0076] Referring to FIG. 8 , when the main assembly cover 201 is open, a user can see the recording head unit 105 , ink containers 1 K, 1 Y, 1 M, and 1 C, carriage 205 having an IC, moving range of the carriage 205 , and their adjacencies. In reality, as the main assembly cover 201 is opened, the sequence for moving the carriage 205 to roughly the center (which hereinafter may be referred to as container replacement position) of its moving range is automatically carried out, making it possible for the user to replace any or all of the ink containers.
[0077] The recording head unit 105 of the printer in this embodiment is provided with four recording heads 105 a ( FIG. 4 ) corresponding to four inks, one for one, different in color. Recording is made as the four recording heads 105 a borne on the carriage 205 are reciprocally moved by the reciprocal movement of the carriage 205 along the surface of the recording medium such recording paper while ejecting ink in response to recording signals. More specifically, the carriage 205 is engaged with a guiding shaft 207 extended in the moving direction of the carriage 205 , being enabled to slide along the guiding shaft 207 , and is reciprocally moved by the combination of the carriage motor and driving force transmitting mechanism. The black, cyan, magenta, and yellow inks are ejected from the corresponding recording heads according to the ejection data sent from the control circuit of the main assembly through a flexible cable 206 . Further, the main assembly is provided with a paper conveying mechanism comprising paper conveying rollers, discharge rollers, etc., being enabled to convey recording mediums (unshown) fed from the automatic sheet feeding apparatus 202 , to the delivery tray 203 . The carriage 205 is structured so that the recording head unit 105 integral with the ink container holder is removably mountable on the carriage 205 . The ink containers 1 are removably mountable into the recording head 105 .
[0078] As for the recording operation of this printer, while the recording head is moved by the above described movement of the carriage 205 , in a manner to scan the surface of the recording medium, it ejects ink therefrom, recording thereby on the recording medium by a predetermined width matching the length of the line of ejection orifices of the recording head. During the interval between a given scanning movement of the recording head unit 105 in the direction perpendicular to the direction in which recording medium is to be conveyed, and the following scanning movement of the recording head unit 105 , the recording medium is conveyed in the direction perpendicular to the direction in which the recording head unit 105 is reciprocally moved, by a distance equal to the scanning width of the recording head unit 105 in terms of the direction parallel to the recording medium conveyance direction. As a result, recording is incrementally made on the recording medium by the width equal to the scanning width of the recording head unit 105 . The main assembly is provided with an ejection performance recovery unit comprising a cap for covering the surface of each recording head having the ejection orifices. The ejection performance recovery unit is located at one end of the range across which the recording head unit 105 is moved by the movement of the carriage 205 . The recording head unit 105 is moved for every predetermined length of time to the position in which it opposes the recovery unit, and in which it is subjected to the performance recovery procedure such as preliminary ejection.
[0079] The number of ink containers employed by an ink jet recording head, manner in which color ink is stored in an ink container, structures of a recording head and an ink jet recording apparatus to which ink containers are attached, do not need to be limited to the above described ones.
[0080] For example, referring to FIG. 9 , an ink jet recording apparatus may be structured so that three (for example, three containers for cyan, magenta, and yellow inks, one for one) of the four color ink containers such as those in the first embodiment are mounted in the same holder, or attached to the same recording head unit. Further, referring to FIG. 10 , an ink container may be provided with two ink outlets 7 A and 7 B. In this case, the internal space of the ink container may be divided into two separate ink chambers, in which two inks different in tone are stored one for one. In this case, obviously, the structures of the holder and recording head unit have to be modified to accommodate such an ink container. Further, referring to FIG. 11 , the ink outlet of an ink container may be off-center, as long as it can be satisfactorily connected to the ink inlet of a recording head unit.
[0081] Regarding the tone of ink, single ink with a specific tone, or two or more inks which are identical in color, but different in tone, may be used. When using multiple inks different in color, the number of inks different in color may be four as it was in the above described embodiment, or may be just three. Further, two or more inks which are the same in color, but different in tone, may be employed for each color component, in addition to, or in place of, inks different in color; for example, cyan and magenta inks which are lighter in tone. Further, inks different in color from the abovementioned ones may be employed in addition to the abovementioned one; for example, red, green, and blue inks. Regarding the type of liquid to be stored in an ink container, such ink (liquid) that contains ingredients for better fixing an image to recording medium, improving color development, and/or improving image durability, may be stored, in addition to the ordinary ink, that is, liquid which contains coloring ingredients.
2. Additional Embodiments
[0082] The above described embodiment of the present invention is not intended to limit the scope of the present invention. Rather, the present invention can be embodied in various forms within the intent of the present invention.
[0083] In the above described first embodiment, the ink container is provided with a springy latching member as the ink container anchoring second member which extends diagonally upward from the bottom portion of the external surface of the front wall of the ink container. As the ink container is mounted into the holder, the latching member is elastically deformed by the force applied to mount the ink container into the holder, keeping thereby the ink container pressured toward a predetermined referential point for mounting the ink container. However, the position, shape, direction in which force is generated by the latching member, of the latching member are optional.
[0084] FIGS. 12( a )-( c ) are schematic sectional views of the combination of the ink container and holder in another embodiment of the present invention, showing the springy latching member thereof for keeping the ink container pressured toward the predetermined referential point for mounting the ink container, being different in structure from the one in the first embodiment, and also, showing the operation for mounting the ink container into the holder. In the case of this combination, the latching member 303 as a member for keeping the ink container 301 pressured toward the predetermined referential point extends diagonally downward from the top end portion of the front wall of the ink container 301 to take the force applied to mount the ink container. The latching member 303 is resiliently deformable in the direction indicated by an arrow mark c in FIG. 12( a ).
[0085] The ink container 301 is also provided with an ink container anchoring first portion 305 , which is on the external surface of the back wall of the ink container 301 , and an ink container anchoring second portion 306 , which is on the free end portion of the latching member 303 . Designated by a referential symbol 303 g is a rib which can be used by a user to manipulate the ink container 301 when the user mounts the ink container 303 . The bottom wall of the ink container 301 is provided with an ink outlet 307 . The bottom portion of the front end of the ink container 301 are structured so that the front and bottom walls of the ink container 301 are connected by a slanted wall 430 , to the external surface of which a circuit board and a contact pad are attached. In FIG. 12( a ), the virtually the entirety of the internal space of the ink container 301 is filled with a porous member 315 capable of absorbing and retaining ink, although the ink container 301 may be structured so that the porous member 315 occupies a part of the internal space of the ink container 301 as in the first embodiment. Referring to FIGS. 12( b ) and 12 ( c ), the recording head unit 405 in this embodiment is structured so that its ink passage between the ink inlet 407 and the recording head 405 a vertically extends downward from the ink inlet 405 and then, horizontally bends, and also, so that the ink is virtually horizontally ejected from the recording head 405 . However, the direction in which ink is to be ejected is optional.
[0086] The procedure for mounting the ink container 301 into the holder 450 of the recording head unit 405 is as follows: First, the ink container 301 is to be inserted into the ink holder 450 from above ( FIG. 4( a )) so that the ink container anchoring first portion 305 in the form of a projection is put through the ink container anchoring portion 455 , that is, a through hole, of the holder 450 . Then, the ink container 301 is to be pushed down in the direction indicated by an arrow mark P by the top end of the front wall of the ink container 301 , with the latching lever 303 being rotating in the direction indicated by an arrow mark c by pressing the rib 303 g in order to prevent the ink container anchoring second portion 306 from interfering with the ink container anchoring second portion 456 of the holder 450 . Further, in order to allow the ink container 303 to smoothly rotate about the ink container anchoring first portion 305 in the direction indicated by an arrow mark R, it is possible to have the tip of the ink container anchoring second portion 306 and the tip of the ink container anchoring second portion 456 chamfered.
[0087] As the ink container anchoring second portion 306 is lowered to the recess 457 located below the ink container anchoring second portion 456 , the former is fitted into the latter by the resiliency of the latching lever 303 , anchoring thereby the ink container 301 while the resiliency of the latching lever 303 keeping the ink container 301 pressured toward the back wall of the holder 450 , keeping thereby the ink container in contact with the back wall of the holder 450 . During this process of mounting the ink container 301 into the holder 450 , which is similar to that in the first embodiment, the ink outlet 307 of the ink container 301 is coupled with the ink inlet 407 of the recording head unit (holder 450 ), and the circuit board or contact pad 402 disposed on the external surface of the slanted wall 430 of the ink container 301 is reliably placed in contact with the connector 452 disposed on the internal surface of the slanted wall portion 456 of the recording head unit (holder 450 ).
[0088] The shape of the springy member, or latching lever, for keeping the ink container pressured does not need to be in the form of a cantilever like the one in the second embodiment; it is optional. FIG. 13 shows one of the optional forms for the springy member. In this case, the springy latching lever 30 is virtually the same in shape as the latching lever 3 in the first embodiment, having the ink container anchoring second portion 6 , except that the free end of the latching lever 30 is connected to the ink container 301 with a flexible member.
[0089] In the preceding embodiments, the resilient latching levers were structured so that the ink container was pressured by the resiliency of the latching lever straight toward the referential point (ink container anchoring first portion of holder, or internal surface of back wall of holder) for mounting an ink container. However, the direction in which pressure is to be applied by the resiliency of the latching member is optional; it should be determined according to the position, structure, etc., of the referential portion.
[0090] FIG. 14 shows one of the optional structural arrangements for an ink container and holder therefor. It is roughly the same as the one shown in FIG. 12 , except that the latching portion 306 a as the ink container anchoring second portion of the latching lever 303 a of the ink container 301 , and the ink container anchoring second portion 456 a of the holder 450 , are structured so that the former fits into the recess 457 a of the latter from outward side of the holder to anchor the ink container 301 to the holder.
[0091] Further, in the preceding embodiments, the ink container was to be inserted vertically downward into the holder. However, the direction in which the ink container is to be inserted is also optional.
[0092] FIG. 15 shows one of these options. In this case, the ink container 1 identical in structure to the one in the first embodiment is to be horizontally pushed into the holder 550 of the recording head unit 505 . The positional relationship between the various portions of the ink container and the ink container anchoring first portion 5 is the same as that in the first embodiment, and so are the manner in which the contact pad 102 is placed in contact with the connector 552 of the holder through the rotational movement of the ink container 1 in the direction indicated by an arrow mark R about the ink container anchoring first portion 5 put through the ink container anchoring first portion of the holder, the manner in which the ink outlet 7 of the ink container 1 is coupled with the ink inlet 507 of the recording head unit 505 , and the manner in which the ink container anchoring second portion 6 of the ink container 1 fits into the recess 157 of the back wall of the holder 550 , are also the same as those in the first embodiment. Incidentally, this recording head unit 505 ejects ink vertically downward, and the ink passage from the ink inlet 507 of the recording head unit 505 to the recording head 505 a is bent as indicated by the dotted line.
[0093] Also in the case of the structural arrangement shown in FIG. 15 , the contact pad 102 is located above the level of the point of ink leakage from the ink outlet 7 , eliminating the possibility that the leaked ink will travel to the contact pad 102 .
[0094] Further, in the preceding embodiments, the springy latching member for keeping the ink container pressured toward the referential portion for mounting the ink container is provided on the ink container side. However, it may be a third member independent from the ink container and recording head unit. More specifically, it may be such an independent member which is V-shaped in cross section, having a first arm portion which is to be placed in contact with the external surface of the front wall of an ink container and has a latching portion, and a second arm portion which has a latching portion to latch with the catch portion on the internal surface of the front wall of the holder. The amount of its resiliency is determined by the angle formed by the two arm portions. It is to be inserted into the gap between the front wall of the ink container and the front wall of the holder, at the end of the process of mounting the ink container. Or, it may be such an independent third member as the one disclosed in Japanese Laid-open Patent Application 8-230206, which is independent from an ink container, and keeps the ink container pressured downward in coordination with a recording head unit.
[0095] Also in the preceding embodiments, the circuit board or contact pad was disposed on the external surface of the slanted connective wall, which appears as if it were formed by chamfering the bottom front corner of the ink container, between the front and bottom walls of the ink container. However, as long as the force applied to the ink container to mount the ink container can be made to act in the proper direction to establish reliable electrical connection between the ink container and holder, and as long as ink leakage is not concerned, the ink container 1 may be provided with an contact pad mount protruding from the edge between the top and bottom walls of the ink container, as shown in FIG. 16 , and the contact pad 502 may be disposed on the end surface of the contact pad mount.
[0096] Also in the preceding embodiments, the information storage element was disposed on the opposite surface of the circuit board from the surface on which the contact pad is located. However, the information storage element and contact pad may be disposed on the same surface of the circuit board, as long as the information storage element does not interfere while the contact pad is being placed with the connector of the recording head unit. Further, if the preferable location for the circuit board or information storage element is different from the preferable location for the contact pad because of the structure of the ink container and/or the portions thereof for attaching the ink container, the circuit board with the information storage element and the contact pad may be separately disposed on the optimal locations therefor, and connected with wiring. In other words, it is not mandatory that both the information storage and the contact pad are integrally placed on the circuit board.
[0097] Also in the preceding embodiments, the ink container was removably mounted into the recording head unit having the ink container holder. However, the ink container and recording head may be structured to be inseparable. In such a case, the inseparable combination of ink container and recording head is removably mounted in the carriage. The structural arrangement, in the preceding embodiment, for the electrical contacts through which recording signals are transmitted to the recording head, and also, through which the electrical signal reflecting the conditions of the ink container and recording head are exchanged between the combination of the ink container and recording head, and the main assembly, in order to display the conditions, is also applicable, with just as preferable results as those obtained by the preceding embodiments, to the inseparable combination of an ink container and recording head, and the holder therefor.
[0098] Also in the preceding embodiments, the information regarding the ink containers was displayed through the electrical connection between the ink container and main assembly of an ink jet recording apparatus. However, the present invention is also applicable to any mechanical connection, as long as the information regarding the ink containers can be displayed to a user through the mechanical contact between the electrical contacts of the ink containers and those of the main assembly. For example, the mechanical contact between the ink container and main assembly may be for magnetically transmitting information. In such a case, the contact pad is replaced with a magnetic storage means, and the connector is replaced with a magnetic head.
[0099] The preceding embodiments are not intended to limit the structures of the anchoring portions of the ink container and the structure of the holder, to those in the embodiments. For example, instead of providing the holder of the recording head unit with the ink container anchoring second portion and connector, the carriage may be provided with the ink container anchoring second portion and connector. In other words, the ink container anchoring second portion 156 , connector 152 , and wiring 159 for the connector, may be attached to the carriage. In the case of such a structural arrangement, as the recording head unit is mounted into the carriage, the entirety of the anchoring portion of the ink container is realized, and the process of coupling the ink outlet with the ink inlet, and the process of placing the pad in contact with the connector, are completed through the same movement of the ink container as that shown in FIG. 4 .
[0100] Further, the addition of the following features, which will be described next, to the ink container in accordance with the present invention further improves an ink jet printer in usability.
[0101] Generally, an ink container is filled with ordinary ink. The ink to be filled into an ink container may be pigment ink or dye ink. The color of the ink to be filled into an ink container may be red, green, blue, etc., in addition to black, yellow, magenta, and cyan. Regarding the tone of ink, cyan and magenta inks lighter in tone than the ordinary cyan and magenta inks may be employed in addition to the abovementioned ones. Further, an ink container may be filled with solution for treating ink and/recording medium for improving ink and recording medium in fixation, color development, durability, and the like properties.
[0102] An ink jet printer designed so that it can employ three to eight ink containers among the abovementioned ink containers different in the color and tone of the inks they store can yield an image comparable to a photographic image.
[0103] Incidentally, in the case of an ink container, such as the one shown in FIG. 3 , the internal space of which is divided into a first chamber in which ink is directly stored, and a second chamber in which ink is stored in the ink absorbent member packed in the chamber, if the ink absorbent member is made up of two pieces of ink absorbent members which are vertically stacked (interface of which is located above passage through which gas (air) is introduced from the second chamber to the first chamber), the ink container is desired to be filled with ink by an amount enough for the ink to completely fill the entirety of the bottom piece of the absorbent member and reach the interface between the top and bottom pieces. Filling the ink container by the amount described above can prevent the occurrence of such a situation, during the distribution of an ink container, that the ink in the first chamber travels into the second chamber and leaks out of the ink container through the air vent of the ink container.
[0104] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0105] This application claims priority from Japanese Patent Application No. 435940/2003 filed Dec. 26, 2003, which is hereby incorporated by reference.
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A liquid container detachably mountable to a mounting portion of an apparatus, the mounting portion including a first locking portion and a second locking portion, the liquid container including a casing for containing liquid and a supply port for supplying the liquid to an ink jet head, the liquid container includes a first engaging portion provided at a first side of the casing and engageable with the first locking portion; a second engaging portion provided opposed to a second side of the casing which is opposite the first side, the second engaging portion being engageable with the second locking portion; a supporting member for displaceably supporting the second engaging portion; a contact contactable to a member provided in the mounting portion to permit information display means to display information relating to the liquid container, wherein the supply port is disposed in a third side of the casing which is between the first side and the second side, and the contact is disposed at a corner region between the second side and the third side.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 08/611,594 filed on Mar. 8, 1996 by the applicant herein, and issuing as U.S. Pat. No. 5,771,157 on Jun. 23, 1998.
BACKGROUND OF THE INVENTION
It is well known that microcircuits are intricate and delicate articles whose performance depends on maintaining the functions provided by extremely small circuit features. Reliable operation depends on protecting the entire microcircuit from environmentally caused harm arising from sources such as mechanical damage, corrosion caused by moisture and airborne chemical vapors, and particulate contamination. This invention provides for lower manufacturing cost of printed circuit board assemblies using a known type of structure for protecting individual microcircuits from damage arising from environmental sources after manufacturing is done. The invention does not compromise either the level of protection or the operating characteristics.
Microcircuits are most frequently formed on a silicon wafer by photolithographic processes. Typically there will be hundreds of individual microcircuits formed on the wafer by a series of photolithographic steps. After the photolithographic process steps are completed and the microcircuits have been formed, the wafer is sliced by a diamond saw to form a number of small rectangular dice, each carrying (usually) a single microcircuit. In the manufacturing process, small connection pads around the periphery of the actual circuit are formed as a part of the microcircuit's conductors, and these are present on the individual dice. Thin wires are bonded to these connection pads and to other pads off the die itself for connecting the microcircuit to other devices which provide signals and power to the microcircuit, or use the signals which the microcircuit generates. As is well known of course, microcircuits are usually mounted on and electrically connected to a printed circuit board. Depending on its type there will be as many as several hundred individual connections from a microcircuit to the circuit board on which it is mounted.
The need to protect individual microcircuits from external damage was mentioned above. This protection can be provided by enclosing the microcircuit within a package of some type. When such a package is used, it will have external pins or pads of some kind which are internally connected to the microcircuit, and by which the microcircuit makes its external connections. These connections can take a variety of forms. Pins or legs extending from the package surface can be connected to printed circuit wiring either by soldering or by mounting in a permanent socket mounted on the printed circuit board. External connection pads are usually placed around the outer edge of the package; these also can either be soldered to properly positioned pads on the printed circuit board, or the entire package can be inserted in a socket which has spring contacts which press against the pads. A socket is used where it may be desirable to remove the microcircuit from the circuit board at a later time.
While pre-packaging microcircuits in individual packages during the initial manufacturing process makes them easy to ship and mount, there are some disadvantages. In the first place at least one extra connection for each microcircuit pad is required. Secondly, additional area on a printed circuit board must be allotted for each microcircuit package, which is a problem if space constraints are important. Thirdly, the additional steps in the mounting process may add to the cost. That is, other things being equal, the microcircuit mounting part of the process involves additional steps in mounting the individual microcircuit in the package, and then mounting the package itself on the printed circuit board. Each of these process steps is likely to add cost and reduce yield/reliability. Eliminating any of these steps has the potential to reduce cost and increase yield. Accordingly, there has been motivation to develop a means of microcircuit connection which omits as a part of the microcircuit manufacturing process, the step of packaging individual microcircuits.
This alternate type of microcircuit connection has been realized in the process known as chip-on-board (COB) surface mounting. Briefly, in this process a die cut conventionally from a wafer and carrying a completed microcircuit with exposed connection pads is mechanically attached to a printed circuit board, typically with an adhesive. Then leads are attached between the microcircuit's connection pads and the corresponding pads on the circuit board. Lastly, some type of mechanical protection for the microcircuit and the leads is applied. The COB process as presently practiced mounts a microcircuit in perhaps 30-50% less area on the printed circuit board than the same microcircuit when mounted as pre-packaged component. This is an important advantage because the application may not permit a larger printed circuit board and in any case, a smaller board is cheaper.
There is a definitive discussion of the COB process in the publication ANSI/IPC-SM-784, Guidelines for Chip-on-Board Technology Implementation, dated November 1990, and available from the Institute for Interconnecting and Packaging Electronic Circuits, 7380 N. Lincoln Ave., Lincolnwood, Ill. 60646 (hereafter "the Guidelines"). The remainder of this disclosure assumes the reader to be familiar with the Guidelines.
The printed circuit board used in COB mounting may be made either from an inorganic material such as a ceramic, or from an epoxy or other organic material. Because organic printed circuit boards are cheaper, it is preferred to use them unless some special factor requires use of inorganic printed circuit boards. Of the organic materials used for printed circuit boards, cellulose epoxy mat (CEM) is among the least expensive, but is also among the most sensitive to heat. A designation for a type of generic CEM board material is CEM-1 . 100% epoxy mat is a more expensive board material that has advantages where conductor paths on both sides are necessary. FR-4 is a generic term for 100% epoxy mat. Because of its low price and generally good performance, CEM is usually preferred if compatible with the manufacturing processes required and the usage expected. CEM and 100% epoxy mat boards have a foil layer from which are etched the conductors which electrically connect the components carried on the board. Most often, the foil layer is formed of copper because of its outstanding electrical and heat conductivity. Areas of the foil conductors form connection pads to which the wires from the microcircuits are attached.
The Guidelines describe three different connection processes for electrically connecting the die's connection pads to the printed circuit board pads. These are thermocompression, thermosonic, and ultrasonic wire bonding. These processes rely on at least one of pressure, heat and vibration to form a bond between individual wires and pads. The Guidelines explain these processes and their advantages and disadvantages. Briefly, which of these processes to use in a particular situation depends on a number of factors, such as the number of interconnections to be made, the reliability required, the type of use to which the printed circuit board will be put, the density of the microcircuits on the board, etc.
Ultrasonic bonding, also called wedge bonding, is often preferred because it is overall the cheapest, under the proper conditions it makes a very satisfactory connection, and it does not rely on external heating of the parts. Wedge bonding uses a wedge-shaped bonding tool to press the wire strongly against the pad. High frequency acoustic energy without external heat is then applied to the bonding tool which vibrates the wire against the pad to form a mechanical and electrical bond between the wire and the pad. Aluminum wire is customary for use when wedge bonding as usually forming both cheaper and better bonds than gold, the other wire commonly used for chip connection.
Wedge bonding of aluminum wire to the aluminum die pads formed during the photolithographic steps of microcircuit manufacture is a widely accepted technique. The pads on the printed circuit board to which the die pads are electrically connected are part of the copper foil which is etched to form the printed circuit conductor paths on the board. It is known to be quite difficult to consistently form acceptable bonds between aluminum wire and copper pads. For this reason, the Guidelines, p. 11, specify that the copper foil on the printed circuit board must have a gold over nickel coating to create a surface to which the aluminum wire will form an acceptable bond. Even though most of the copper foil and the gold layer on it is removed during the etching process, it is customary to plate the nickel and gold layers on the foil before it is attached to the printed circuit board. The use of the nickel and gold layers allows a good electrical and mechanical connection between the aluminum wire and the copper foil, but the cost of the gold plating on the copper foil is a disadvantage of COB mounting.
I am not familiar with the metallurgical factors which influence those skilled in art to apply the gold and nickel layers to the copper foil before the bonding step. I suspect that yields may suffer and even that longevity of the bond may decrease when the gold and nickel layers are not present. Transactions on Components, Hybrids, and Manufacturing Technology, vol. CHMT-7, No. 4, December, 1984, Effects of Ambient Atmosphere on Aluminum-Copper Wirebond Reliability, by Dennis R. Olsen et al. discusses a mechanism by which the wedge bonded interface between an aluminum wire and a bare copper surface deteriorates over time in a vacuum, but appears to have a relatively long life in the presence of air. The received wisdom with respect to wedge bonding of aluminum wires to the copper pads on printed circuit boards is that a gold layer must be present on the copper surface for high yield and a long-lived bond.
Since the conductor pattern on a printed circuit board is formed by etching a copper foil which is attached to the substrate insulating sheet, this means that the gold layer must be originally applied to the entire printed circuit board surface. It is possible to recover at least some of the gold from the etchant but these steps add cost to the process. In any case, gold remains on the exterior surface of the entire conductor pattern, creating added material cost of the final printed circuit board. Accordingly, there is economic motivation to omit the gold plating on copper surfaces preparatory for wedge bonding aluminum wires to them if bond quality does not suffer.
Mechanical protection of the microcircuit and the connections to it is usually provided by encapsulating or enclosing the entire die and surrounding board with a self-hardening liquid, typically either silicone or epoxy, see the Guidelines, p. 33. Such encapsulation provides excellent protection against mechanical damage and particulate contamination. And while these materials are not completely hermetic, they do limit substantially the amount of air and water vapor which can reach the individual connections between the printed circuit board and the circuitry on the die itself.
To summarize, the apparent present state of the art regarding the processes used for bonding aluminum wire to a copper surface such as in the COB chip mounting process, is to plate a nickel layer on the copper surface, plate a gold layer on the nickel layer, and then wedge bond the aluminum wire to the gold layer surface.
BRIEF DESCRIPTION OF THE INVENTION
I have discovered a variant of the conventional COB process in which the steps creating the gold and nickel layers on the copper preparatory to the aluminum wire to copper bonding step are eliminated. Bonding (preferably ultrasonically) the aluminum wire directly to the copper pad without previously forming nickel and gold layers appears to produce excellent bonds if certain changes are made to the conventional process. The variant process as I presently practice it involves the combination of specific types of materials and specific process steps which are widely used in the production of printed circuit board assemblies. The parts of the COB process which appear to be critical in implementing this disclosure's invention are the selection of the board material, the values of certain parameters in the ultrasonic wedge bonding step for forming the bond between the aluminum wire and the copper connection pad, cleanliness of the copper connection pad, and the materials used in the microcircuit protection step. There appears to be a relationship between the coefficient of thermal expansion (CTE) of the printed circuit board and the microcircuit encapsulant materials used in the ability to reliably form acceptable bonds between an aluminum wire and a bare copper connection pad.
For the laminate of the printed circuit board I use a laminate of a conventional organic material. In the process as presently practiced, I prefer to use the CEM material called CEM-1 which has a CTE of 14-20×10 -6 cm/cm/° C. Based on preliminary tests, I believe that 100% epoxy mat laminate material, i.e. FR-4 (CTE=12×10 -6 cm/cm/° C.) will also be successful. I believe that other materials of which printed circuit boards are commonly comprised, which have a CTE similar to that of CEM-1, and which are otherwise suitable may also be used successfully, although these have not been tested by me. I prefer CEM-1 because it is suitable for the intended application and is less expensive than suitable alternatives.
I use conventional wedge bonding apparatus with some of the settings and adjustments different from the default levels to form the bond between the aluminum wire and the copper connection pad.
For protecting the microcircuit and its connections to the printed circuit board, I have found that particular types of "high purity, low stress liquid encapsulant" resin materials (hereafter "low stress materials") as they are generically termed, appear to be helpful in eliminating the need for the nickel and gold layers in the process. After hardening, these encapsulants have a nominal CTE of approximately 15 (22 maximum) ×10 -6 cm/cm/° C., which is substantially lower than the value of approximately 29×10 -6 cm/cm/° C. for other encapsulants now commonly in use. Particular encapsulants of this type whose use is known by me to successfully allow elimination of the gold and nickel layers are commercially available from The Dexter Corporation, Electronic Materials Div., 15051 East Don Julian Road, Industry, Calif. 91746 as encapsulants type Hysol FP4450, type Hysol FP4451, type Hysol FP4402, and type Hysol FP4650. The process as it is presently practiced uses the FP4450 material.
The specific CTE's for these low stress materials are
______________________________________FP4402 19 (22 maximum) × 10.sup.-6 cm/cm/° C.FP4450, 51 15 (22 maximum)FP4650 12 (15 maximum)______________________________________
At the present time, I believe that the characteristic or characteristics of low stress materials which permits the nickel and gold layers to be eliminated for the most part arises from the fact that the hardened resin which low stress materials form has a CTE very close to that of the CEM-1 board material which I prefer. I believe that similar CTE's reduce the mechanical stress on the bond arising from thermal cycling. A second characteristic, only theoretical at this time, which may be related is that low stress encapsulant materials may have an elastic modulus substantially different from that of CEM-1. I speculate that other types of encapsulants now in use may have an elastic modulus closer to that of CEM-1. It is possible that if one of the materials has a very low elastic modulus, temperature changes in the stiffer material creates less stress at the bond site. A third characteristic, also theoretical at this point, which may also be a factor in the ability to eliminate the gold and nickel layers is that low stress materials may limit the chemical or metallurgical deterioration of the wire bond. Another possible explanation of the phenomenon at work here is that the CTE of the low stress materials simply matches the CTE of aluminum (22×10 -6 cm/cm/° C.) better than other encapsulants presently in use. The low stress materials may have greater dimensional stability during hardening than other encapsulant materials. It may simply be that the lower CTE of low stress encapsulant materials reduces the stress on the individual bonds. Yet another possible cause is that the low stress materials form a stronger bond to the printed circuit board than do other materials. It may be that more than one of these characteristics are essential and that the low stress materials have each of those characteristics necessary. Or there may even be a necessary characteristic of which I am presently unaware. At any rate I have found the use of CEM-1 or FR-4 board material along with low stress encapsulant materials eliminates the need for gold and nickel layers on copper circuit board conductors. I believe the industry is generally unaware of this opportunity to reduce the cost of the assembled circuit.
A circuit board assembly incorporating my invention has a CEM-1 or other laminate formed of organic material and having a predetermined CTE. A bare copper foil is attached to a surface of the board, from which the on-board conductors are formed. A microcircuit element, typically carried on a die, is mounted on the surface of the printed circuit board adjacent to a surface of the bare copper foil. At least one (typically, many more than one) aluminum wire is electrically connected to connection pads on both the microcircuit and the copper foil. There is a bare bonding site on the copper foil for each aluminum wire, to which the aluminum wire is mechanically and electrically connected, typically by ultrasonic bonding. A volume of rigid encapsulant material is bonded to the printed circuit board and encloses and envelops the microcircuit element, the aluminum wire, and the bonding site. The printed circuit board laminate and the encapsulant material have similar CTE's.
A process for manufacturing this circuit board and which incorporates my invention includes the first step of providing a printed circuit board made of material having a predetermined coefficient of thermal expansion and having a bare copper foil attached to a surface thereof. Then a microcircuit element having a connection pad is mounted to the printed circuit board surface adjacent to a surface of the bare copper foil. One end of an aluminum wire is bonded to the connection pad on the microcircuit element. The other end of the aluminum wire is bonded, preferably using ultrasonic bonding, to the bare copper foil. Then the microcircuit element, the wire, and the connection pad on the printed circuit board are all encapsulated with a liquified material which hardens into a rigid encapsulant material having a coefficient of thermal expansion approximately equal to the predetermined coefficient of thermal expansion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a portion of a partially completed printed circuit board assembly showing a single microcircuit mounted thereon and electrically connected to the copper foil thereon, and before the encapsulation step.
FIG. 2 is a plan view of a completed printed circuit board assembly with only the encapsulant visible.
FIG. 3 is a magnified view of a portion of FIG. 1.
FIG. 4 is a cross section view of the portion of the microcircuit and the printed circuit board on which it is mounted, shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a portion of a commercial version of a conventional printed circuit board assembly 10 in partly complete and final form respectively. FIG. 3 is a magnified view of a portion of assembly 10 indicated by ref. no. 3. and in which the invention is shown in more detail. A laminate board 12 made of an organic material carries bare copper foil conductive paths 15 on a first surface thereof. The board 12 is preferably made of cellulose epoxy mat (CEM-1) material if only one side of the board is to have circuit paths. I believe that in the situations where both sides of circuit board 12 have circuit paths then the required more expensive 100% epoxy mat (FR-4) material can be used in practicing my invention. Paths 15 provide the electrical connections between the various electrical components and to the terminals by which the circuit which the components form are connected to off-board conductors.
A microcircuit 30 itself is carried on a silicon die 28 having a bottom surface by which die 28 is attached with a bonding agent to the first surface of board 12. A top surface of die 28 carries the microcircuit 30 which has a plurality of connection pads 32 (see FIG. 3) around the periphery of die 28. The details of microcircuit 30 have been omitted from FIG. 1 but are entirely conventional. Connection pads 32 are usually formed of aluminum. Bare dies 28 carrying microcircuits 30 are available in quantities of any size from most of the large microcircuit manufacturers.
A plurality of aluminum wires 22 form connections from die connection pads 32 of microcircuit 30 to the board connection pads 19 forming a part of paths 15. To avoid cluttering FIGS. 1 and 2, only a few of these wires 22 are shown, but the reader should understand that in most assemblies 10 there is a wire 22 connected between each die connection pad 32 and a corresponding copper connection pad 19. These connections are formed by first wedge bonding 1.25 mil (0.032 mm) aluminum wire 22 onto each of the connection pads 32 and then onto its associated board connection pad 19. Board 12 should be prepared with a short rinse of either ENTEK Micro-Etch ME-1020, or with 100° F. (37.5° C.) 1% sulfuric acid with 85 gms/liter sodium persulfate before the die 28 is mounted. Each of the board connection pads 19 has a bare copper surface to which the bond is made. The wire is used as it comes off the spool and appears to need no special treatment.
After all of the wires 22 have been bonded into place a dam is placed on the laminate 12 completely encircling all of the individual connection pads 19. Liquid low stress material is poured or injected into the space enclosed by the dam. The low stress material hardens over a period of a few hours to form, in combination with the dam, the encapsulant 38 shown in FIG. 2. The reader should understand that in actuality the preferred materials for the encapsulant 38 of a completed assembly 10 is totally opaque after hardening, and circuit features within it cannot be seen by the naked eye. Each of the wires 22, each of the connection pads 19 and 32, and the die 28 are all completely embedded in the encapsulant 38 and protected from damage and contamination. There is in the preferred embodiment about a 30 mil (0.76 mm) thickness of encapsulant 38 above die 28. There should be a thickness of at least 20 mil (0.51 mm) of encapsulant 38 above the feature of the encapsulated components projecting farthest above the surface of laminate 12. A preferred embodiment has the periphery of encapsulant 38 following approximately the shape defined by the individual board connection pads 19, and hence is "squarish" with large radii on the corners. I do not believe the actual shape of encapsulant 38 is critical so long as every one of the board connection pads 19 as well as the space within them are completely surrounded by encapsulant 38 to a depth of at least 20 mil.
FIG. 4 shows in magnified cross section a typical connection between a connection pad 32 and a connection pad 19 and as illustrated in FIG. 3. The encapsulant 38 is shown in dotted outline to illustrate its shape and position after applying to the printed circuit board. The actual aluminum wire to copper pad bond site is present at 35. I find that such bonds made according to the following detailed specification are of quality equal to those made between a gold layer on the copper connection pad and the aluminum wire 22. It is very likely that most of these specific dimensions and other parameter values are not critical, but fall within accepted ranges for the particular dimension or other value. Those dimensions and values which may be critical to the quality of the bond are identified as such.
______________________________________Laminate 12:Material CEM-1Thickness 62 mil (1.57 mm)Connection pad 19 thickness 2.4 mil (.061 mm) nominalConnection pad 19 width 12 mil (.3 mm)Connection pad 19 material Standard bare circuit board copper foilPreparation Short rinse with either ENTEK Micro-Etch ME-1020, or with 100° F. (37.5° C.) 1% sulfuric acid with 85 gms/liter sodium persulfateDie:Material Standard IC siliconThickness 20 mil (.51 mm) nominalLength 180 mil (4.6 mm) nominalWidth 140 mil (3.6 mm) nominalWire:Material 99% Al, 1% SiDiameter 1.25 mil (.032 mm)Length 150 mil (3.8 mm) nominalElongation 1-4%Tensile strength 19-21 gmPreparation As purchasedEncapsulant:Type (from Dexter-Hysol) Hysol FP4450, Hysol FP4402, or Hysol FP4650Thickness 50 mil (1.27 mm) nominalMaximum dimension in plane 0.5-.55 in (12.7-14 mm) nominal______________________________________
The ENTEK cleaning fluid is available from Enthone-OMI, PO Box 1900, New Haven, Conn. 06508. It is a commonly used material for connection pad cleaning as is the sulfuric acid solution.
Bonding was performed with a standard wire bonding unit. The unit used is available from Kulicke & Soffa, 2102 Blair Mill Rd., Willow Grove, Pa. 19090 as Model No. 1470. The ultrasonic generator unit is also provided by Kulicke & Soffa as Model No. 4320A, having a 60 KHZ output. The bonding tool, available from Micro-Swiss div. of Kulicke & Soffa, is made of tungsten carbide and is described as a "wedge/concave-matte" by Micro-Swiss.
There are a number of operator-settable parameters associated with this, or any wire bonding unit. Those settings for attaching the wire 22 to the die 28 connection pads 32 do not affect the quality of the bond to the copper connection pads 19. Those settings for attaching the aluminum wires 22 to the copper connection pads 19 are provided with as much detail as possible in order to allow the process of my invention to be replicated by the public. The "pulse" parameter is a standard value associated with movement of the bonding tool. The wire bonding unit has internally programmed default parameter values; some of the preferred parameter values differ somewhat from the default values.
______________________________________Parameter Al-Cu bond--actual (default)______________________________________Tool inflection point (TIP) 20 (16) pulsesContact velocity (CVL) 8 (3) within permitted range 1-255, where 1 is fastestOvertravel (OVT) 6 (5) pulsesBond time (BTM) 30-40 (40) msecPower setting 2.8-3.8 (2.0) indicated dial gradationsBond force 25-30 gm______________________________________
The bond time, power, and overtravel settings may all be critical values in accomplishing satisfactory bonds. The power setting on the Kulicke & Soffa Model No. 4320A ultrasonic generator is controlled by a dial whose scale indicates settings from 1 to 10. The spectral power value range which corresponds is not available. It may be necessary to experiment briefly in order to determine an appropriate power setting. The bond time is specified in msec. The overtravel and other settings are specified as pulses, for which numerical values are entered into the controller of the Kulicke & Soffa Model No. 1470 bonding machine.
Loop height and clamp closed position parameters apply only to the first bond, made to die connection pads 32. These probably do not affect the aluminum to copper bond on connection pads 19.
The preceding has described my invention and a preferred means for its practice.
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In a process for fabricating a printed circuit board assembly carrying a chip on board type microcircuit package, aluminum wires are bonded to the aluminum pads on the microcircuit and to bare copper connector pads on the printed circuit board to form the electrical connection between them. The microcircuit, aluminum wires, and copper connection pads are then encapsulated with a material such as low stress liquid encapsulant having a thermal expansion coefficient approximately equal to that of the printed circuit board substrate material. Preferably the process includes steps of mounting the microcircuit and forming the copper connector pads on a printed circuit board laminate comprising cellulose epoxy mat such as CEM-1.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of toy projectile launching devices. More specifically, the present invention comprises a projectile launcher which launches a spin-stabilized orb.
2. Description of the Related Art
Toy projectile launchers are commonly used by children for target practice and for war-type games. Projectile launchers come in many forms, such as slingshots, bows, gun-type devices, and a multitude of other devices. Of course, each of those devices typically uses a different type of projectile. For example, a bow uses an arrow as a projectile and a slingshot launches a small round pellet, rock, or water balloon.
In addition, particular launchers are designed to launch different projectiles. As an example, the reader will realize that gun-type projectile launchers are often used to launch a variety of projectiles, including bullets, spherical pellets, cylindrical pellets, and many others. Oftentimes, the type of projectile to be launched decides the mechanism incorporated in the toy launcher. For example, a designer may not employ the same launching mechanism for a flat disk as he or she would for spherical projectile.
Toy projectile launchers currently exist in the art. An example of a projectile launcher is found in U.S. Pat. No. 4,059,089 to Lehman (1977). The Lehman device launches projectiles using a trigger and plunger setup. A similar approach is taken in U.S. Pat. No. 8,336,531 to Fan et al. (2012). In other cases, a device that sprays water may be used as a children's toy.
Oftentimes, the projectile to be launched is fabricated out of a rigid material-such as plastic or wood. A hard projectile material generally assists with the transfer of momentum from the launcher to the projectile, allowing a higher velocity. However, there are obvious safety concerns when dealing with a hard projectile. Thus, toy manufacturers have limitations on the velocity that may be imparted to a hard projectile.
On the other hand, a manufacturer may increase the velocity of a projectile if it is fabricated from a soft and flexible material. Unfortunately, it is typically more difficult to impart a high velocity upon a flexible projectile than it is on a rigid projectile. The deformation of the projectile as the launching mechanism contacts the projectile reduces the momentum transferred to the projectile, thereby reducing the velocity. It is also difficult to stabilize the flight path of a soft projectile. The deformation introduced by the momentum-transferring mechanism tends to remain as the projectile leaves the launcher. This deformation often causes the projectile to tumble in flight. Thus, what is needed is a projectile launcher that (1) limits the reduction of momentum when launching a flexible projectile and, (2) produces a stable flight path for the flexible projectile. The present invention solves this and other problems, as will be described more particularly in the following text.
BRIEF DESCRIPTION OF THE INVENTION
The present invention comprises a toy projectile launching device. The device preferably includes a handle, barrel, muzzle, trigger, cocking shaft, and cocking handle. The device uses a spring loaded shaft in order to launch an orb. In addition, the launching mechanism of the device imparts rotation upon the orb, which stabilizes the orb in flight—thereby achieving an increase in sustained velocity and an increase in the distance traveled. The novel method of launching the orb imparts rotation on a flexible orb, which can be difficult. In addition, this method of launching allows the orb to reach a high velocity despite the flexible nature of the orb material.
In a preferred embodiment, the orb launching device can be cocked and left in the cocked position until the user is ready to fire the device. This is preferably done using a trigger system. In other embodiments the orbs are launched by simply pulling the cocking handle back and releasing it in one continuous sequence.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view, showing a preferred embodiment of the present invention.
FIG. 2 is a perspective view, showing some of the components of the present invention.
FIG. 2B is a perspective view, showing the core in more detail.
FIG. 3 is a sectional view, showing the present invention in an un-cocked state.
FIG. 4 is a sectional view, showing the present invention as it is being cocked.
FIG. 5 is a sectional view, showing the present invention as a user begins to cock the orb launching device.
FIG. 6 is a sectional view, showing the present invention as a user continues to cock the orb launching device.
FIG. 7 is a sectional view, showing the instant when the firing tab enters the helical groove in the core.
FIG. 8 is a sectional view, showing the orb launching device in a fully cocked state.
FIG. 9 is perspective view, showing an alternate embodiment of the core.
FIG. 10 is an elevation view, showing an alternate embodiment of the present invention.
REFERENCE NUMERALS IN THE DRAWINGS
10 orb launching device
12 launcher handle
14 chassis
16 muzzle
18 trigger
19 trigger pivot
20 cocking shaft
22 cocking handle
24 resistance grip
26 core
28 orb
30 central bore of core
32 orb retention rib
34 loading surface
36 helical cut
37 helical rib
38 central bore of orb
39 helical cut extreme
40 cocking shaft screw
42 retention surface
44 cocking spring
46 spring anchor
48 firing tab
50 trigger plunger
52 trigger catch
54 trigger plunger spring
56 catch plunger
58 catch spring
60 vertical wall
61 angled wall
62 main core body
64 orb holder
66 launching shaft
68 cocking knob
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a projectile launching device for use in target practice and other games played using a device which launches soft projectiles. FIG. 1 shows a preferred embodiment. Preferably, orb launching device 10 includes launcher handle 12 , chassis 14 , muzzle 16 , trigger 18 , cocking shaft 20 , and cocking handle 22 . Cocking shaft 20 is configured to slide in and out of chassis 14 . In addition, orb launching device 10 includes resistance grip 24 . Resistance grip 24 preferably allows the user to maintain a sufficient grip while pulling cocking handle 22 back in order to cock orb launching device 10 . The reader will note that resistance grip 24 is shown as a multi-finger grip, but should not be limited to this. Resistance grip 24 could just as easily be a handle or other type of grip similar to launcher handle 12 or like that on a rifle.
FIG. 2 shows orb launching device 10 partially exploded in order to show details of the firing mechanism of orb launching device 10 proximate muzzle 16 . The projectile in this particular embodiment is orb 28 . Core 26 holds orb 28 prior to firing orb 28 . Orb 28 is a solid object defined by a profile revolved about a longitudinal axis of symmetry (a “solid of revolution”). It is preferably made of a pliable material having enough mass so that its momentum will retain reasonable velocity in flight. The orb includes a central bore 38 that is centered on the longitudinal axis.
Preferably, core 26 includes central bore 30 , orb retention ribs 32 , loading surface 34 , and helical cut 36 . FIG. 2B shows core 26 in more detail. The reader will observe how helical cut 36 wraps around the perimeter of the core. Helical rib 37 segregates adjacent portions of helical cut 36 . In this embodiment, multiple helical cuts and multiple helical grooves are included.
Returning now to FIG. 2 , orb 28 is loaded onto core 26 by pressing the aft portion of orb 28 against loading surface 34 on core 26 . In a preferred embodiment of the present invention, orb 28 is fabricated using foam or another flexible material. Thus, orb retention ribs 32 preferably have an effective diameter that is slightly greater than the diameter of the central bore 38 of orb 28 . This allows the user to load orb 28 while carrying around orb launching device 10 without fear of orb 28 disengaging from core 26 . The reader will note that orb retention ribs 32 include fillets on the loading end such that orb 28 easily fits onto core 26 .
Another advantage to orb 28 being fabricated from a flexible material is that orb launching device 10 can fire orb 28 at a high speed with little fear of injuring someone/thing nearby. The present invention allows for a high-speed yet soft projectile.
Preferably, the central bore 30 of core 26 is axially aligned with cocking shaft 20 . Preferably, the diameter of central bore 30 of core 26 is slightly larger than the outer diameter of cocking shaft 20 such that core 26 is capable of translating axially along cocking shaft 20 . The diameters of central bore 30 of core 26 and cocking shaft 20 are such that core 26 can rotate as well as translate on that axis. The importance of this will become apparent in the following text.
Cocking shaft screw 40 is affixed to cocking shaft 20 . Those familiar with the art will realize that shaft screw 40 can be attached to cocking shaft 20 using multiple techniques. Some examples of how the two can be affixed are that shaft screw 40 can be externally threaded while cocking shaft 20 is internally threaded, shaft screw 40 and cocking shaft 20 can be a snap-type attachment, or shaft screw 40 can be affixed to shaft 20 using epoxy or another adhesive (The use of the word “screw” to name this component should not be viewed as limiting the feature to threaded devices). Although it is not visible in FIG. 2 , central bore 30 includes an additional surface which is large enough to catch cocking shaft screw 40 , thereby preventing core 26 from disengaging from shaft 20 (although core 26 is free to rotate around shaft 20 ). In addition, as the user pulls cocking shaft 20 back, cocking shaft screw 40 engages this surface within central bore 30 , thereby pulling core 26 back as well. This will be discussed further in the following text.
FIG. 3 shows a sectional view of orb launching device 10 in an “un-cocked” state. In this state, orb 28 is not capable of being fired (until a user cocks the device). The reader will note that this is the result of two factors—(1) cocking shaft 20 is not pulled back and (2) trigger 18 is in a depressed state. As discussed in the preceding text, cocking shaft screw 40 is attached to cocking shaft 20 . The reader will note that cocking shaft screw 40 does not fit flush over shaft 20 but instead extends outward from the perimeter of cocking shaft 20 .
As discussed previously, central bore 30 of core 26 includes retention surface 42 (an annular flange). The overlapping portion of screw 40 is separated from retention surface 42 in the configuration of FIG. 3 . However, when a user grasps cocking shaft 20 and pulls it toward the cocking position (toward the right in the orientation of FIG. 3 ), the overlapping portion of screw 40 bears against retention surface 42 and pulls core 26 along with the cocking shaft.
Preferably, cocking spring 44 fits over cocking shaft 20 in such a way that it is capable of translation/compression, but with as little play as possible. In a preferred embodiment of the present invention, one end of cocking spring 44 is embedded within core 26 , thereby allowing torsional stress to be applied to cocking spring 44 as core 26 is rotated. Of course, the other end of spring 44 must also be fixed in order to build a torsional force within cocking spring 44 . This is achieved using spring anchor 46 , which is fixedly attached to chassis 14 (either directly or indirectly). Spring anchor 46 includes helical grooves and a stop that prevent cocking spring 44 from rotating past a certain point within spring anchor 46 , thereby building torsional tension as spring 44 is rotated. Although spring anchor 46 is illustrated as a separate part in this embodiment, spring anchor 46 may be integral to the chassis of the orb launcher 10 . Still looking at FIG. 3 , those skilled in the art will realize that as a user urges cocking shaft 20 to the right, core 26 and the attached orb 28 are also moved to the right. At the same time, cocking spring 44 is compressed linearly. This is discussed further in the subsequent text.
FIGS. 4-8 show the cocking sequence used in a preferred embodiment of the launcher. The mechanism employed both compresses and twists spring 44 . This dual motion is significant. When the compressed and twisted spring is released (such as by pulling the launcher's trigger), core 26 is both accelerated linearly and rotationally. It thereby propels the orb forward and also spins the orb so that when the orb is propelled free of the launcher it is spin-stabilized in flight.
The mechanisms that are used in this particular embodiment to both compress and twist spring 44 will now be described in detail. The reader should bear in mind that many other mechanisms could be employed to achieve these objectives. FIG. 4 shows orb launching device 10 as the user first pulls back on cocking handle 22 . As illustrated, cocking shaft screw 40 is engaged with retention surface 42 , which has caused core 26 to travel back as well. In addition, cocking spring 44 has begun to compress. The reader will note that up to this point there is no significant torsional stress on cocking spring 44 (pure compression does introduce a small amount of torsional stress in a coil spring).
In FIG. 5 , the user has continued to pull rearward on cocking handle 22 . The reader will note that trigger 18 pivots about trigger pivot 19 . Preferably, core 26 does not interact with firing tab 48 while the device is being cocked. In the event that firing tab 48 does interact with the core, it does so in the following manner. The firing tab has an angled forward-facing surface and a vertical rearward facing surface. In the position shown in FIG. 5 , the aft extreme of core 26 (a flat, annular surface) has ridden over angled wall 61 (the forward-facing wall) of firing tab 48 . In FIG. 6 , helical rib 37 has just come to rest against the angled forward-facing wall 61 of firing tab 48 in this instantaneous snapshot.
Trigger 18 and firing tab 48 are preferably held in place while orb launching device 10 is being moved to the completely cocked position. This is achieved using trigger plunger 50 and trigger catch 52 . Trigger plunger 50 is loaded using trigger plunger spring 54 . Trigger plunger spring 54 preferably maintains a constant force on trigger plunger 50 , which urges trigger 18 forward and urges firing tab 48 upward. However, trigger catch 52 prevents trigger 18 from rotating about trigger pivot 19 (The reader will note that a protrusion on the forward facing portion of trigger catch 52 engages a notch on a rear surface of trigger 18 ). Trigger catch 52 is urged forward and into engagement with the trigger by catch spring 58 . The trigger catch assembly keeps trigger 18 in the position shown until trigger catch 52 is forced backwards by core 26 (as the launcher is fully cocked).
Preferably, as the user continues to pull rearward on cocking handle 22 in FIG. 6 , helical rib 37 does not interact with the forward-facing angled wall 61 of firing tab 48 . However, in some embodiments, or in the event that trigger 18 or firing tab 48 are misaligned, helical rib 37 slides along the forward-facing angled wall 61 of firing tab 48 without hindering the axial motion of core 26 .
Finally cocking handle 22 is pulled rearward until the aft end of core 26 contacts the forward end of trigger catch 52 and pushes it rearward. This is shown in FIG. 7 . As this occurs trigger catch 52 moves out of engagement with trigger 18 and trigger 18 pivots clockwise (in the orientation of FIG. 7 ) so that firing tab 48 moved upward and into full engagement with the helical ribs and helical groove of core 26 . Vertical wall 60 (rearward-facing) of firing tab 48 bears against the helical rib on the core.
At this point, the user releases cocking handle 22 . FIG. 8 illustrates the configuration of orb launching device 10 the moment after the user has released cocking handle 22 . The reader will note that in FIG. 7 , vertical wall 60 is resting against helical rib 37 in a manner that is unstable. Cocking spring 44 is urging core 26 to the left (in FIG. 7 ). Thus, once cocking handle 22 is released vertical wall 60 on firing tab 48 translates along helical rib 37 within helical cut 36 . This translation occurs until firing tab 48 reaches helical cut extreme 39 (shown in FIG. 2B ). As firing tab 48 translates within helical cut 36 , core 26 rotates axially over cocking shaft 20 . Because both ends of cocking spring 44 are prevented from rotating, this rotation creates a torsional stress on cocking spring 44 in addition to the compressive stress.
The reader will also note that cocking shaft 20 , cocking handle 22 , cocking shaft screw 40 have returned to the unloaded state in FIG. 8 . Once the user releases cocking handle 22 , cocking shaft 20 returns to the state shown in FIG. 3 . Those familiar with the art will note that this can be done using many different techniques. In a preferred embodiment, cocking shaft 20 is spring loaded or elastically pulled back to the position shown in FIG. 3 after every cocking of orb launcher 10 .
The launcher is at this point cocked and ready to fire. The reader will recall that cocking spring 44 has been both compressed and twisted at this point. It is held on both ends so that it cannot untwist. One end is secured in a rotation-limiting way to the chassis, while the opposite end is secured in a rotation-limiting way to core 26 . In addition, core 26 is unable to twist or move forward because it is held in place by firing tab 48 .
In order to fire the launcher, the user pulls trigger 18 . Trigger 18 then pivots in an anti-clockwise direction (in the orientation of FIG. 8 )—thereby pulling firing tab 48 free of the helical groove in the core. Cocking spring 44 then thrusts core 26 and orb 28 forward. At the same time—because of the torsion imparted to spring 44 —core 26 and orb 28 are also accelerated rotationally.
Those familiar with the art will realize that when a user is playing a war-type game whereby players fire orbs 28 at each other, the pre-cocked state gives the user an advantage, allowing him or her to fire orb launching device immediately.
The rotation of core 26 imparts rotation upon orb 28 . Rotation of orb 28 increases the likelihood that orb 28 will remain traveling along the major axis of orb 28 , which is the orientation with the least amount of drag. As orb 28 travels, the velocity and distance are maximized as it travels along the major axis. By rotating core 26 while cocking orb launching device 10 , the trigger assembly is simplified. Firing tab 48 is only required to release core 26 because the required rotation is already imparted upon core 26 . Once the user pulls trigger 18 , orb launching device 10 returns to the state shown in FIG. 3 .
FIG. 9 shows an alternate embodiment of core 26 . This particular embodiment imparts rotation upon orb 28 without out the need to “wind up” core 26 . In other words, this particular embodiment of core 26 does not require a torsional stress to be imparted upon cocking spring 44 . Preferably, main core body 62 is connected to spring 44 and cocking shaft 20 . Orb holder 64 begins pressed against main core body 62 , such that threaded shaft 66 is not visible. Once main core body 62 reaches the end of cocking shaft 20 , main core body 62 stops. However, the momentum coupled with thread shaft 66 cause orb holder 64 to rotate and continue to travel axially, thereby imparting rotation upon orb 28 .
In addition to the orb launching device 10 shown in FIGS. 1-8 , the core 26 shown in FIG. 9 can be used with a pneumatic embodiment of orb launcher 10 . This version would allow the user to use similar cocking and firing method as the preferred embodiment, but using a chamber of air. This burst of air would force main core body 62 to muzzle 16 . Then, when core 26 stops orb holder 64 will rotate and release orb 28 .
FIG. 10 shows an alternate embodiment of orb launching device 10 . The reader will note that this is a simplified version of the present invention. Preferably, orb launching device 10 includes handle 12 , barrel 14 , cocking shaft 20 , cocking handle 22 , launching shaft 66 , cocking spring 44 , core 26 , and spring anchor 46 . Preferably, cocking shaft 20 translates within a channel located within barrel 14 which allows cocking shaft 20 to travel linearly along the firing axis.
The firing mechanism for this particular embodiment is very similar to that seen in FIGS. 1-8 . The user pulls back on cocking handle 22 , which traverses cocking shaft 20 backwards through the channel in barrel 14 . As this occurs cocking knob 68 rotates core 26 as knob 68 pulls core 26 back. As before, cocking spring 44 is embedded into core 26 , thereby preventing rotation of cocking spring 44 in conjunction with spring anchor 46 . The reader will note that this embodiment of orb launcher 10 does not include a trigger system. Thus, a different launching mechanism must be employed. In order to launch orb 28 , the channel in barrel 14 ramps downward towards the handle 12 of orb launching device 10 . Once cocking handle 22 reaches the ramp in the channel, cocking knob 68 is forced downward. This disengages cocking knob 68 from core 26 , thereby launching orb 28 . Of course, there are advantages and disadvantages to each embodiment-simplicity on one side and convenience/ease of use on the other. The embodiment of FIG. 10 may also include some additional housing components and covers to avoid the users' from placing hands and/or fingers into the firing mechanism. In addition, cocking shaft 20 would be well suited to fit into a channel that connects to handle 12 .
The preceding description contains significant detail regarding novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed to the following claims, rather than specific examples given.
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A toy projectile launching device. The device preferably includes a handle, barrel, muzzle, trigger, cocking shaft, and cocking handle. The device uses a spring loaded shaft in order to launch an orb. In addition, the launching mechanism of the device imparts rotation upon the orb, which stabilizes the orb in flight—thereby achieving an increase in sustained velocity and an increase in the distance traveled.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
A reconfigurable power system that comprises multiple loads and prime movers and electric machines connected to an AC bus via power electronic devices.
2. Description of the Prior Art
Efforts have been underway to develop high-speed generators and power converters used to transfer power between a high speed turbine, a high speed energy storage flywheel and a 450 Vrms, 3-phase, 60 Hz distribution system. The system would incorporate high speed generators which convert rotational energy to electrical energy, rectifiers that convert high frequency AC power to DC power and inverters which convert DC power to AC power. The system also includes a high frequency drive motor to allow charging of the flywheel energy store directly from the 450 Vrms 3-phase Hz distribution grid. During discharge of the flywheel energy store, the power flow can be directed to the 450 Vrms distribution grid or be rectified and routed through the inverters.
Although the system noted hereinabove when implemented, will meet the system requirements, it would be desirable if the system had the capability of being reconfigured such that the flywheel portion is essentially capable of operating as a full back-up to the turbine portion of the system. In addition, it would be desirable if the high speed generators were multiple phase-set electric machines.
SUMMARY OF THE INVENTION
The present invention provides a reconfigurable power system that comprises multiple loads and prime movers and electric machines connected to an AC bus utilizing multiple phase-set electrical machines in conjunction with suitable power electronic devices.
The advantages of this system is that common power electronic devices can be used for both the flywheel and turbine (both potential loads and prime movers), and common electric machines can be used for coupling with both flywheel and turbine. The nature of the power requirements of a flywheel are well suited for a multiple phase set electric machine. In particular, when providing power to the flywheel, the power demand is low and when power is extracted from the flywheel a much higher power capacity electric machine is needed. A multiple phase set electric machine can be configured to run on one phase set (or any number of phase sets corresponding to the number of power electronic devices dedicated for a variable frequency drive), when motoring the flywheel and all of the phase sets when providing power to the grid through the same power electronic devices normally used to provide power to the grid from the multiple phase set electric machine coupled to the turbine. Some built-in system redundancy can be provided, but if common electric machines are used and common electric power electronic devices are used, then what would otherwise be a special purpose variable frequency drive for motoring the flywheel can be eliminated in favor of one of the common power electronic devices. If a common power electronic device normally feeding generating power to the grid fails, then the system user has the option of re-configuring the system using the common power electronic device normally serving as a variable frequency device and vice versa. This system re-configuration could be performed on a real-time as needed basis; for example the flywheel could be powered periodically rather than continuously as the needs and priority of the system change.
The present invention thus provides an efficient power system comprising a number of electric machines with multiple phase set stators and power electronic devices (which may or may not include switch gear and filters) configured to provide bi-directional power flow through at least one of the electric machines. In particular, a first electric machine is coupled to a turbine engine and a second electric machine is coupled to a flywheel. The first electric machine is used as a motor to start the turbine and as a generator when the turbine is producing power. The second machine is used as a motor to “spin up” the flywheel and as a generator when the flywheel is providing power.
DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention as well as other objects and further features thereof, reference is made to the following description which is to be read in conjunction with the accompanying drawing wherein:
FIG. 1 illustrates a preferred embodiment of the system of the present invention;
FIG. 2 illustrates an operating mode of the preferred embodiment shown in FIG. 1 wherein the electric machine acts as a motor to start the turbine and the flywheel portion of the system is charging, both sub-systems being independent;
FIG. 3 illustrates an operating mode of the preferred embodiment shown in FIG. 1 wherein the turbine operates to run the elective machine as a generator and the flywheel is charging, each sub-system acting independently;
FIG. 4 illustrates an operating mode of the preferred embodiment shown in FIG. 1 wherein the gas turbine is off-line and the flywheel is discharging, both sub-systems acting cooperatively;
FIG. 5 illustrates an alternative embodiment wherein a DC connection is provided; and
FIG. 6 illustrates an operating mode of system shown in FIG. 5 wherein the gas turbine is on-line and the flywheel is discharging, both sub-system acting cooperatively.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the reconfigurable power system 10 using multiple phase-set electric machines in accordance with the teachings of the present invention is illustrated. Electric machines 12 and 14 (although only two machines are illustrated, more than that number can be utilized) are illustrated as being coupled to turbine 16 and flywheel 18 , respectively (although other prime movers can be utilized). System 10 is configured to provide bi-directional power flow in at least one of the electric machines 12 and 14 . Electric machine 12 , coupled via shaft 20 to turbine 16 , can be used as a motor to start turbine 16 and, alternately, as a generator when turbine 16 is producing electric power. Electric machine 14 , coupled to flywheel 18 via shaft 22 , is used as a motor to “spin up” flywheel 18 and as a generator when the flywheel is generating electric power. As is well known, flywheels store kinetic energy to be used in driving a machine for a short time period and functions essentially as a back-up in case of a system power failure.
The preferred electric machine for use in system 10 is disclosed in copending application Ser. No. 11/751,450, filed May 21, 2007 and assigned to the assignee of the present invention. The advantages of using such a machine is described in that application and the teachings thereof necessary for an understanding of the present invention is incorporated herein by reference. The multi-phase winding sets used in the machine can be independent, space shifted, three phase winding sets. Each set is supplied by a dc-ac power electronics building block (“PEBB”), such as block 156 discussed hereinafter. Permanent-magnet machines are the preferred machine topology.
Sets of three phase windings 30 , 32 , 34 and 36 from machine 12 is coupled to switches 40 , 42 , 44 and 46 respectively. The output from switches 40 , 42 , 44 and 46 are coupled to input/output filters 50 , 52 , 54 and 56 , respectively (the system can operate without the filters if necessary). The output from the filters are coupled to block 70 (first power device) comprising a series of AC/DC and DC/AC converters, the output therefrom being coupled to input/output filters 80 , 82 , 84 and 86 , the outputs of which are coupled to three-phase AC bus 100 , bus 100 operating at a frequency range between 50 and 60 hz and at a voltage range between 450V and 1000 VAC. The AC/DC converters comprise blocks 71 , 72 , 73 and 74 and the DC/AC converters comprise blocks 75 , 76 , 77 and 78 . It should be noted that the converter blocks are bi-directional i.e. they can be used as either AC/DC or DC/AC converters.
Referring to that portion of system 10 involving flywheel 18 , the output from four sets of three phase winding 140 , 142 , 144 and 146 are, in one version, coupled to switches 40 , 42 , 44 and 46 , the system then operating in the manner described hereinabove with reference to machine 12 . In some modes of operation, three phase winding 146 is connected to power device 150 comprising switch 152 , input/output filter 154 , AC/DC converter 156 DC/AC converter 158 and input/output filter 160 . The output of power device 150 is connected to three phase AC bus 101 . Blocks 41 , 43 and 45 are part of the dual-pole double system throw switches that either connect the high speed turbine 16 and motor/generator 12 to grid 100 or motor/generator 14 and flywheel 18 to grid 101 .
The flywheel generates power while the gas turbine 16 is generating power through the high speed generator 12 or when gas turbine 16 is disconnected from the system 10 .
The system 10 described hereinabove has three modes of operation. In the first mode, blocks 150 , powered by bus 101 , causes machine 14 to operate as a motor to spin-up flywheel 18 (switch 152 closes the connection between machine 14 and PEBB 150 ) and switches 40 , 42 , 44 and 46 connect machine 12 , operating as a generator, to grid 100 through the filters and block 70 . In the second mode ( FIG. 3 ), blocks 150 , powered by bus 101 , causes machine 14 to operate as a motor to maintain power on the flywheel 18 (switch 152 is open) and switches 40 , 42 , 44 and 46 connect machine 12 , operating as a generator, to grid 100 through the filters and block 70 . When there is a failure ( FIG. 4 ) in gas turbine 16 or generator 12 (or if there is a requirement for power from the flywheel), switches 40 , 42 , 44 and 46 disconnect generator 12 and turbine 16 and instead connect to machine 14 which is running as a generator as flywheel 18 feeds power back to grid 100 through the filters 50 , 52 , 54 and 56 and block 70 .
In an alternate mode of operation, when the system requests power simultaneously from gas turbine 16 and flywheel 18 , flywheel 18 is sized to handle the peak load (turbine power, base load and any pulsed load or overload) so when flywheel 18 is on line it provides sufficient power for the total peak load. This eliminates the need for gas turbine 16 to supply power to the load thereby providing a system with improved efficiency over the prior art since gas turbine 16 is optimized for the base load only and would be unloaded when the load increases beyond the base load.
Under normal operation, the switch blocks are connecting the gas turbine 16 to PEBB block, or converter, 70 and then to AC grid 100 ; at this time, switch 152 is connecting the motor 14 to flywheel 18 to keep the flywheel spinning, i.e. storing energy and ready for use. When the generator 12 and turbine 16 is disconnected from the system by switches 40 , 42 . . . 46 the flywheel generator 14 is connected to feed the base load and the additional pulsed or peaking load. When a pulsed or peaking load is completed, switches 40 , 42 . . . 46 reconnect gas turbine 16 which is still operational even through having been disconnected from the system. The switch 152 connecting flywheel 18 is the same as switches 40 , 42 . . . 46 and comprise dual pole transfer switches, either for connecting the generator turbine/generator to the AC grid 100 or for connecting the flywheel/generator 14 , 18 to the grid 101 .
The PEBB is used to control the electric machine coupled to the turbine such that it switches between functioning as a motor or a generator “on the fly” i.e. the direction of power flow determines if the electric machine is a motor or generator (the PEBB corresponds to the AC/DC blocks forming converter 70 ). Alternatively, a separate active module could be used for motoring and a separate possible module used for generating. In this case, a contactor can be used to toggle which PEBB is active. In the case of starting the turbine 16 and then using the turbine as a prime mover, the contactor would only be switched after the rotation of the turbine is self-sustained. Otherwise, any active PEBB would be used without a contactor.
Each PEBB preferably comprises a three-phase diode bridge or active rectifiers (diode blocks are not used as dc-ac blocks; if a 2-level insulated-gate bipolar transistor three phase bridge is used as a AC/DC converter then the same bridges can be used as DC/AC converter).
The time-dominant mode of operation for the electric machine coupled to the flywheel is low power motoring (only providing make-up and initial spin-up power).
The key differences between both power paths are the time involved and the disparate power levels for motoring and generating for the turbine and flywheel.
Since the charge/discharge (motoring/generating) cycles of the flywheel are significantly disproportionate in power requirements, the ability to have a variable frequency device 150 essentially χ/N (wherein χ is preferably 1 and N the number of phase sets) allows the system to use the same PEBB's for both turbine generating and flywheel generating.
In summary, system 10 provides a power generation system that consists of a gas turbine/generator (or multiples thereof) and a motor/generator that is spinning a flywheel. System 10 can be a stand alone network or can be used to support an existing AC network handling peak loads. For example, the AC network might be able to handle 5 MW continuously, but there can be loads that can come in and out intermittently that are approximately 10 MW. In that case, system 10 can be used to support the extra load. A unique feature of the system 10 is that the same machine, configured as a space shifted split stator as disclosed in the copending '450 application can be used to be the generator rotated by gas turbine 16 and also the motor/generator 14 spinning flywheel 18 (as a motor) and rotated by the flywheel acting as a generator. The PEBB's used in the system can also be identical on the AC/DC side and DC/AC side. One block that is AC/DC can be used to spin, or rotate, the motor that spins up flywheel 18 . Multiples (N) of the same blocks can be utilized to convert the energy from the flywheel/generator 18 to feed back to the bus, or grid, 100 . The same blocks are used to convert the energy from the gas turbine generator 16 to the common AC bus, or grid 100 . The reconfiguration enables switching between the flywheel/generator 14 , 18 and gas turbine/generator 12 , 16 without having to bring in new PEBB's assuming that the gas turbine generator and flywheel do not have to be on at the same time.
System 10 can be adapted to the following configurations: (1) using multiple PEBB's that are switched from the flywheel subsystem to the gas turbine subsystem; (2) the flywheel subsystem contains at least one conventionally wound three-phase machine; (3) the flywheel sub-system contains multiple flywheels, motor/generators, PEBB modules, not necessarily in a 1:1:1 relationship.
FIG. 2 illustrates a variation of the system shown in FIG. 1 . In particular, system 100 ′ comprises subsystems 102 and 104 , sub-system 102 functioning to start gas turbine (generator) 106 via motor 108 . Sub-system 104 functions to charge (rotate) flywheel 110 utilizing motor 112 . The power flow of sub-systems 102 and 104 is in the direction illustrated by arrow 114 . Subsystems 102 and 104 function independently of each other.
FIG. 3 illustrates the system of FIG. 1 wherein (system 200 comprising sub-systems 202 and 204 ) gas turbine 206 in sub-system 202 operates in a manner such that generator 208 generates AC power in the direction of arrows 210 . Sub-system 204 utilizes motor 212 to charge (rotate) flywheel 214 . Power flows in the direction of arrow 216 . Sub-system 202 and 204 act independently of each other. In this mode of operation, motor 212 is used to provide make-up and initial spin-up power for flywheel 214 .
FIG. 4 illustrates the system of FIG. 1 wherein the gas turbine 16 is off-line and flywheel 18 is discharging (rotating) and causing generator 12 to generate power. Since sub-systems 300 and 302 act cooperatively, the power from generator 14 flows to the switches in sub-system 302 and then to the grid 100 as illustrated by arrows 306 .
FIG. 5 illustrates system 400 comprising sub-systems 402 and 404 . The system provides a DC connection wherein prime movers 406 and 408 operate simultaneously. In particular, sub-systems 402 and 404 share a DC connection whereas in FIG. 4 an AC connection is shared.
FIG. 6 illustrates system 500 comprising sub-systems 502 and 504 , an operating mode of system 400 . System 500 is used to meet temporary peak power demand. In particular, flywheel 504 has the capacity to work simultaneously with gas turbine 508 to meet peak power demand. In this system the gas turbine DC/AC modules are rated for peak power and can use passive rectification and flywheel AC/DC modules are selected for active rectification and are rated for flywheel charging. The negative DC connection can be always active; the positive DC connection requires a contactor for safety and/or margin reasons.
While the invention has been described with reference to its preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its essential teachings.
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A reconfigurable power system that includes a gas turbine, flywheel, a first electric machine coupled to the gas turbine, a second electric machine coupled to the flywheel, the first and second electric machines being substantially similar in configuration, a first power device for coupling power from the first electric machine to a power grid, a second power device coupled to the second electric machine for driving the flywheel and coupling power from the second electric machine to the power grid, and a switch for coupling either the power generated by the first electric machine or the second electric machine to the grid.
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BACKGROUND
[0001] The present disclosure relates to a pump, and more particularly to a fuel gear pump for gas turbine engines.
[0002] Fuel gear pumps are commonly used to provide fuel flow and pressure for gas turbine engines and other systems on aircrafts. The gear pump must perform over a wide system operating range and provide critical flows and pressures for various functions. Typically, these pumps receive rotational power from an accessory gearbox through a drive shaft.
[0003] In a fuel gear pump, a shaft seal is frequently used to seal internal fuel from entry into a shaft cavity. Typically, the shaft seal performance, most notably leakage, may be monitored throughout operation, where too much leakage may cause detrimental effects. In addition, the shaft seal may need to be periodically removed, examined, possibly repaired or replaced, then re-installed. Dependant on the arrangement of the unit, the shaft seal may be difficult to access, which is usually the case in a dual gear stage pump.
SUMMARY
[0004] A shaft assembly according to an exemplary aspect of the present disclosure includes a shaft with a first radial shoulder and a second radial shoulder along a shaft axis. A seal retaining sleeve is defined around the shaft axis and a retainer plate at least partially between the first radial shoulder and the second radial shoulder is adjacent to the seal retaining sleeve.
[0005] A gear pump according to an exemplary aspect of the present disclosure includes an input shaft which at least partially extends from a housing along an input shaft axis, the input shaft defines a first radial shoulder and a second radial shoulder. A seal retaining sleeve is located within a bore in the housing. A retainer plate is mounted to the housing at least partially between the first radial shoulder and the second radial shoulder to restrain an axial position of the input shaft, and the retainer plate is adjacent to the seal retaining sleeve.
[0006] A method of installing a shaft assembly within a housing according to an exemplary aspect of the present disclosure includes positioning a shaft seal within a bore in the housing, a seal retaining sleeve within the bore in the housing, and a shaft at least partially within the bore through the seal retaining sleeve and the shaft seal along a shaft axis. Attaching a retainer plate to the housing, the retainer plate is located at least partially between a first radial shoulder and a second radial shoulder to restrain an axial position of the shaft, and the retainer plate is adjacent to the seal retaining sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0008] FIG. 1 is a block diagram of a gear pump driven by an accessory gearbox to communicate a fluid such as fuel to a gas turbine;
[0009] FIG. 2 is an end view of a gear pump;
[0010] FIG. 3 is a sectional view of the gear pump taken along line 3 - 3 in FIG. 2 ;
[0011] FIG. 4 is a sectional view of the gear pump taken along line 4 - 4 in FIG. 2 ;
[0012] FIG. 5 is a perspective view of the gear pump with the housing removed;
[0013] FIG. 6 is another perspective view of the gear pump with the housing removed;
[0014] FIG. 7 is another perspective view of the gear pump with the housing removed;
[0015] FIG. 8 is a perspective view of the gear pump from the same perspective as in FIG. 5 ;
[0016] FIG. 9 is a perspective view of the gear pump from the same perspective as in FIG. 7 ;
[0017] FIG. 10 is a perspective view of the gear pump from the same perspective as in FIG. 6 ;
[0018] FIG. 11 is an expanded sectional view of an input shaft assembly of the gear pump;
[0019] FIG. 12 is an end view of a retainer plate of the input shaft assembly;
[0020] FIG. 13 is an expanded sectional view of an input shaft assembly of the gear pump while being installed into an accessory gearbox;
[0021] FIG. 14 is an end view of the input shaft assembly of the gear pump;
[0022] FIG. 15 is a perspective isometric view of the seal retaining sleeve;
[0023] FIG. 16 is an expanded sectional view of the seal retaining sleeve with a sensor system integrated therewith;
[0024] FIG. 17 is a side view of one dimensional embodiment of a seal retaining sleeve; and
[0025] FIG. 18 is a side view of another dimensional embodiment of a seal retaining sleeve.
DETAILED DESCRIPTION
[0026] FIG. 1 schematically illustrates a gear pump 20 driven by an accessory gearbox 22 to communicate a fluid such as fuel to a gas turbine 24 . It should be appreciated that the present application is not limited to use in conjunction with a specific system. Thus, although the present application is, for convenience of explanation, depicted and described as being implemented in an aircraft fuel pump, it should be appreciated that it can be implemented in numerous other systems. In addition, although a dual stage gear pump is disclosed, other machines with a shaft will also benefit herefrom.
[0027] With reference to FIG. 2 , the gear pump 20 generally includes a housing 30 that includes an input shaft assembly 32 and a coupling shaft assembly 34 to power a main stage 36 and a motive stage 38 ( FIGS. 3 and 4 ). Rotational power is transferred from the gas turbine 24 to the accessory gearbox 22 then to the gear pump 20 through the input shaft assembly 32 . In the disclosed, non-limiting embodiment, the input shaft assembly 32 interfaces with the accessory gearbox 22 and receives a lubricant therefrom while the coupling shaft assembly 34 is lubricated with fuel.
[0028] With reference to FIG. 3 , the input shaft assembly 32 is defined along an input axis A and the coupling shaft assembly 34 is defined along a coupling axis B parallel to the input axis A. The main stage 36 generally includes a main drive gear 40 , a main driven gear 42 , a main drive bearing 44 and a main driven bearing 46 . The motive stage 38 generally includes a motive drive gear 50 , a motive driven gear 52 , a motive drive bearing 54 and a motive driven bearing 56 ( FIG. 4 ).
[0029] The main drive gear 40 is in meshed engagement with the main driven gear 42 and the motive drive gear 50 is in meshed engagement with the motive driven gear 52 ( FIGS. 5-7 ). The input shaft assembly 32 drives the coupling shaft assembly 34 through the main stage 36 to drive the motive stage 38 . A boost stage 58 is also driven by the input shaft assembly 32 to define a centrifugal pump with an impeller and integrated inducer.
[0030] The stages 36 , 38 , 58 work mostly independently. Each stage 36 , 38 , 58 includes a separate inlet and discharge ( FIGS. 8-10 ). As the meshed gears 40 , 42 and 50 , 52 rotate, respective volumes of fluid are communicated from the main stage inlet MI to the main stage discharge MD and from a motive stage inlet ml to a motive stage discharge mD such that the main stage 36 communicates a main fuel flow while the motive stage 38 supplies a motive fuel flow. The main stage inlet MI and main stage discharge MD as well as the motive stage inlet ml and motive stage discharge mD are respectively directed along generally linear paths through the respective gear stage 36 , 38 .
[0031] In the disclosed non-limiting embodiment, an aircraft fuel system provides flow and pressure to the boost stage inlet BI. A portion of the boost stage discharge is routed internally to the motive stage inlet ml. The remainder of the boost stage discharge is discharged from the gear pump 20 to the aircraft fuel system, then returns to the main stage inlet MI. The motive stage discharge mD is communicated to the aircraft fuel system. The main stage discharge MD is also communicated to the aircraft fuel system to provide at least two main functions: actuation and engine burn flow. There may be alternative or additional relatively minor flow directions and functions, but detailed description thereof need not be further disclosed herein.
[0032] With reference to FIG. 11 , the input shaft assembly 32 includes an input shaft 60 , a spring 62 and a retainer plate 64 . The input shaft 60 is a hollow shaft with splined end sections 66 A, 66 B and radial shoulders 68 A, 68 B therebetween. The splined end section 66 A plugs into a gear G of the accessory gearbox 22 . The splined end section 66 B interfaces with the main drive gear 40 .
[0033] The radial shoulders 68 A, 68 B are generally aligned with the housing 30 to receive the retainer plate 64 therebetween. The retainer plate 64 is attached to the housing 30 through fasteners 70 such as bolts (also illustrated in FIG. 2 ) to position an interrupted opening 65 between the radial shoulders 68 A, 68 B. The interrupted opening 65 in one disclosed non-limiting embodiment is an arcuate surface with an interruption less than 180 degrees ( FIG. 12 ). The axial position of the input shaft 60 is thereby axially constrained by the interaction of the radial shoulders 68 A, 68 B and to the retainer plate 64 .
[0034] With reference to FIG. 13 , the spring 62 biases the input shaft assembly 32 to position the input shaft assembly 32 during gear pump operation. That is, the spring 62 allows the input shaft assembly 32 to move in the housing 30 in response to impact loads, until the input shaft assembly 32 bottoms out on the retainer plate 64 , but during operation, the spring 62 positions the input shaft assembly 32 such that the radial shoulders 68 A, 68 B are spaced from the retainer plate 64 . This assures there are no rotational to stationary part contact during operation.
[0035] The input shaft assembly 32 rotationally mounts the input shaft 60 within a shaft bore 80 which contains a shaft seal 82 such as that manufactured by Qualiseal Technology of Illinois USA and a seal retaining sleeve 84 . The shaft seal 82 is located within the shaft bore 80 then the seal retaining sleeve 84 is located within the shaft bore 80 to position the shaft seal 82 between the seal retaining sleeve 84 and the main drive gear 40 . The retainer plate 64 , through removable attachment to the housing 30 through the fasteners 70 , retains the seal retaining sleeve 84 and thereby the position of the shaft seal 82 ( FIG. 14 ).
[0036] The shaft seal 82 seals fuel from the main stage 36 and the motive stage 38 into the shaft bore 80 then potentially into the accessory gearbox 22 . Performance of the shaft seal 82 , most notably leakage, may be monitored throughout operation, where too much leakage may cause detrimental effects. The shaft seal 82 may periodically require maintenance or replacement. Removal of the shaft seal 82 is facilitated by removal of the retainer plate 64 and the seal retaining sleeve 84 as compared to conventional systems which locate the shaft seal deep within the housing. That is, unlike many conventional designs, the gear pump 20 does not have to be mostly or completely disassembled in order to access and remove the shaft seal 82 .
[0037] The seal retaining sleeve 84 includes radial end flanges 86 , 88 which may be of different diameters ( FIG. 15 ). The different diameters facilitate the assembly-proof location of the seal retaining sleeve 84 into the shaft bore 80 which reduces in diameter toward the shaft seal 82 . The reduced diameter shaft bore 80 over the axial length thereof further facilitates and eases location of the shaft seal 82 through the shaft bore 80 .
[0038] The seal retaining sleeve 84 includes apertures 90 which facilitate removal through receipt of a tool (not shown) which engages the apertures 90 . The apertures 90 may further permit receipt of a sensor system S (illustrated schematically; FIG. 16 ) or other monitor which, for example only, senses and tracks the position of the seal retaining sleeve 84 relative the shaft bore 80 which monitors wear of the shaft seal 82 . Alternatively, or additionally, the sensor system S may be utilized to detect any fuel leakage past the shaft seal 82 and into the seal retaining sleeve 84 and the shaft bore 80 . It should be understood by those skilled in the art with the benefit of this disclosure that these functions may be enacted in either dedicated hardware circuitry or programmed software routines capable of execution in a microprocessor based electronics control embodiment. In one non-limiting embodiment, the module may be a portion of a flight control computer, a portion of a central vehicle control, an interactive vehicle dynamics module, a stand-alone line replaceable unit or other system.
[0039] The seal retaining sleeve 84 may alternatively or additionally include anti-rotation features 92 such as flats (illustrated; FIG. 15 ), grooves, keys, or other features to further rotationally assembly-proof and align the seal retaining sleeve 84 for specific leakage, performance and assembly monitoring.
[0040] With reference to FIG. 17 , the seal retaining sleeve 84 defines an overall axial length SA along the axis of rotation A and an outer diameter dimension SD of the radial end flange 86 . It should be understood that the radial end flange 86 in the disclosed non-limiting embodiment defines the maximum outer diameter dimension to closely fit into the shaft bore 80 opposite the shaft seal 82 , however, other maximum outer diameter surfaces may alternatively or additionally be utilized herewith.
[0041] The axial dimension SA in one disclosed non-limiting dimensional embodiment is 1.600-2.000 inches (40.6-50.8 mm) with a nominal dimension of 1.800 inches (45.7 mm). The maximum outer diameter dimension SD in this disclosed non-limiting dimensional embodiment is 1.368-1.768 inches (34.7-44.9 mm) with a nominal maximum outer diameter dimension of 1.568 inches (39.8 mm). In this disclosed non-limiting dimensional embodiment, a ratio of SD/SA is defined between 0.68-1.11.
[0042] With reference to FIG. 18 , another non-limiting embodiment of the seal retaining sleeve 84 ′ defines an overall axial length SA along the axis of rotation A and an outer diameter dimension SD of the radial end flange 86 ′.
[0043] The axial dimension SA in another disclosed non-limiting dimensional embodiment is 1.695-2.095 inches (43.1-53.2 mm) with a nominal dimension of 1.895 inches (48.1 mm). The maximum outer diameter dimension SD in this disclosed non-limiting dimensional embodiment is 1.174-1.574 inches (29.8-40.0 mm) with a nominal maximum outer diameter dimension of 1.374 inches (34.9 mm). In this disclosed non-limiting dimensional embodiment, a ratio of SD/SA is defined between 0.69-0.93. The disclosed ratios permit the seal retaining sleeve 84 to closely fit into the shaft bore 80 and properly locate the shaft seal 82 as retained by the retainer plate 64 .
[0044] It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom.
[0045] Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure.
[0046] The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.
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A shaft assembly includes a shaft with a first radial shoulder and a second radial shoulder along a shaft axis. A seal retaining sleeve is defined around the shaft axis to position a shaft seal. A retainer plate at least partially between the first radial shoulder and the second radial shoulder is adjacent to the seal retaining sleeve to position and provide access to the seal retaining sleeve and shaft seal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/229,012, filed on Sep. 9, 2011, now U.S. Pat. No. 8,697,591, which issued Apr. 15, 2014, which is a continuation-in-part of U.S. patent application Ser. No. 12/940,764, filed on Nov. 5, 2010, now U.S. Pat. No. 8,697,590, which issued Apr. 15, 2014, which is a continuation of U.S. patent application Ser. No. 11/610,761, filed on Dec. 14, 2006, now U.S. Pat. No. 7,829,490, which issued Nov. 9, 2010, the contents of which are hereby herein incorporated by reference in their entireties.
BACKGROUND
This invention relates to glass compositions that can be used, for example, to form glass fibers. Such glass fibers can be used in a wide variety of end-use applications.
For example, in some embodiments, glass fibers are adapted for formation into fibers that can be employed for reinforcing composite substrates comprising a printed circuit board (“PCB”). More particularly, some embodiments of the present invention relate to glass fiber reinforcements that have electrical properties that permit enhancing performance of a PCB.
“D k ” is the dielectric constant of a material, also known as “permittivity” and is a measure of the ability of a material to store electric energy. A material to be used as a capacitor desirably has a relatively high D k , whereas a material to be used as part of a PCB substrate desirably has a low D k , particularly for high speed circuits. D k is the ratio of the charge that would be stored (i.e., the capacitance) of a given material between two metal plates to the amount of charge that would be stored by a void (air or vacuum) between the same two metal plates. “D f ” or dissipation factor is the measure of the loss of power in a dielectric material. D f is the ratio of the resistive loss component of the current to the capacitive component of current, and is equal to the tangent of the loss angle. For high speed circuitry, it is desired that the D f of materials comprising a PCB substrate be relatively low.
PCB's have commonly been reinforced with glass fibers of the “E-glass” family of compositions, which is based on “Standard Specification for Glass Fiber Strands” D 578 American Society for Testing and Materials. By this definition, E-glass for electronic applications contains 5 to 10 weight percent B 2 O 3 , which reflects recognition of the desirable effect of B 2 O 3 on dielectric properties of glass compositions. E-glass fibers for electronic applications typically have D k in the range 6.7-7.3 at 1 MHz frequency. Standard electronic E-glass is also formulated to provide melting and forming temperatures conducive to practical manufacturing. Forming temperatures (the temperature at which the viscosity is 1000 poise), also referred to herein as T F , for commercial electronic E-glass are typically in the range of 1170° C.-1250° C.
High performance printed circuit boards require substrate reinforcements having lower D k compared to E-glass for better performance, i.e., less noise signal transmission, for applications in telecommunication and electronic computing. Optionally, reducing D f relative to E-glass is also desired by the electronic industry. While the PCB industry has a need for low dielectric fiber glass, manufacture of glass fiber reinforcement requires economical viability issues to be addressed in order for low dielectric fibers to achieve successful commercialization. To this end, some low D k glass compositions proposed in the prior art do not adequately address the economic issues.
Some low dielectric glasses in the prior art are characterized by high SiO 2 content or high B 2 O 3 content, or a combination of both high SiO 2 and high B 2 O 3 . An example of the latter is known as “D-glass.” Detailed information on this approach to low D k glass can be found in an article by L. Navias and R. L. Green, “Dielectric Properties of Glasses at Ultra-High Frequencies and their Relation to Composition,” J. Am. Ceram. Soc., 29, 267-276 (1946), in U.S. Patent Application 2003/0054936 A1 (S. Tamura), and in patent application JP 3409806 B2 (Y. Hirokazu). Fibers of SiO 2 and glasses of the D-glass type have been used as reinforcement in fabric form for PCB substrates, e.g., laminates comprised of woven fibers and epoxy resin. Although both of those approaches successfully provide low D k , sometimes as low as about 3.8 or 4.3, the high melting and forming temperatures of such compositions result in undesirably high costs for such fibers. D-glass fibers typically require forming temperatures in excess of 1400° C., and SiO 2 fibers entail forming temperatures on the order of about 2000° C. Furthermore, D-glass is characterized by high B 2 O 3 content, as much as 20 weight percent or greater. Since B 2 O 3 is one of the most costly raw materials required for manufacturing conventional electronic E-glass, the use of much greater amounts of B 2 O 3 in D-glass significantly increases its cost compared to E-glass. Therefore, neither SiO 2 nor D-glass fibers provide a practical solution for manufacturing high performance PCB substrate materials on a large scale.
Other low dielectric fiber glasses based on high B 2 O 3 concentrations (i.e., 11 to 25 weight percent) plus other relatively costly ingredients such as ZnO (up to 10 weight percent) and BaO (up to 10 weight percent) have been described in JP 3409806B2 (Hirokazu), with reported D k values in the 4.8-5.6 range at 1 MHz. The inclusion of BaO in these compositions is problematic because of cost as well as environmental reasons. In spite of the high concentrations of the costly B 2 O 3 in the compositions of this reference, the fiber forming temperatures disclosed are relatively high, e.g., 1355° C.-1429° C. Similarly, other low dielectric glasses based on high B 2 O 3 concentrations (i.e., 14-20 weight percent) plus relatively costly TiO 2 (up to 5 weight percent) have been described in U.S. Patent Application 2003/0054936 A1 (Tamura), with D k =4.6-4.8 and dissipation factor D f =0.0007-0.001 at 1 MHz. In Japanese Patent Application JP 02154843A (Hiroshi et al.) there are disclosed boron-free low dielectric glasses with D k in the range 5.2-5.3 at 1 MHz. Although these boron-free glasses provide low D k with presumably relatively low raw material cost, their disadvantage is that fiber forming temperatures at 1000 poise melt viscosity are high, between 1376° C. and 1548° C. Additionally, these boron-free glasses have very narrow forming windows (the difference between the forming temperature and the liquidus temperature), typically 25° C. or lower (in some cases negative), whereas a window of about 55° C. or higher would commonly be considered expedient in the commercial fiber glass industry.
To improve PCB performance while managing the increase in cost, it would be advantageous to provide compositions for fiber glasses that offer significant improvements of electrical properties (D k and/or D f ) relative to E-glass compositions, and at the same time provide practical forming temperatures lower than the SiO 2 and D-glass types and the other prior art approaches to low dielectric glass discussed above. To significantly lower raw material costs, it would be desirable to maintain B 2 O 3 content less than that of D-glass, e.g., below 13 weight percent or below 12 percent. It can also be advantageous in some situations for the glass composition to fall within the ASTM definition of electronic E-glass, and thus to require no more than 10 weight percent B 2 O 3 . It would also be advantageous to manufacture low D k glass fibers without requiring costly materials such as BaO or ZnO that are unconventional in the fiber glass industry. In addition, commercially practical glass compositions desirably have tolerance to impurities in raw materials, which also permits the use of less costly batch materials.
Since an important function of glass fiber in PCB composites is to provide mechanical strength, improvements in electrical properties would best be achieved without significantly sacrificing glass fiber strength. Glass fiber strength can be expressed in terms of Young's modulus or pristine tensile strength. It would also be desirable if new low dielectric fiber glass solutions would be used to make PCB without requiring major changes in the resins used, or at least without requiring substantially more costly resins, as would be required by some alternative approaches.
In some embodiments, glass compositions of the present invention are adapted for formation into fibers that can be used in the reinforcement of other polymeric resins in a variety of other end-use applications including, without limitation, aerospace, aviation, wind energy, laminates, radome, and other applications. In such applications, electrical properties, such as those discussed above, may or may not be important. In some applications, other properties, such as specific strength or specific modulus or weight, may be important. In some embodiments, the glass fibers may be first arranged into a fabric. In some embodiments, glass fibers of the present invention can be provided in other forms including, for example and without limitation, as chopped strands (dry or wet), yarns, wovings, prepregs, etc. In short, various embodiments of the glass compositions (and any fibers formed therefrom) can be used in a variety of applications.
SUMMARY
Embodiments of the present invention relate generally to glass compositions and to glass fibers formed from glass compositions. In some embodiments, glass fibers can be used in a number of applications including electrical applications (e.g., printed circuit boards) and reinforcement applications (e.g., fiber glass reinforced composites that can be used in a variety of applications). In some embodiments, fiberizable glass compositions of the present invention can provide improved electrical performance (i.e., low D k and/or low D f ) relative to standard E-glass, while providing temperature-viscosity relationships that are more conducive to commercially practical fiber forming than prior art low D k glass proposals. Some embodiments of glass compositions or glass fibers of the present invention can be made commercially with relatively low raw material batch cost. In some embodiments, glass fibers of the present invention can provide desirable and/or commercially acceptable mechanical properties.
In another aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
53.5-77
weight percent;
B 2 O 3
4.5-14.5
weight percent;
Al 2 O 3
4.5-18.5
weight percent;
MgO
4-12.5
weight percent;
CaO
0-10.5
weight percent;
Li 2 O
0-4
weight percent;
Na 2 O
0-2
weight percent;
K 2 O
0-1
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-2
weight percent;
TiO 2
0-2
weight percent; and
other constituents
0-5
weight percent total.
In another aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
60-77
weight percent;
B 2 O 3
4.5-14.5
weight percent;
Al 2 O 3
4.5-18.5
weight percent;
MgO
8-12.5
weight percent;
CaO
0-4
weight percent;
Li 2 O
0-3
weight percent;
Na 2 O
0-2
weight percent;
K 2 O
0-1
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-2
weight percent;
TiO 2
0-2
weight percent; and
other constituents
0-5
weight percent total.
In one aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
60-68
weight percent;
B 2 O 3
7-13
weight percent;
Al 2 O 3
9-15
weight percent;
MgO
8-15
weight percent;
CaO
0-4
weight percent;
Li 2 O
0-2
weight percent;
Na 2 O
0-1
weight percent;
K 2 O
0-1
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-1
weight percent; and
TiO 2
0-2
weight percent.
In another aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
at least 60
weight percent;
B 2 O 3
5-11
weight percent;
Al 2 O 3
5-18
weight percent;
MgO
5-12
weight percent;
CaO
0-10
weight percent;
Li 2 O
0-3
weight percent;
Na 2 O
0-2
weight percent;
K 2 O
0-1
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-2
weight percent;
TiO 2
0-2
weight percent; and
other constituents
0-5
weight percent total.
In another aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
60-68
weight percent;
B 2 O 3
5-10
weight percent;
Al 2 O 3
10-18
weight percent;
MgO
8-12
weight percent;
CaO
0-4
weight percent;
Li 2 O
0-3
weight percent;
Na 2 O
0-2
weight percent;
K 2 O
0-1
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-2
weight percent;
TiO 2
0-2
weight percent; and
other constituents
0-5
weight percent total.
In another aspect of the invention, glass compositions can comprise the following constituents, which may be in the form of glass fibers:
SiO 2
62-68
weight percent;
B 2 O 3
7-9
weight percent;
Al 2 O 3
11-18
weight percent;
MgO
8-11
weight percent;
CaO
1-2
weight percent;
Li 2 O
1-2
weight percent;
Na 2 O
0-0.5
weight percent;
K 2 O
0-0.5
weight percent;
Fe 2 O 3
0-0.5
weight percent;
F 2
0.5-1
weight percent;
TiO 2
0-1
weight percent; and
other constituents
0-5
weight percent total.
In some embodiments, the compositions of the invention are characterized by relatively low content of CaO, for example, on the order of about 0-4 weight percent. In yet other embodiments, the CaO content can be on the order of about 0-3 weight percent. In yet other embodiments, the CaO content can be on the order of about 0-2 weight percent. In general, minimizing the CaO content yields improvements in electrical properties, and the CaO content has been reduced to such low levels in some embodiments that it can be considered an optional constituent. In some other embodiments, the CaO content can be on the order of about 1-2 weight percent.
On the other hand, the MgO content is relatively high for glasses of this type, wherein in some embodiments the MgO content is double that of the CaO content (on a weight percent basis). Some embodiments of the invention can have MgO content greater than about 5.0 weight percent, and in other embodiments the MgO content can be greater than 8.0 weight percent. In some embodiments, the compositions of the invention are characterized by a MgO content, for example, on the order of about 8-13 weight percent. In yet other embodiments, the MgO content can be on the order of about 9-12 weight percent. In some other embodiments, the MgO content can be on the order of about 8-12 weight percent. In yet some other embodiments, the MgO content can be on the order of about 8-10 weight percent.
In some embodiments, the compositions of the invention are characterized by a (MgO+CaO) content, for example, that is less than 16 weight percent. In yet other embodiments, the (MgO+CaO) content is less than 13 weight percent. In some other embodiments, the (MgO+CaO) content is 7-16 weight percent. In yet some other embodiments, the (MgO+CaO) content can be on the order of about 10-13 weight percent.
In yet some other embodiments, the compositions of the invention are characterized by a ratio of (MgO+CaO)/(Li 2 O+Na 2 O+K 2 O) content can be on the order of about 9.0. In certain embodiments, the ratio of Li 2 O/(MgO+CaO) content can be on the order of about 0-2.0. In yet some other embodiments, the ratio of Li 2 O/(MgO+CaO) content can be on the order of about 1-2.0. In certain embodiments, the ratio of Li 2 O/(MgO+CaO) content can be on the order of about 1.0.
In some other embodiments, the (SiO 2 +B 2 O 3 ) content can be on the order of 70-76 weight percent. In yet other embodiments, the (SiO 2 +B 2 O 3 ) content can be on the order of 70 weight percent. In other embodiments, the (SiO 2 +B 2 O 3 ) content can be on the order of 73 weight percent. In still other embodiments, the ratio of the weight percent of Al 2 O 3 to the weigh percent of B 2 O 3 is on the order of 1-3. In some other embodiments, the ratio of the weight percent of Al 2 O 3 to the weigh percent of B 2 O 3 is on the order of 1.5-2.5. In certain embodiments, the SiO 2 content is on the order of 65-68 weight percent.
As noted above, some low D k compositions of the prior art have the disadvantage of requiring the inclusion of substantial amounts of BaO, and it can be noted that BaO is not required in the glass compositions of the present invention. Although the advantageous electrical and manufacturing properties of the invention do not preclude the presence of BaO, the absence of deliberate inclusions of BaO can be considered an additional advantage of some embodiments of the present invention. Thus, embodiments of the present invention can be characterized by the presence of less than 1.0 weight percent BaO. In those embodiments in which only trace impurity amounts are present, the BaO content can be characterized as being no more than 0.05 weight percent.
The compositions of the invention include B 2 O 3 in amounts less that the prior art approaches that rely upon high B 2 O 3 to achieve low D k . This results in significant cost savings. In some embodiments the B 2 O 3 content need be no more than 13 weight percent, or no more than 12 weight percent. Some embodiments of the invention also fall within the ASTM definition of electronic E-glass, i.e., no more than 10 weight percent B 2 O 3 .
In some embodiments, the compositions of the invention are characterized by a B 2 O 3 content, for example, on the order of about 5-11 weight percent. In some embodiments, the B 2 O 3 content can be 6-11 weight percent. The B 2 O 3 content, in some embodiments, can be 6-9 weight percent. In some embodiments, the B 2 O 3 content can be 5-10 weight percent. In some other embodiments, the B 2 O 3 content is not greater than 9 weight percent. In yet some other embodiments, the B 2 O 3 content is not greater than 8 weight percent.
In some embodiments, the compositions of the invention are characterized by a Al 2 O 3 content, for example on the order of about 5-18 weight percent. The Al 2 O 3 content, in some embodiments, can be 9-18 weight percent. In yet other embodiments, the Al 2 O 3 content is on the order of about 10-18 weight percent. In some other embodiments, the Al 2 O 3 content is on the order of about 10-16 weight percent. In yet some other embodiments, the Al 2 O 3 content is on the order of about 10-14 weight percent. In certain embodiments, the Al 2 O 3 content is on the order of about 11-14 weight percent.
In some embodiments, Li 2 O is an optional constituent. In some embodiments, the compositions of the invention are characterized by a Li 2 O content, for example on the order of about 0.4-2.0 weight percent. In some embodiments, the Li 2 O content is greater than the (Na 2 O+K 2 O) content. In some embodiments, the (Li 2 O+Na 2 O+K 2 O) content is not greater than 2 weight percent. In some embodiments, the (Li 2 O+Na 2 O+K 2 O) content is on the order of about 1-2 weight percent.
In certain embodiments, the compositions of the invention are characterized by a TiO 2 content for example on the order of about 0-1 weight percent.
In the composition set forth above, the constituents are proportioned so as to yield a glass having a dielectric constant lower than that of standard E-glass. With reference to a standard electronic E-glass for comparison, this may be less than about 6.7 at 1 MHz frequency. In other embodiments, the dielectric constant (D k ) may be less than 6 at 1 MHz frequency. In other embodiments, the dielectric constant (D k ) may be less than 5.8 at 1 MHz frequency. Further embodiments exhibit dielectric constants (D k ) less than 5.6 or even lower at 1 MHz frequency. In other embodiments, the dielectric constant (D k ) may be less than 5.4 at 1 MHz frequency. In yet other embodiments, the dielectric constant (D k ) may be less than 5.2 at 1 MHz frequency. In yet other embodiments, the dielectric constant (D k ) may be less than 5.0 at 1 MHz frequency.
The compositions set forth above possess desirable temperature-viscosity relationships conducive to practical commercial manufacture of glass fibers. In general, lower temperatures are required for making fibers compared to the D-glass type of composition in the prior art. The desirable characteristics may be expressed in a number of ways, and they may be attained by the compositions of the present invention singly or in combination. In general, glass compositions within the ranges set forth above can be made that exhibit forming temperatures (T F ) at 1000 poise viscosity no greater than 1370° C. The T F of some embodiments are no greater than 1320° C., or no greater than 1300° C., or no greater than 1290° C., or no greater than 1260° C., or no greater than 1250° C. These compositions also encompass glasses in which the difference between the forming temperature and the liquidus temperature (T L ) is positive, and in some embodiments the forming temperature is at least 55° C. greater than the liquidus temperature, which is advantageous for commercial manufacturing of fibers from these glass compositions.
In general, minimizing alkali oxide content of the glass compositions assists lowering D k . In those embodiments in which it is desired to optimize reduction of D k the total alkali oxide content is no more than 2 weight percent of the glass composition. In compositions of the present invention it has been found that minimizing Na 2 O and K 2 O are more effective in this regard than Li 2 O. The presence of alkali oxides generally results in lower forming temperatures. Therefore, in those embodiments of the invention in which providing relatively low forming temperatures is a priority, Li 2 O is included in significant amounts, e.g. at least 0.4 weight percent. For this purpose, in some embodiments the Li 2 O content is greater than either the Na 2 O or K 2 O contents, and in other embodiments the Li 2 O content is greater than the sum of the Na 2 O and K 2 O contents, in some embodiments greater by a factor of two or more.
In some embodiments, glass compositions suitable for fiber forming may comprise the following constituents, which may be in the form of glass fibers:
SiO 2 62-68 weight percent; B 2 O 3 less than about 9 weight percent; Al 2 O 3 10-18 weight percent; MgO 8-12 weight percent; and CaO 0-4 weight percent;
wherein the glass exhibits a dielectric constant (D k ) less than 6.7 and a forming temperature (T F ) at 1000 poise viscosity no greater than 1370° C.
In some embodiments of the invention, the glass compositions may comprise the following constituents, which may be in the form of glass fibers:
B 2 O 3 less than 14 weight percent; Al 2 O 3 9-15 weight percent; MgO 8-15 weight percent; CaO 0-4 weight percent; and SiO 2 60-68 weight percent;
wherein the glass exhibits a dielectric constant (D k ) less than 6.7 and forming temperature (T F ) at 1000 poise viscosity no greater than 1370° C.
In some other embodiments of the invention, the glass compositions may comprise the following constituents, which may be in the form of glass fibers:
B 2 O 3 less than 9 weight percent; Al 2 O 3 11-18 weight percent; MgO 8-11 weight percent; CaO 1-2 weight percent; and SiO 2 62-68 weight percent;
wherein the glass exhibits a dielectric constant (D k ) less than 6.7 and forming temperature (T F ) at 1000 poise viscosity no greater than 1370° C.
In certain embodiments of the invention, the glass compositions may comprise the following constituents, which may be in the form of glass fibers:
SiO 2 60-68 weight percent; B 2 O 3 7-13 weight percent; Al 2 O 3 9-15 weight percent; MgO 8-15 weight percent; CaO 0-3 weight percent; Li 2 O 0.4-2 weight percent; Na 2 O 0-1 weight percent; K 2 O 0-1 weight percent; Fe 2 O 3 0-1 weight percent; F 2 0-1 weight percent; and TiO 2 0-2 weight percent;
wherein the glass exhibits a dielectric constant (D k ) less than 5.9 and forming temperature (T F ) at 1000 poise viscosity no greater than 1300° C.
In some embodiments of the invention, the glass compositions comprise the following constituents, which may be in the form of glass fibers:
SiO 2
60-68
weight percent;
B 2 O 3
7-11
weight percent;
Al 2 O 3
9-13
weight percent;
MgO
8-13
weight percent;
CaO
0-3
weight percent;
Li 2 O
0.4-2
weight percent;
Na 2 O
0-1
weight percent;
K 2 O
0-1
weight percent;
(Na 2 O + K 2 O + Li 2 O)
0-2
weight percent;
Fe 2 O 3
0-1
weight percent;
F 2
0-1
weight percent; and
TiO 2
0-2
weight percent.
In addition to or instead of the features of the invention described above, some embodiments of the compositions of the present invention can be utilized to provide glasses having dissipation factors (D f ) lower than standard electronic E-glass. In some embodiments, D F may be no more than 0.0150 at 1 GHz, and in other embodiments no more than 0.0100 at 1 GHz.
In some embodiments of glass compositions, D F is no more than 0.007 at 1 GHz, and in other embodiments no more than 0.003 at 1 GHz, and in yet other embodiments no more than 0.002 at 1 GHz.
One advantageous aspect of the invention present in some of the embodiments is reliance upon constituents that are conventional in the fiber glass industry and avoidance of substantial amounts of constituents whose raw material sources are costly. For this aspect of the invention, constituents in addition to those explicitly set forth in the compositional definition of the glasses of the present invention may be included even though not required, but in total amounts no greater than 5 weight percent. These optional constituents include melting aids, fining aids, colorants, trace impurities and other additives known to those of skill in glassmaking. Relative to some prior art low D k glasses, no BaO is required in the compositions of the present invention, but inclusion of minor amounts of BaO (e.g., up to about 1 weight percent) would not be precluded. Likewise, major amounts of ZnO are not required in the present invention, but in some embodiments minor amounts (e.g., up to about 2.0 weight percent) may be included. In those embodiments of the invention in which optional constituents are minimized, the total of optional constituents is no more than 2 weight percent, or no more than 1 weight percent. Alternatively, some embodiments of the invention can be said to consist essentially of the named constituents.
DETAILED DESCRIPTION
To lower D k and D f , including SiO 2 and B 2 O 3 , which have low electrical polarizability, is useful in the compositions of the present invention. Although B 2 O 3 by itself can be melted at a low temperature (350° C.), it is not stable against moisture attack in ambient air and hence, a fiber of pure B 2 O 3 is not practical for use in PCB laminates. Both SiO 2 and B 2 O 3 are network formers, and the mixture of two would result in significantly higher fiber forming temperature than E-glass, as is the case with D-glass. To lower fiber-forming temperature, MgO and Al 2 O 3 are included, replacing some of the SiO 2 . Calcium oxide (CaO) and SrO can be also used in combination with MgO, although they are less desirable than MgO because both have higher polarizability than MgO.
To lower batch cost, B 2 O 3 is utilized at lower concentrations than in D-glass. However, sufficient B 2 O 3 is included to prevent phase separation in glass melts, thereby providing better mechanical properties for glass fibers made from the compositions.
The choice of batch ingredients and their cost are significantly dependent upon their purity requirements. Typical commercial ingredients, such as for E-glass making, contain impurities of Na 2 O, K 2 O, Fe 2 O 3 or FeO, SrO, F 2 , TiO 2 , SO 3 , etc. in various chemical forms. A majority of the cations from these impurities would increase the D k of the glasses by forming nonbridging oxygens with SiO 2 and/or B 2 O 3 in the glass.
Sulfate (expressed as SO 3 ) may also be present as a refining agent. Small amounts of impurities may also be present from raw materials or from contamination during the melting processes, such as SrO, BaO, Cl 2 , P 2 O 5 , Cr 2 O 3 , or NiO (not limited to these particular chemical forms). Other refining agents and/or processing aids may also be present such as As 2 O 3 , MnO, MnO 2 , Sb 2 O 3 , or SnO 2 , (not limited to these particular chemical forms). These impurities and refining agents, when present, are each typically present in amounts less than 0.5% by weight of the total glass composition. Optionally, elements from rare earth group of the Periodic Table of the Elements may be added to compositions of the present invention, including atomic numbers 21 (Sc), 39 (Y), and 57 (La) through 71 (Lu). These may serve as either processing aids or to improve the electrical, physical (thermal and optical), mechanical, and chemical properties of the glasses. The rare earth additives may be included with regard for the original chemical forms and oxidization states. Adding rare earth elements is considered optional, particularly in those embodiments of the present invention having the objective of minimizing raw material cost, because they would increase batch costs even at low concentrations. In any case, their costs would typically dictate that the rare earth components (measured as oxides), when included, be present in amounts no greater than about 0.1-1.0% by weight of the total glass composition.
The invention will be illustrated through the following series of specific embodiments. However, it will be understood by one of skill in the art that many other embodiments are contemplated by the principles of the invention.
The glasses in these examples were made by melting mixtures of reagent grade chemicals in powder form in 10% Rh/Pt crucibles at the temperatures between 1500° C. and 1550° C. (2732° F.-2822° F.) for four hours. Each batch was about 1200 grams. After the 4-hour melting period, the molten glass was poured onto a steel plate for quenching. To compensate volatility loss of B 2 O 3 (typically about 5% of the total target B 2 O 3 concentration in laboratory batch melting condition for the 1200 gram batch size), the boron retention factor in the batch calculation was set at 95%. Other volatile species, such as fluoride and alkali oxides, were not adjusted in the batches for their emission loss because of their low concentrations in the glasses. The compositions in the examples represent as-batched compositions. Since reagent chemicals were used in preparing the glasses with an adequate adjustment of B 2 O 3 , the as-batched compositions illustrated in the invention are considered to be close to the measured compositions.
Melt viscosity as a function of temperature and liquidus temperature were determined by using ASTM Test Method C965 “Standard Practice for Measuring Viscosity of Glass Above the Softening Point,” and C829 “Standard Practices for Measurement of Liquidus Temperature of Glass by the Gradient Furnace Method,” respectively.
A polished disk of each glass sample with 40 mm diameter and 1-1.5 mm thickness was used for electrical property and mechanical property measurements, which were made from annealed glasses. Dielectric constant (D k ) and dissipation factor (D f ) of each glass were determined from 1 MHz to 1 GHz by ASTM Test Method D150 “Standard Test Methods for A-C Loss Characteristics and Permittivity (Dielectric Constant) of Solid Electrical Insulating Materials.” According to the procedure, all samples were preconditioned at 25° C. under 50% humidity for 40 hours. Selective tests were performed for glass density using ASTM Test Method C729 “Standard Test Method for Density of Glass by the Sink-Float Comparator,” for which all samples were annealed.
For selected compositions, a microindentation method was used to determine Young's modulus (from the initial slope of the curve of indentation loading—indentation depth, in the indenter unloading cycle), and microhardness (from the maximum indentation load and the maximum indentation depth). For the tests, the same disk samples, which had been tested for D k and D f , were used. Five indentation measurements were made to obtain average Young's modulus and microhardness data. The microindentation apparatus was calibrated using a commercial standard reference glass block with a product name BK7. The reference glass has Young's modulus 90.1 GPa with one standard deviation of 0.26 GPa and microhardness 4.1 GPa with one standard deviation of 0.02 GPa, all of which were based on five measurements.
All compositional values in the examples are expressed in weight percent.
Table 1 Compositions
Examples 1-8 provide glass compositions (Table 1) by weight percentage: SiO 2 62.5-67.5%, B 2 O 3 8.4-9.4%, Al 2 O 3 10.3-16.0%, MgO 6.5-11.1%, CaO 1.5-5.2%, Li 2 O 1.0%, Na 2 O 0.0%, K 2 O 0.8%, Fe 2 O 3 0.2-0.8%, F 2 0.0%, TiO 2 0.0%, and sulfate (expressed as SO 3 ) 0.0%.
The glasses were found to have D k of 5.44-5.67 and Df of 0.0006-0.0031 at 1 MHz, and D k of 5.47-6.67 and D f of 0.0048-0.0077 at 1 GHz frequency. The electric properties of the compositions in Series III illustrate significantly lower (i.e., improved) D k and D f over standard E-glass with D k of 7.29 and D f of 0.003 at 1 MHz and D k of 7.14 and D f of 0.0168 at 1 GHz.
In terms of fiber forming properties, the compositions in Table 1 have forming temperatures (T F ) of 1300-1372° C. and forming windows (T F -T L ) of 89-222° C. This can be compared to a standard E-glass which has T F typically in the range 1170-1215° C. To prevent glass devitrification in fiber forming, a forming window (T F -T L ) greater than 55° C. is desirable. All of the compositions in Table 1 exhibit satisfactory forming windows. Although the compositions of Table 1 have higher forming temperatures than E-glass, they have significantly lower forming temperatures than D-glass (typically about 1410° C.).
TABLE 1
1
2
3
4
5
6
7
8
Al 2 O 3
11.02
9.45
11.64
12.71
15.95
10.38
10.37
11.21
B 2 O 3
8.55
8.64
8.58
8.56
8.46
8.71
9.87
9.28
CaO
5.10
5.15
3.27
2.48
1.50
2.95
2.01
1.54
CoO
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.62
Fe 2 O 3
0.39
0.40
0.39
0.39
0.39
0.53
0.80
0.27
K 2 O
0.77
0.78
0.77
0.77
0.76
0.79
0.79
0.78
Li 2 O
0.98
0.99
0.98
0.98
0.97
1.00
1.00
1.00
MgO
6.70
7.44
8.04
8.69
9.24
10.39
11.05
11.04
SiO 2
66.48
67.16
66.32
65.42
62.72
65.26
64.12
64.26
Properties
D k , 1 MHz
5.62
5.59
5.44
5.47
5.50
5.67
5.57
5.50
D k , 1 GHz
5.65
5.62
5.46
5.47
5.53
5.67
5.56
5.50
D f , 1 MHz
0.0010
0.0006
0.0016
0.0008
0.0020
0.0031
0.0012
0.0010
D f , 1 GHz
0.0048
0.0059
0.0055
0.0051
0.0077
0.0051
0.0053
0.0049
T L (° C.)
1209
1228
1215
1180
1143
1219
1211
1213
T F (° C.)
1370
1353
1360
1372
1365
1319
1300
1316
T F − T L (° C.)
161
125
145
192
222
100
89
103
Table 2 Compositions
Examples 9-15 provide glass compositions: SiO 2 60.8-68.0%, B 2 O 3 8.6 and 11.0%, Al 2 O 3 8.7-12.2%, MgO 9.5-12.5%, CaO 1.0-3.0%, Li 2 O 0.5-1.5%, Na 2 O 0.5%, K 2 O 0.8%, Fe 2 O 3 0.4%, F 2 0.3%, TiO 2 0.2%, and sulfate (expressed as SO 3 ) 0.0%.
The glasses were found to have D k of 5.55-5.95 and D f of 0.0002-0.0013 at 1 MHz, and D k of 5.54-5.94 and D f of 0.0040-0.0058 at 1 GHz frequency. The electric properties of the compositions in Table 2 illustrate significantly lower (improved) D k and D f over standard &glass with D k of 7.29 and D f of 0.003 at 1 MHz, and D k of 7.14 and D f of 0.0168 at 1 GHz.
In terms of mechanical properties, the compositions of Table 2 have Young's modulus of 86.5-91.5 GPa and microhardness of 4.0-4.2 GPa, both of which are equal or higher than standard E glass that has Young's modulus of 85.9 GPa and microhardness of 3.8 GPa. The Young's moduli of the compositions in the Table 2 are also significantly higher than D-glass which is about 55 GPa based on literature data.
In terms of fiber forming properties, the compositions of Table 2 have forming temperature (T F ) of 1224-1365° C., and forming windows (T F -T L ) of 6-105° C. as compared to standard E-glass having T F in the range 1170-1215° C. Some, but not all, of the Table 2 compositions have a forming window (T F -T L ) greater than 55° C., which is considered preferable in some circumstances to avoid glass devitrification in commercial fiber forming operations. The Table 2 compositions have lower forming temperatures than those of D-glass (1410° C.), although higher than E-glass.
TABLE 2
EXAMPLE:
9
10
11
12
13
14
15
Al 2 O 3
12.02
11.88
10.41
12.08
12.18
8.76
12.04
B 2 O 3
10.98
10.86
9.90
8.71
8.79
8.79
8.68
CaO
1.07
2.90
2.02
2.95
1.09
1.09
2.94
F 2
0.32
0.31
0.32
0.32
0.32
0.32
0.32
Fe 2 O 3
0.40
0.39
0.40
0.40
0.40
0.40
0.40
K 2 O
0.78
0.77
0.79
0.79
0.79
0.79
0.78
Li 2 O
0.50
0.49
1.00
0.50
1.51
1.51
1.49
MgO
12.35
9.56
11.10
12.41
12.51
9.81
9.69
Na 2 O
0.51
0.51
0.52
0.52
0.52
0.52
0.52
SiO 2
60.87
62.13
63.35
61.14
61.68
67.80
62.95
TiO 2
0.20
0.20
0.20
0.20
0.20
0.20
0.20
Properties
D k , 1 MHz
5.69
5.55
5.74
5.84
5.95
5.60
5.88
D k , 1 GHz
5.65
5.54
5.71
5.83
5.94
5.55
5.86
D f , 1 MHz
0.0007
0.0013
0.0007
0.0006
0.0002
0.0002
0.0011
D f , 1 GHz
0.0042
0.0040
0.0058
0.0043
0.0048
0.0045
0.0053
T L (° C.)
1214
1209
1232
1246
1248
1263
1215
T F (° C.)
1288
1314
1287
1277
1254
1365
1285
T F − T L (° C.)
74
105
55
31
6
102
70
E (GPa)
90.5
87.4
86.8
86.5
89.6
87.2
91.5
H (GPa)
4.12
4.02
4.02
4.03
4.14
4.07
4.19
TABLE 3
EXAMPLES:
16
17
18
19
20
Al 2 O 3
10.37
11.58
8.41
11.58
12.05
B 2 O 3
8.71
10.93
10.66
8.98
8.69
CaO
2.01
2.63
3.02
1.78
2.12
F 2
0.32
0.30
0.30
0.30
0.30
Fe 2 O 3
0.40
0.27
0.27
0.27
0.27
K 2 O
0.79
0.25
0.25
0.16
0.10
Li 2 O
0.50
1.21
1.53
0.59
1.40
MgO
11.06
10.04
9.65
11.65
10.57
Na 2 O
0.52
0.25
0.57
0.35
0.15
SiO 2
65.13
62.55
65.35
64.35
64.35
TiO 2
0.20
0.00
0.00
0.00
0.00
Total
100.00
100.00
100.00
100.00
100.00
D k , 1 MHz
5.43
5.57
5.30
5.42
D k , 1 GHz
5.33
5.48
5.22
5.33
D f , 1 MHz
0.0057
0.0033
0.0031
0.0051
D f , 1 GHz
0.0003
0.0001
0.0008
0.0014
T L (° C.)
1231
1161
1196
1254
1193
T F (° C.)
1327
1262
1254
1312
1299
T F − T L (° C.)
96
101
58
58
106
T M (° C.)
1703
1592
1641
1634
1633
E (GPa)
85.3
86.1
85.7
91.8
89.5
Std E (GPa)
0.4
0.6
2.5
1.7
1.5
H (GPa)
3.99
4.00
4.03
4.22
4.13
Std H (GPa)
0.01
0.02
0.09
0.08
0.05
EXAMPLES:
21
22
23
24
25
26
Al 2 O 3
12.04
12.04
12.04
12.04
12.04
12.54
B 2 O 3
8.65
8.69
10.73
10.73
11.07
8.73
CaO
2.06
2.98
2.98
2.98
2.98
2.88
F 2
0.45
0.45
0.45
0.45
0.45
2.00
Fe 2 O 3
0.35
0.35
0.35
0.35
0.35
0.35
K 2 O
0.4
0.4
0.4
0.4
0.4
0.40
Li 2 O
1.53
1.05
1.05
0.59
0.48
MgO
10.47
10.62
9.97
11.26
11.26
11.26
Na 2 O
0.5
0.5
0.5
0.5
0.5
0.50
SiO 2
63.05
62.42
61.03
60.2
59.97
61.34
TiO 2
0.5
0.5
0.5
0.5
0.5
Total
100.00
100.00
100.00
100.00
100.00
100.00
D k , 1 MHz
5.75
5.73
5.61
5.64
5.63
5.35
D k , 1 GHz
5.68
5.61
5.55
5.54
5.49
5.38
D f , 1 MHz
0.004
0.0058
0.0020
0.0046
0.0040
0.0063
D f , 1 GHz
0.0021
0.0024
0.0034
0.0019
0.0023
0.0001
T L (° C.)
1185
1191
1141
1171
1149
1227
T F (° C.)
1256
1258
1244
1246
1249
1301
T F − T L (° C.)
71
67
103
75
100
T M (° C.)
1587
1581
1587
1548
1553
E (GPa)
Std E (GPa)
H (GPa)
Std H (GPa)
σ f (KPSI/GPa)
475.7/
520.9/
466.5/
522.0
3.28
3.59
3.22
Std σ f
37.3/
18.3/
41.8/
18.70
(KPSI/GPa)
0.26
0.13
0.29
Density (g/cm 3 )
2.4209*
2.4324*
2.4348*
TABLE 4
EXAMPLE:
27
28
E-Glass
Al 2 O 3
12.42
12.57
13.98
B 2 O 3
9.59
8.59
5.91
CaO
0.11
0.10
22.95
F 2
0.35
0.26
0.71
Fe 2 O 3
0.21
0.21
0.36
K 2 O
0.18
0.18
0.11
Li 2 O
0.80
1.01
0
MgO
10.25
10.41
0.74
Na 2 O
0.15
0.18
0.89
SiO 2
65.47
65.96
54.15
TiO 2
0.17
0.17
0.07
D k , 1 MHz
5.3
5.4
7.3
D k , 1 GHz
5.3
5.4
7.1
D f , 1 MHz
0.003
0.008
D f , 1 GHz
0.011
0.012
0.0168
T L (° C.)
1184
1201
1079
T F (° C.)
1269
1282
1173
T F − T L (° C.)
85
81
94
E (GPa)
H (GPa)
3.195
3.694
Examples 29-62 provide glass compositions (Table 5) by weight percentage: SiO 2 53.74-76.97%, B 2 O 3 4.47-14.28%, Al 2 O 3 4.63-15.44%, MgO 4.20-12.16%, CaO 1.04-10.15%, Li 2 O 0.0-3.2%, Na 2 O 0.0-1.61%, K 2 O 0.01-0.05%, Fe 2 O 3 0.06-0.35%, F 2 0.49-1.48%, TiO 2 0.05-0.65%, and sulfate (expressed as SO 3 ) 0.0-0.16%.
Examples 29-62 provide glass compositions (Table 5) by weight percentage wherein the (MgO+CaO) content is 7.81-16.00%, the ratio CaO/MgO is 0.09-1.74%, the (SiO 2 +B 2 O 3 ) content is 67.68-81.44%, the ratio Al 2 O 3 /B 2 O 3 is 0.90-1.71%, the (Li 2 O+Na 2 O+K 2 O) content is 0.03-3.38%, and the ratio Li 2 O/(Li 2 O+Na 2 O+K 2 O) is 0.00-0.95%.
In terms of mechanical properties, the compositions of Table 5 have a fiber density of 2.331-2.416 g/cm 3 and an average fiber tensile strength (or fiber strength) of 3050-3578 MPa.
To measure fiber tensile strength, fiber samples from the glass compositions were produced from a 10 Rh/90 Pt single tip fiber drawing unit. Approximately, 85 grams of cullet of a given composition was fed into the bushing melting unit and conditioned at a temperature close or equal to the 100 Poise melt viscosity for two hours. The melt was subsequently lowered to a temperature close or equal to the 1000 Poise melt viscosity and stabilized for one hour prior to fiber drawing. Fiber diameter was controlled to produce an approximately 10 μm diameter fiber by controlling the speed of the fiber drawing winder. All fiber samples were captured in air without any contact with foreign objects. The fiber drawing was completed in a room with a controlled humidity of between 40 and 45% RH.
Fiber tensile strength was measured using a Kawabata KES-G1 (Kato Tech Co. Ltd., Japan) tensile strength analyzer equipped with a Kawabata type C load cell. Fiber samples were mounted on paper framing strips using a resin adhesive. A tensile force was applied to the fiber until failure, from which the fiber strength was determined based on the fiber diameter and breaking stress. The test was done at room temperature under the controlled humidity between 40-45% RH. The average values and standard deviations were computed based on a sample size of 65-72 fibers for each composition.
The glasses were found to have D k of 4.83-5.67 and D f of 0.003-0.007 at 1 GHz. The electric properties of the compositions in Table 5 illustrate significantly lower (i.e., improved) D k and D f over standard E-glass which has a D k of 7.14 and a D f of 0.0168 at 1 GHz.
In terms of fiber forming properties, the compositions in Table 5 have forming temperatures (T F ) of 1247-1439° C. and forming windows (T F -T L ) of 53-243° C. The compositions in Table 5 have liquidus temperature (T L ) of 1058-1279° C. This can be compared to a standard E-glass which has T F typically in the range 1170-1215° C. To prevent glass devitrification in fiber forming, a forming window (T F -T L ) greater than 55° C. is sometimes desirable. All of the compositions in Table 5 exhibit satisfactory forming windows.
TABLE 5
wt %
29
30
31
32
33
SiO 2
64.24
58.62
57.83
61.00
61.56
Al 2 O 3
11.54
12.90
12.86
12.87
12.82
Fe 2 O 3
0.28
0.33
0.33
0.33
0.32
CaO
1.70
1.04
2.48
2.48
1.08
MgO
11.69
11.63
12.16
9.31
10.69
Na 2 O
0.01
0.00
0.00
0.00
0.00
K 2 O
0.03
0.03
0.03
0.03
0.03
B 2 O 3
8.96
14.28
13.15
12.81
12.30
F 2
0.53
0.62
0.61
0.61
0.65
TiO 2
0.40
0.54
0.54
0.54
0.54
Li 2 O
0.60
0.00
0.00
0.00
0.00
SO 3
0.01
0.01
0.01
0.01
0.01
Total
100.00
100.00
100.00
100.00
100.00
(MgO + CaO)
13.39
12.67
14.64
11.79
11.77
CaO/Mg
0.15
0.09
0.20
0.27
0.10
MgO/(MgO + CaO)
0.87
0.92
0.83
0.79
0.91
SiO 2 + B 2 O 3
73.20
72.90
70.98
73.81
73.86
Al 2 O 3 /B 2 O 3
1.29
0.90
0.98
1.00
1.04
(Li 2 O + Na 2 O + K 2 O)
0.64
0.03
0.03
0.03
0.03
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.94
0.00
0.00
0.00
0.00
T L (° C.)
1196
1228
1205
1180
1249
T F (° C.)
1331
1300
1258
1334
1332
T F − T L (° C.)
135
72
53
154
83
D k @ 1 GHz
5.26
***
***
5.30
***
D f @ 1 GHz
0.0017
***
***
0.001
***
Fiber density (g/cm 3 )
***
***
***
***
***
Fiber strength (MPa)
***
***
***
***
***
wt %
34
35
36
37
38
SiO 2
63.83
65.21
66.70
60.02
53.74
Al 2 O 3
10.97
10.56
10.11
12.32
15.44
Fe 2 O 3
0.26
0.25
0.24
0.29
0.24
CaO
2.38
2.29
2.19
4.01
3.83
MgO
10.64
10.23
9.79
9.95
10.53
Na 2 O
0.29
0.28
0.27
0.33
0.09
K 2 O
0.03
0.03
0.03
0.03
0.03
B 2 O 3
9.32
8.96
8.57
10.48
13.94
F 2
1.20
1.16
1.11
1.35
1.48
TiO 2
0.36
0.35
0.33
0.41
0.65
Li 2 O
0.70
0.67
0.64
0.79
0.02
SO 3
0.14
0.14
0.13
0.16
0.14
Total
100.13
100.13
100.12
100.15
100.13
(MgO + CaO)
13.02
12.52
11.98
13.96
14.36
CaO/MgO
0.22
0.22
0.22
0.40
0.36
MgO/(MgO + CaO)
0.82
0.82
0.82
0.71
0.73
SiO 2 + B 2 O 3
73.15
74.17
75.27
70.50
67.68
Al 2 O 3 /B 2 O 3
1.18
1.18
1.18
1.18
1.11
(Li 2 O + Na 2 O + K 2 O)
1.02
0.98
0.94
1.15
0.14
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.69
0.68
0.68
0.69
0.16
T L (° C.)
1255
1267
1279
1058
1175
T F (° C.)
1313
1320
1333
1266
1247
T F − T L (° C.)
58
53
54
208
72
D k @ 1 GHz
***
5.46
5.43
5.56
5.57
D f @ 1 GHz
***
0.0036
0.0020
0.0025
0.00437
Fiber density (g/cm 3 )
2.402
2.408
2.352
2.416
***
Fiber strength (MPa)
3310
3354
3369
3413
***
wt %
39
40
41
42
43
SiO 2
62.54
63.83
65.21
66.70
59.60
Al 2 O 3
11.36
10.97
10.56
10.11
13.52
Fe 2 O 3
0.27
0.26
0.25
0.24
0.33
CaO
2.47
2.38
2.29
2.19
1.80
MgO
11.02
10.64
10.23
9.79
9.77
Na 2 O
0.31
0.29
0.28
0.27
0.10
K 2 O
0.03
0.03
0.03
0.03
0.03
B 2 O 3
9.65
9.32
8.96
8.57
12.70
F 2
1.25
1.20
1.16
1.11
1.21
TiO 2
0.37
0.36
0.35
0.33
0.51
Li 2 O
0.73
0.70
0.67
0.64
0.41
SO 3
0.15
0.14
0.14
0.13
0.15
Total
100.14
100.13
100.13
100.12
100.14
(MgO + CaO)
13.49
13.02
12.52
11.98
11.57
CaO/MgO
0.22
0.22
0.22
0.22
0.18
MgO/(MgO + CaO)
0.82
0.82
0.82
0.82
0.84
SiO 2 + B 2 O 3
72.19
73.15
74.17
75.27
72.30
Al 2 O 3 /B 2 O 3
1.18
1.18
1.18
1.18
1.06
(Li 2 O + Na 2 O + K 2 O)
1.07
1.02
0.98
0.94
0.54
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.68
0.69
0.68
0.68
0.76
T L (° C.)
1238
1249
1266
1276
1083
T F (° C.)
1293
1313
1342
1368
1310
T F − T L (° C.)
55
64
76
92
227
D k @ 1 GHz
5.45
5.31
5.39
5.25
5.20
D f @ 1 GHz
0.00531
0.00579
0.00525
0.00491
0.00302
Fiber density (g/cm 3 )
2.403
***
***
***
***
Fiber strength (MPa)
3467
***
***
***
***
wt %
44
45
46
47
48
SiO 2
59.90
60.45
62.68
65.30
65.06
Al 2 O 3
13.23
13.06
12.28
11.51
12.58
Fe 2 O 3
0.34
0.35
0.20
0.19
0.25
CaO
1.86
1.58
1.65
1.39
1.25
MgO
10.14
10.50
8.74
8.18
6.56
Na 2 O
0.10
0.10
0.10
0.09
0.13
K 2 O
0.03
0.03
0.02
0.02
0.05
B 2 O 3
12.40
12.29
12.69
11.89
10.03
F 2
1.26
1.07
1.11
0.94
0.82
TiO 2
0.53
0.55
0.51
0.48
0.07
Li 2 O
0.20
0.00
0.00
0.00
3.20
SO 3
0.15
0.16
0.15
0.14
0.11
Total
100.14
100.15
100.14
100.13
100.10
RO (MgO + CaO)
12.00
12.08
10.39
9.57
7.81
CaO/Mg
0.18
0.15
0.19
0.17
0.19
MgO/(MgO + CaO)
0.85
0.87
0.84
0.85
0.84
SiO 2 + B 2 O 3
72.30
72.74
75.37
77.19
75.09
Al 2 O 3 /B 2 O 3
1.07
1.06
0.97
0.97
1.25
(Li 2 O + Na 2 O + K 2 O)
0.33
0.13
0.12
0.11
3.38
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.61
0.00
0.00
0.00
0.95
T L (° C.)
1129
1211
1201
1196
***
T F (° C.)
1303
1378
1378
1439
***
T F − T L (° C.)
174
167
177
243
***
Dk @ 1 GHz
5.24
5.05
4.94
4.83
5.67
Df @ 1 GHz
0.00473
0.00449
0.00508
0.00254
0.007
Fiber density (g/cm 3 )
2.387
2.385
2.354
2.34
2.345
Fiber strength (MPa)
3483
3362
3166
3050
3578
wt %
49
50
51
52
53
SiO 2
61.14
60.83
62.45
61.88
66.25
Al 2 O 3
12.90
13.02
12.52
12.72
10.60
Fe 2 O 3
0.27
0.28
0.26
0.28
0.18
CaO
1.72
1.74
1.59
1.63
3.33
MgO
9.25
9.36
8.98
9.13
5.98
Na 2 O
0.10
0.10
0.10
0.10
0.86
K 2 O
0.03
0.03
0.03
0.03
0.02
B 2 O 3
12.70
12.70
12.29
12.38
11.44
F 2
1.16
1.17
1.08
1.10
0.90
TiO 2
0.51
0.51
0.50
0.50
0.44
Li 2 O
0.21
0.25
0.21
0.25
0.00
SO 3
0.15
0.15
0.14
0.14
0.00
Total
100.14
100.14
100.13
100.13
100.00
(MgO + CaO)
10.97
11.10
10.57
10.76
9.31
CaO/Mg
0.19
0.19
0.18
0.18
0.56
MgO/(MgO + CaO)
0.84
0.84
0.85
0.85
0.64
SiO 2 + B 2 O 3
73.84
73.53
74.74
74.26
77.69
Al 2 O 3 /B 2 O 3
1.02
1.03
1.02
1.03
0.93
(Li 2 O + Na 2 O + K 2 O)
0.34
0.38
0.34
0.38
0.88
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.62
0.66
0.62
0.66
0.00
T L (° C.)
1179
1179
1186
1191
***
T F (° C.)
1342
1340
1374
1366
***
T F − T L (° C.)
163
161
188
175
***
D k @ 1 GHz
***
5.24
4.96
5.06
5.03
D f @ 1 GHz
***
0.0018
0.0015
0.0014
0.0027
Fiber density (g/cm 3 )
2.358
2.362
2.338
***
2.331
Fiber strength (MPa)
3545
3530
3234
***
3161
wt %
54
55
56
57
58
SiO 2
66.11
69.19
70.68
69.44
69.40
Al 2 O 3
10.58
10.37
8.87
7.20
7.21
Fe 2 O 3
0.18
0.18
0.16
0.13
0.14
CaO
5.31
5.20
5.50
5.57
10.15
MgO
4.20
7.13
7.54
10.39
5.85
Na 2 O
0.86
0.55
0.59
0.59
0.59
K 2 O
0.02
0.02
0.02
0.02
0.02
B 2 O 3
11.41
6.39
5.72
5.80
5.79
F 2
0.90
0.53
0.55
0.55
0.55
TiO 2
0.44
0.43
0.37
0.30
0.30
Li 2 O
0.00
0.00
0.00
0.00
0.00
SO 3
0.00
0.00
0.00
0.00
0.00
Total
100.00
100.00
100.00
100.00
100.00
(MgO + CaO)
9.51
12.33
13.04
15.96
16.00
CaO/Mg
1.26
0.73
0.73
0.54
1.74
MgO/(MgO + CaO)
0.44
0.58
0.58
0.65
0.37
SiO 2 + B 2 O 3
77.52
75.58
76.40
75.24
75.19
Al 2 O 3 /B 2 O 3
0.93
1.62
1.55
1.24
1.25
(Li 2 O + Na 2 O + K 2 O)
0.88
0.57
0.61
0.61
0.61
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.00
0.00
0.00
0.00
0.00
T L (° C.)
***
***
***
***
***
T F (° C.)
***
***
***
***
***
T F − T L (° C.)
***
***
***
***
***
D k @ 1 GHz
***
***
***
***
***
D f @ 1 GHz
***
***
***
***
***
Fiber density (g/cm 3 )
2.341
***
***
***
***
Fiber strength (MPa)
3372
***
***
***
***
wt %
59
60
61
62
SiO 2
69.26
71.45
74.07
76.97
Al 2 O 3
8.72
5.30
7.27
4.63
Fe 2 O 3
0.13
0.06
0.09
0.10
CaO
4.89
5.24
4.88
5.69
MgO
9.92
10.63
4.77
5.56
Na 2 O
0.53
0.58
0.73
1.61
K 2 O
0.03
0.02
0.03
0.01
B 2 O 3
5.09
4.96
6.39
4.47
F 2
0.49
0.50
0.66
0.77
TiO 2
0.27
0.05
0.17
0.19
Li 2 O
0.69
1.20
0.95
0.00
SO 3
0.00
0.00
0.00
0.00
Total
100.00
100.00
100.00
100.00
(MgO + CaO)
14.81
15.87
9.65
11.25
CaO/Mg
0.49
0.49
1.02
1.02
MgO/(MgO + CaO)
0.67
0.67
0.49
0.49
SiO 2 + B 2 O 3
74.35
76.41
80.46
81.44
Al 2 O 3 /B 2 O 3
1.71
1.07
1.14
1.04
(Li 2 O + Na 2 O + K 2 O)
1.25
1.80
1.71
1.62
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.55
0.67
0.56
0.00
T L (° C.)
***
***
***
***
T F (° C.)
1358/1355
1331/1333
1493/1484
***
T F − T L (° C.)
***
***
***
***
D k @ 1 GHz
***
***
***
***
D f @ 1 GHz
***
***
***
***
Fiber density (g/cm 3 )
***
***
***
***
Fiber strength (MPa)
***
***
***
***
Examples 63-73 provide glass compositions (Table 6) by weight percentage: SiO 2 62.35-68.35%, B 2 O 3 6.72-8.67%, Al 2 O 3 10.53-18.04%, MgO 8.14-11.44%, CaO 1.67-2.12%, Li 2 O 1.07-1.38%, Na 2 O 0.02%, K 2 O 0.03-0.04%, Fe 2 O 3 0.23-0.33%, F 2 0.49-0.60%, TiO 2 0.26-0.61%, and sulfate (expressed as SO 3 ) 0.0%.
Examples 63-73 provide glass compositions (Table 6) by weight percentage wherein the (MgO+CaO) content is 9.81-13.34%, the ratio CaO/MgO is 0.16-0.20, the (SiO 2 +B 2 O 3 ) content is 69.59-76.02%, the ratio Al 2 O 3 /B 2 O 3 is 1.37-2.69, the (Li 2 O+Na 2 O+K 2 O) content is 1.09-1.40%, and the ratio Li 2 O/(Li 2 O+Na 2 O+K 2 O) is 0.98.
In terms of mechanical properties, the compositions of Table 6 have a fiber density of 2.371-2.407 g/cm 3 and an average fiber tensile strength (or fiber strength) of 3730-4076 MPa. The fiber tensile strengths for the fibers made from the compositions of Table 6 were measured in the same way as the fiber tensile strengths measured in connection with the compositions of Table 5.
The fibers formed from the compositions were found to have Young's modulus (E) values ranging from 73.84-81.80 GPa. The Young's modulus (E) values for the fibers were measured using the sonic modulus method on fibers. Elastic modulus values for the fibers drawn from glass melts having the recited compositions were determined using an ultrasonic acoustic pulse technique on a Panatherm 5010 instrument from Panametrics, Inc. of Waltham, Mass. Extensional wave reflection time was obtained using twenty micro-second duration, 200 kHz pulses. The sample length was measured and the respective extensional wave velocity (V E ) was calculated. Fiber density (ρ) was measured using a Micromeritics AccuPyc 1330 pycnometer. In general, 20 measurements were made for each composition and the average Young's modulus (E) was calculated according to the formula E=V E 2 *ρ. The fiber failure strain was calculated using Hooke's Law based on the known fiber strength and Young's modulus values.
The glasses were found to have D k of 5.20-5.54 and Df of 0.0010-0.0020 at 1 GHz. The electric properties of the compositions in Table 6 illustrate significantly lower (i.e., improved) D k and D f over standard E-glass with D k of 7.14 and D f of 0.0168 at 1 GHz.
In terms of fiber forming properties, the compositions in Table 6 have forming temperatures (T F ) of 1303-1388° C. and forming windows (T F -T L ) of 51-144° C.
TABLE 6
wt %
63
64
65
66
67
SiO 2
64.25
65.35
66.38
67.35
68.35
Al 2 O 3
11.88
11.52
11.18
10.86
10.53
Fe 2 O 3
0.26
0.25
0.24
0.24
0.23
CaO
2.12
2.05
1.99
1.93
1.87
MgO
10.50
10.17
9.87
9.58
9.29
Na 2 O
0.02
0.02
0.02
0.02
0.02
K 2 O
0.04
0.03
0.03
0.03
0.03
B 2 O 3
8.67
8.40
8.15
7.91
7.67
F 2
0.60
0.58
0.56
0.54
0.53
TiO 2
0.30
0.29
0.28
0.27
0.26
Li 2 O
1.38
1.33
1.29
1.26
1.22
SO 3
0.00
0.00
0.00
0.00
0.00
Total
100.00
100.00
100.00
100.00
100.00
(MgO + CaO)
12.61
12.22
11.86
11.51
11.16
CaO/MgO
0.20
0.20
0.20
0.20
0.20
MgO/(MgO + CaO)
0.83
0.83
0.83
0.83
0.83
SiO 2 + B 2 O 3
72.92
73.75
74.53
75.26
76.02
Al 2 O 3 /B 2 O 3
1.37
1.37
1.37
1.37
1.37
(Li 2 O + Na 2 O + K 2 O)
1.40
1.36
1.32
1.28
1.24
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.98
0.98
0.98
0.98
0.98
T L (° C.)
1241
1259
1266
1268
1287
T F (° C.)
1306
1329
1349
1374
1388
T F − T L (° C.)
65
70
83
106
101
D k @ 1 GHz
5.44
5.35
5.29
5.31
5.2
D f @ 1 GHz
0.0013
0.0016
0.001
0.002
0.0013
Fiber density (g/cm 3 )
2.395
2.385
2.384
2.375
2.371
Fiber strength (MPa)
3730
3759
3813
3743
3738
Young's Modulus (GPa)
***
***
***
74.25
***
Fiber failure strain (%)
***
***
***
5.04
***
wt %
68
69
70
71
72
73
SiO 2
64.39
63.63
62.87
65.45
65.61
62.35
Al 2 O 3
14.05
16.04
18.04
11.05
14.29
14.74
Fe 2 O 3
0.28
0.30
0.33
0.24
0.28
0.29
CaO
1.90
1.79
1.67
1.91
1.77
1.79
MgO
9.39
8.77
8.14
11.44
8.72
11.37
Na 2 O
0.02
0.02
0.02
0.02
0.02
0.02
K 2 O
0.04
0.04
0.04
0.03
0.04
0.04
B 2 O 3
7.75
7.23
6.72
7.80
7.19
7.28
F 2
0.54
0.51
0.49
0.54
0.51
0.51
TiO 2
0.41
0.51
0.61
0.28
0.43
0.45
Li 2 O
1.23
1.15
1.07
1.24
1.14
1.16
SO 3
0.00
0.00
0.00
0.00
0.00
0.00
Total
100.00
100.00
100.00
100.00
100.00
100.00
(MgO + CaO)
11.29
10.55
9.81
13.34
10.49
13.16
CaO/MgO
0.20
0.20
0.20
0.17
0.20
0.16
MgO/(MgO + CaO)
0.83
0.83
0.83
0.86
0.83
0.86
SiO 2 + B 2 O 3
72.14
70.87
69.59
73.25
72.80
69.63
Al 2 O 3 /B 2 O 3
1.81
2.22
2.69
1.42
1.99
2.02
(Li 2 O + Na 2 O + K 2 O)
1.25
1.17
1.09
1.26
1.16
1.18
Li 2 O/(Li 2 O + Na 2 O + K 2 O)
0.98
0.98
0.98
0.98
0.98
0.98
T L (° C.)
1231
1219
1236
1266
1235
1220
T F (° C.)
1349
1362
1368
1317
1379
1303
T F − T L (° C.)
118
143
132
51
144
83
D k @ 1 GHz
5.4
5.38
5.39
5.54
5.52
5.58
D f @ 1 GHz
0.0016
0.0013
0.002
0.0015
0.0016
0.0015
Fiber density (g/cm 3 )
2.393
2.398
2.407
***
***
***
Fiber strength (MPa)
3954
3977
4076
***
***
***
Young's Modulus (GPa)
73.84
80.34
81.57
80.69
81.80
***
Fiber failure strain (%)
5.36
4.95
5.00
4.68
4.72
***
It is to be understood that the present description illustrates aspects of the invention relevant to a clear understanding of the invention. Certain aspects of the invention that would be apparent to those of ordinary skill in the art and that, therefore, would not facilitate a better understanding of the invention have not been presented in order to simplify the present description. Although the present invention has been described in connection with certain embodiments, the present invention is not limited to the particular embodiments disclosed, but is intended to cover modifications that are within the spirit and scope of the invention.
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Glass compositions are provided that are useful in a variety of applications including, for example, electronics applications, reinforcement applications, and others. Some embodiments of glass compositions can provide desirable dielectric constants, desirable dissipation factors, and/or desirable mechanical properties while also having desirable fiber forming properties.
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FIELD OF THE INVENTION
[0001] This invention relates to novel methods, materials and apparatus for investigating asthma in humans. More particularly, the present invention relates to novel methods, materials and apparatus for investigating asthma in humans using dust mite allergen.
BACKGROUND OF THE INVENTION
[0002] Asthma is a chronic inflammatory disease of the airways characterized by variable airflow obstruction and airway hyper-responsiveness with clinical signs such as recurrent episodes of wheezing, breathlessness, chest tightness, and coughing. As asthma morbidity and mortality have increased, so has the importance of controlling this disease. Asthma is estimated to affect between 100 and 150 million people worldwide. In 1998 approximately 180,000 deaths worldwide were attributed to asthma. In Western Europe, the prevalence of asthma has doubled during the 10-year period preceding 1998. In the United States, asthma affects an estimated 14.6 million people (6% of the population) and the prevalence of asthma has increased by 60% since the early 1980s. In 1997 there were over 5,000 deaths in the United States attributed to asthma. Asthma is the third leading cause of preventable hospitalizations in the United States. Therefore, it is apparent that asthma is a significant disease from both a medical and economic perspective.
[0003] The inhalation of dust in the household or at the workplace has been recognized as potentially hazardous for homeowners and workers, respectively. Particularly, it has been shown that when dust is disturbed occupants are exposed transiently to higher dust borne mite allergens. It has been roundly suggested that dust mite allergen present in household dusts is the major allergen causing allergic asthma today.
[0004] Despite the epidemic rise in asthma rates world-wide, on average rising 50 percent every decade, there is no consensus on the cause. There are currently two opposing theories. One theory, the “hygiene hypothesis”, suggests that the recent rise in allergic disease among children in affluent societies is due to a lack of exposure to infections and unhygienic contact such as dust mite allergen such that children do not acquire immunity to them, thereby leading to the increased incidence of allergy and asthma.
[0005] The other allergen overexposure theory proposes that components of a Western lifestyle are increasingly placing us in static, artificial environs which includes increased time indoors and a sedentary lifestyle which lead to increased and longer duration exposures to allergens such as dust mite allergen which in turn are in part responsible for the increased incidence of allergy and asthma seen particularly in industrialized nations of Western societies.
[0006] Under either scenario, a relationship between dust mite allergen and asthma clearly exists. However, as is evident from the polarity of the causative theories, little is known about the relevant concentrations of airborne mite allergens and their clinical impact. In particular, little is known about the exact levels of dust mite allergen, which are significant in the etiology, or progression, of asthma.
[0007] It is thought that proteolytic activity is the central biochemical property that endows these molecules with intrinsic allergenicity. In particular, it is the cysteine protease region of dust mite, Der p1, that is the major allergenic molecules responsible for the increase in asthma and atopic conditions worldwide. These proteases induce Th2-driven inflammatory responses in the airways by disrupting the epithelial cell junctions so that these, and other molecules, gain access to, and alter the function of, underlying cells of the innate immune system (dendritic cells, mast cells, basophils and macrophages) and B and T cells. Another mechanism of dust mite allergen activity recently proposed is through their interactions at proteinase-activated receptors (or “PAR”), a family of G protein-coupled receptors that are widely distributed in the mammalian body. In the respiratory systems, PARs, particularly PAR-2 and PAR-1, are expressed in the epithelial and smooth muscle cells. In the lung epithelial cells, PAR-2 can be activated by exogenous proteinases including house dust mite allergens. Clinical evidence also suggests possible involvement of PARs, particularly PAR-2, in respiratory diseases. PARs thus appear to play critical roles in the respiratory systems, and respiratory diseases including asthma.
[0008] There have been two major hurdles to the understanding of dust mite allergen exposures.
[0009] First, it is evident that there is a range of exposure level and duration to dust mite allergen in the natural indoor setting. A number of studies have been conducted to measure ‘typical’ exposures to dust mite allergens in the home, daycare, school and work with comparisons made between different socio-economic groups. However, exposures to dust mite allergen can vary widely depending on whether dust is settled or disturbed or the level of dust mite allergen in bedding and in the bedroom, a site of long duration exposure. These findings indicate that the level and duration of exposure to dust mite allergen in any exposure study will be critical and will have to be tightly controlled and monitored.
[0010] Secondly, few clinical trials on exposure to dust mite allergen in controlled environments have been performed, largely due to issues of safety and possibility for adverse reaction, which in the asthmatic is a real clinical concern. Patients with asthma require special consideration due to the nature of the condition, which can be intolerably exacerbated with dust mite allergen exposure. For this reason, subjects with at least moderate asthma are usually excluded from studies. See, for example, the U.S. Food and Drug Administration guidelines. However, the European Agency for Evaluation of Medical Products, EMEA, allows inclusion of moderately asthmatic subjects for the purpose of obtaining safety data. In this case, patients with mild and intermittent asthma have been admitted to seasonal (“SAR”) and perennial allergic rhino-conjunctivitis (“PAR”) studies and can be studied under dust mite allergen exposure conditions which are tightly controlled and monitored.
[0011] These experimental hurdles have resulted in the performance of few dust mite allergen exposure studies to date due in large part to the inability to ensure subject exposure to house dust mite allergen in a continuous, controlled and long-term challenge. This has resulted from the following biophysical barriers.
[0012] Dust mite allergen, unlike pollen allergens, is found on irregularly-shaped particles of large aerodynamic diameter. This makes dust mite allergen bearing particles difficult to aerosolize as well as to maintain at constant airborne concentrations.
[0013] Further, a significant barrier to achieving stable allergen exposures has been the inability to monitor airborne dust mite allergen concentrations in real-time, since the established method of measuring dust mite allergen concentrations, Enzyme-Linked Immuno-Sorbent Assay (or “ELISA”, discussed further below), is both time-consuming and costly.
[0014] For at least these reasons, most of the few prior studies have examined the effects of dust mite allergen in patients with PAR and only one study on asthmatics.
[0015] The main method for the detection and quantification of dust mite allergen is ELISA. ELISA is a known and established method of estimating dust mite allergen in solution. The method used in these assays is called Sandwich ELISA and it is based on the principle of antibody-allergen interaction. Essentially, to utilize this assay, one antibody (the “capture” antibody) is purified and bound to a solid phase attached to the bottom of a plate well. Allergen is then added and allowed to complex with the bound antibody. Unbound products are then removed with a wash, and a labelled second antibody (the “detection” antibody) is allowed to bind to the antigen, thus completing the “sandwich”. The assay is then quantitated by measuring the amount of labelled second antibody bound to the matrix, through the use of a colorimetric substrate.
[0016] Due to the variable exposure in the home, ideally research is needed to study the effects of dust mite allergen concentration in an EEC in which airborne allergen concentration is uniformly controlled and over set exposure times.
[0017] To study the effect of dust mite allergen, spent dust mite cultures are derived from living dust mites (specifically Dermatophagoides pteronyssinus and Dermatophagoides farinae ) which are cultured on a nutritive bed mounted over a grate to allow collection of the dust mite powders. These cultures contain particles of mite parts, feces, and other culture media components. An important component of the dust is dust mite allergen, which is present on the surface of dust particles. These dust mite allergens correspond to peptide sequences which have been isolated and shown experimentally to have allergenic properties. The exact allergens present are dependent on mite species cultured such that Der p1 is derived from Dermatophagoides pteronyssinus and Der f1 is derived from Dermatophagoides farinae . Particle sizes for either Der p1 or Der f1 range from submicron to over 100 microns.
[0018] With respect to particle size, it should be understood that particle penetration into the respiratory tree and lungs is dependent on particle size. Particles 2.5 microns in diameter or less are referred to as fine particulate matter, or PM2.5, and are penetrable to the terminal of the respiratory tree, the lungs. Coarse particulate matter, or PM10, is sized between 2.5 and 10 microns in diameter, and are known to lodge predominantly in the mid to lower respiratory tree. Due to evidence that there is a link between high levels of PM2.5 or PM10 and respiratory irritation and disease, the EPA has recommended that occupational daily exposures to these particles be less than 65 μg/m 3 and 75 μm 3 , respectively.
[0019] Under household conditions, a dust particle on which dust mite allergen is present is seen generally in particles 10 microns or greater, whereas for other household allergens, such as cat allergen, these are carried on particles less than 5 microns.
[0020] As mentioned, the etiology of asthma involves the narrowing of the respiratory tract such that insufficient air passes to the lungs resulting in reduced oxygenation and increased carbon dioxide retention which leads to some of the most devastating symptoms of asthma, such as inability to overcome the increased respiratory resistance and inability to appropriately aerate the lungs and breathe. Therefore, particles bearing allergen which are sized in the 5 to 10 micron range are likely the key determinants of asthma development and attacks. These particles can penetrate and lodge in the lowest part of the respiratory tree (not appreciably in the lungs) resulting in airway inflammatory response and narrowing of the airway, the latter due to constriction of the underlying smooth muscle in response to allergen application.
[0021] With respect to the disease itself, the two fundamental features of asthma are variability of airway caliber and increased bronchial hyperreactivity to non-specific stimuli (or “BHR”). The degree of BHR has been related to the number of inflammatory cells in the blood and airways, suggesting that the physiological dysfunctions in asthma are caused by an underlying inflammatory process. Allergens are considered to be important inducers of BHR in allergic patients.
[0022] Investigation of the disease via the introduction of allergen to an allergenic patient can enable the determination of the efficacy of treatment options. In particular, following high dose allergen exposure in an allergic patient, an early asthmatic reaction (or “EAR”) occurs immediately after exposure and after 3-7 hours, a late asthmatic reaction (or “LAR”) may develop in some patients. The EAR is transient and resolves in one hour. The LAR, on the other hand, is associated with influx of inflammatory cells into the blood and airways as well as the increase of BHR, which sometimes can persist for several days.
[0023] However, as mentioned, hitherto such clinical investigative models have been relatively limited.
[0024] A high dose allergen provocation model has been used to study pathophysiological mechanisms of allergic reactions and to evaluate the effects of novel therapeutic agents being developed for asthma, but this model has been criticized for being too experimental.
[0025] Repeated low dose allergen exposure with a nasal challenge model via a nebulizer has also been used with house dust mite exposure, this more closely resembles exposure to dust mite in the natural setting with intermittent exposures to moderate doses while dusting or making the bed. This can be done in mild asthmatics where the amount of allergen administered daily is about 25% of the dose of allergen that has caused an EAR and LAR. This dose does not lead to significant asthma symptoms, but the BHR is increased. However, this model fails to provide dust mite exposures in a more natural setting like that found in typical indoor environs.
[0026] Investigations can be carried out employing environmental exposure chambers, or “EECs”, which are chambers designed for the study of aerosol particulates. In the past, EECs have been used to look at industrial type exposures to particulate pollutants. For example, aerosolization studies were done with small particulate pollutants in chambers designed by Bryan & Blackmore, which were subsequently used by Briscoe & Day used as a model for the first designs of allergen chambers.
[0027] The first allergen really studied in this manner was ragweed pollen, which has been initially described and reviewed by Day et al. in 1999. In this study, Day describes a design of a chamber in which ragweed pollen is aerosolized and subjects with a history of allergy to ragweed are exposed in a controlled manner to this allergen.
[0028] Up until now, most studies have been conducted to study the effects of drug therapies on the symptoms of allergic rhinitis, particularly SAR.
[0029] Krug et al. carried out the most extensive published validation of a pollen exposure chamber. In this study, a laser counter was used to count pollen particles, but no relationship between particle size or counts was made to allergen content.
[0030] Other methods have been used to expose subjects in a controlled fashion to allergens, such as nasal allergen challenge (nasal lavage) and nebulization of allergen via an inhaler.
[0031] However, the use of chambers to study exposure to other non-pollen allergens such as dust mite allergen has been limited not only in the number of studies published, but also there have been few details provided about the exact methods or chamber designs for non-pollen allergen chambers. Most recently a review was published by Day et al. which provided some insight into the use of environmental chambers for investigating allergenic response, but that review provides little detail with respect to the design and use of the chamber for dust mite allergen challenge.
[0032] Non-pollen allergens have included mostly cat allergen or dust mite allergen studies. Most recently, Berkowitz et al. exposed patients to cat allergen to produce cat allergen induced rhinitis and study the effects of the antihistamine, fexofenadine on subjects with PAR. In this study and its predecessors a live cat challenge model is used for exposing patients to the cat allergen. The methods proved imprecise resulting in a wide range of individual cat allergen exposures, from 94.0 to as high as 9,101.0 ng/m 3 Fel d 1, leading to an inability to comment rigorously on the effectiveness of the test drug treatment in the individual. This indicates the importance of tightly controlling the airborne allergen levels.
[0033] With respect to dust mite, dust mite allergen exposure has been tested in a few published articles in which typical allergic symptom outcomes were measured in patients with PAR not asthma.
[0034] A first study, conducted by Horak et al. in 1994, exposed 12 patients to 40 ng Der p1 per cubic meter. The concentration of dust particles was monitored at 5 minute intervals by counting particles to a level of 4000 particles/m 3 . The preceding abstract to this paper stated that the estimated amount of allergen per particle, Der p1, was 0.02 ng. In neither abstract or publication was it stated what detection methods were used to measure or maintain this particle count, nor was particle count or particle size data provided over the course of the 4 hour study which would indicate the range of particle exposures.
[0035] High exposures to respirable particles sized less than 10 microns, PM10, or less than 2.5 microns, PM2.5 have been linked with respiratory disease and for these reasons the U.S. Environmental Protection Agency (EPA) has set out guidelines for daily exposures to PM10 and PM2.5 (discussed below). Therefore, it should be understood that the total particle count, as well as particle counts in critical PM10 and PM2.5 size categories, are important to monitor as well as to report the range in particle numbers to which patients are exposed. Consequently, tight control of daily particle count exposures is important and mandatory to ensure patient safety and limit the possibility for adverse reactions, particularly in the asthmatic patient.
[0036] In the Horak study, the ELISA method was used every hour to measure allergen content. However, once again allergen concentrations over the course of the experiment were not provided and no indication of variation in the allergen content measured indicated. Later studies increased the level and duration of dust mite allergen exposure to 70 ng/m 3 over 8 h and 110 ng/m 3 over 10 hours total exposure and 5 hours, but as for the initial study no indication of the variation in allergen concentration or particle sizes or counts was provided. Furthermore, although it was stated that the allergen batches were consistent, the particle counts stated varied unpredictably with the allergen content; such that, in the first study 40 ng/m 3 was said to be provided on 4000 particles/m 3 while later studies stated that a higher allergen load, 70 ng/m 3 , was provided on fewer particles, 2500 particles/m 3 . A more recent study did not provide any indication of the target allergen load but stated that it maintained the particle counts at the lowest particle count to date of 1000 particles/m 3 . No indication of the airborne dust mite allergen concentration or the method of particle counting performed was provided.
[0037] In 1997, Ronborg et al. published a study in which asthmatics were exposed to dust mite allergen in a chamber. In this study, a very small, cost-effective, portable chamber was used which had been developed for allergen challenge. This chamber holds only one subject at a time. The method of aerosolization of dust mite allergen involved solubilizing the allergen in buffered saline and human serum albumin (0.3%) and subsequent nebulization of this test solution. This resulted in the total exposure to the allergen over the course of the study to be 1200 ng (if averaged over the course of the entire study, the average exposure is estimated to be 50 ng/m3, however notably exposure would not be constant since there are no mechanisms to maintain this airborne concentration). This chamber's design and mode of exposure results in a profile of dust mite allergen exposure such that the allergen load is not constant over the duration of the study and there is an initial peak of nebulized allergen, followed by a clearing period of several hours. Therefore, the fact that allergen load was not constant over the course of the studies may in part result in some of the patient inconsistencies observed in this study.
[0038] In sum, the dust mite allergen studies discussed above, though pioneering, do not provide the level of control of dust mite allergen exposures that are required, even for the study of patients with mild asthma. A dust mite allergen challenge model for the study of asthma will require that the airborne allergen level be tightly controlled and monitored. The duration of the exposure should be maximized within the bounds of tolerability and safety to allow the study of the efficacy of drug therapies but also to provide insights into the nature of the correlation between dust mite allergen load and the symptoms and etiology of asthma.
[0039] On the basis of the foregoing, there is a need for a novel method and apparatus for applying dust mite allergen in a controlled manner to elucidate the etiological links between allergen particles and asthma.
SUMMARY OF THE INVENTION
[0040] The present invention provides a method, materials and apparatus for investigating asthma in humans using dust mite allergen.
[0041] It is known that dust mite powders need to be of a particular size in order to penetrate the human respiratory tree, namely approximately 10 microns or less in diameter. However, particles that are too small, i.e. less than 2.5 microns in diameter, have a tendency to collect in the lungs. Further, in general, the larger the dust mite particle, the greater the surface area and therefore the greater the allergen content. Finally, it should be borne in mind that it is difficult to effectively aerosolize larger particles.
[0042] According to one aspect of the present invention, dust mite culture is used to prepare a dust mite preparation comprising powders of a controlled particle size, the controlled particles size striking a balance between the considerations listed above. In other words, the controlled particle size allows the particles to be respirable in humans, effectively aerosolized and deliver a significant amount of allergen. The present invention optimizes these factors in order to implement dust mite allergen for an asthma challenge model.
[0043] According to another aspect of the present invention, dust mite powder of a controlled size is aerosolized into an environmental exposure chamber to elucidate the etiological links between dust mite allergen concentration and asthma response in humans. The environmental exposure chamber is specially-designed to promote the homogenous distribution of the allergen.
[0044] Preferably, the dust mite allergen preparation comprises particles having an average diameter of less than 25 microns, and more preferably an average particle size of 5-10 microns. Advantageously, investigation into aerosolized particle number and dust mite allergen concentration has revealed that a very strong correlation exists for particles within the 5-10 micron diameter range. In accordance with yet another aspect of the present invention, this correlation allows for particle counting methods to estimate the allergen concentrations, enabling “real-time” prediction of concentration levels without the use of expensive and time-consuming assay analysis techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] A detailed description of the preferred embodiments are provided herein below by way of example only and with reference to the following drawings, in which:
[0046] FIG. 1 is flowchart illustrating general method steps in accordance with one aspect of the present invention.
[0047] FIG. 2 is a flowchart illustrating the steps in correlating allergen measurements with measurements of particle numbers and sizes to yield an estimate airborne allergen concentration.
[0048] FIG. 3 is a flowchart illustrating an approach for aerosolization within an environmental exposure chamber to achieve a particular airborne allergen concentration.
[0049] FIG. 4 is a graph illustrating sample particle counts obtained in an EEC for different milled dust mite culture particle sizes.
[0050] FIGS. 5A and 5B are graphs illustrating sample particle counts obtained in an EEC for 5 and 10 μm particle sizes, respectively.
[0051] FIG. 6 is a three-dimensional graph illustrating a volumetric model of allergen concentration in an EEC.
[0052] FIG. 7 is a graph illustrating a strong covariation between aerosolized particle number and dust mite allergen concentration for both 5 μm and 10 μm particle sizes.
[0053] FIG. 8 illustrates the covariation between particle number and allergen concentration for 0.5 μm particles.
[0054] FIG. 9 illustrates the covariation between particle number and allergen concentration for 1 μm and 2 μm particles.
[0055] FIG. 10 illustrates the covariation between particle number and allergen concentration for 25 μm particles.
[0056] FIG. 11 illustrates the covariation between particle number and allergen concentration for 5 and 10 μm particles.
[0057] In the figures, embodiments of the invention are illustrated by way of example. It is expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0058] Dust mite allergen for Der p1 is present on spent dust mite cultures from dust mite Dermatophagoides pteronyssinus . The particle size on which the allergen is borne is a critical factor in determining the level to which dust mite allergen can penetrate the human respiratory tree. Dust mite powders from spent dust mite cultures have a preponderance of larger particle sizes greater than 25 microns which are relevant to test respiratory disease of the upper respiratory tract.
[0059] However, in an aspect of the present invention, it has been discovered that there is a clear correlation between airborne allergen concentration in a chamber and particle number of dust mite allergen particles sized 5 or 10 microns. The physical basis for this finding is that larger particles have larger surface area such that as the radius of the particle increases by a unit amount, the surface area increases in a squared unit manner. Since the largest particles aerosolized in an EEC, i.e. 25 microns or greater, do not remain airborne appreciably, the next largest particles, 5 and 10 microns (which are stably airborne), carry a significant amount of allergen and their particle number can be used to predict allergen concentration.
[0060] In this regard, the controlled particle size is essentially a balance of considerations such that the optimal particles are both of a respirable size and of a size that allows effective aerosolization. This is important and advantageous since this indicates that rather than conducting many costly ELISA analyses, initial and fewer ELISA analyses can be used to “calibrate”the allergen content within an EEC. Also, since ELISA analyses take at least 6 hours to perform, laser counting of critical particle sizes can be used as a real-time indication and approximation of airborne allergen concentration.
[0061] The finding that particles sized 5 and 10 microns correlate closely with airborne allergen concentration is particularly advantageous in the EEC setting since these particles can be suspended in a routine and controllable fashion whereas the smallest particles (2.5 microns or less) are easily re-suspended with any movement in the chamber and less controllable. The advantages and appropriateness of the study of dust mite allergen on particles sized 5 to 10 microns are therefore obvious and desirable.
[0062] As discussed above, house dust is a strongly allergenic material because it is usually heavily contaminated with the faecal pellets and skins of the dust mite Dermatophagoides . Generally, in order to produce the required materials in accordance with the present invention, spent dust mite cultures are derived from dust mites housed in an open glass box and bred on a diet of baker's yeast set. Generally, faecal pellets and mite skins are harvested and crudely sieved to produce dust mite powders for research purposes. For example, dust mite powder derived from spent dust mite cultures can be purchased from INDOOR Biotechnologies Inc. (U.S.A.). Preferably these powders are desiccated to inhibit particle clumping and decrease average particle size, however some clumping and particle size increases may still occur. As stated, the allergenic component is believed to be proteins of digestion present in mite cultures which have proteolytic activity, specifically Der p and Der f proteins.
[0063] Because of the clear importance of particle size with respect to studying asthmatic response, dust mite allergen can be prepared having a controlled particle size. This novel concept comprises preparing the dust mite allergen so that the particles have an average diameter in the respirable range, as discussed, namely less than 25 microns, and preferably 2.5 to 15 microns, and more preferably 5 to 10 microns. In this sense, the dust mite allergen particles are engineered or conditioned to improve the suitability for etiological testing. Without this step, the particle sizes for the dust mite are invariably too large, preventing effective aerosolization from being achieved, and consequently hindering (and perhaps even preventing) the use of airborne dust mite allergen for asthma studies.
[0064] In one embodiment of the present invention, mechanical milling is used to condition dust mite allergen powders in order to reduce both particle size and size variation for their use as an experimental inhalant.
[0065] Milling is an example of a mechanical means for preparing dust mite allergen particles of a controlled size. In general, milling is a process involving mechanical impaction using hard materials to create fine powders. Ball milling is a common type of milling, involving colliding hard balls with the relevant material, thereby crushing the material to a power. The longer a material is ball milled, the smaller the average diameter of the particles.
[0066] However, it should be expressly understood that milling or other mechanical methods are only one means of preparing dust mite powder having a controlled particle size, and the present invention contemplates any other means for either achieving the desired result, namely preparing dust mite allergen particles with an average size of 25 microns or less, or more preferably having an average particle size of 5-10 microns. In this regard, any means of sorting particles is acceptable. For example, a cyclone can be used to “sort” dust mite allergen particles, in a manner that is known. Other sorting methods are known, including for example sieving or use of an elutriator.
[0067] Since spent dust mite cultures are hygroscopic, when exposed to air they can become sticky which can lead to reduced product quality and shape and size non-uniformity. Therefore, milling of dust mite cultures is preferably performed under conditions that limits exposure of the milled particles to air, such as an inert environment under low humidity, or in a gaseous environment like nitrogen gas.
[0068] Optical particle counting and impactor train sampling can be used to characterize both the initial parent and ball-milled dust mite sample particle size and particle morphology. Size separated samples can be utilized to determine material specific gravity from settling experiments. Quartz particles of known particle size distribution can be used as “standard” particles for phenomenological comparison.
[0069] In one particular experiment, the data provided after milling demonstrated that 95% (by particle count) of the parent mite culture was comprised of particles greater than 10 μm with most particles being approximately 30 μm in diameter. Particles with 30 μm diameters are calculated to have a settling time of approximately 30 s for an 8 foot fall and 10-30 s breathing zone residence time. For reasons discussed above, these properties are appropriate for use as an experimental inhalant. The controlled milling of parent material resulted in 98% (by particle count) of the particles being less than 10 μm with irregular particle shapes and with suspension times of minutes to hours. Milled dust mite particles had similar aerodynamic characteristics to standard quartz particles of the same size. In this way, dust mite allergen carrier particles were prepared with known particle size and aerodynamics, such that disease relevant particles sized 5-10 μm are increased and particle size variation is decreased.
[0070] According to another aspect of the present invention, the dust mite allergen preparation can then be used within an environmental exposure chamber for the study of dust mite allergen effects on patients. Aerosolization of fine particulate matter is well known in the art. Generally speaking, “aerosolization” refers to any method of converting a powder to a spray or suspension in air. In this regard, the present invention is not limited to any one aerosolization method but contemplates any means to aerosolize the particles into the air of the chamber. What is important is that the aerosolization of dust mite allergen achieves exposure ranges within the EEC that are comparable to that reported for household exposures.
[0071] Preferably, the chamber and aerosolization designs allow for the levels of ambient dust mite allergen to remain stable at a specific level. For example, 100 ng/m3 corresponds with levels that have been reported in household bedroom and living areas. Therefore, the use of this chamber to develop a model for asthma testing will provide etiological insights into asthma as well as a therapeutic test model.
[0072] The general method steps for this approach are illustrated in FIG. 1 . The development of a model to test therapeutic effectiveness under more natural exposure conditions will provide a significant advance both scientifically and from a drug testing and therapeutic and regulatory stand point.
[0073] For the design of an appropriate EEC, regard must be had to certain specifications, namely humidity control, temperature control and HVAC, as well as (i) control of dust mite allergen delivery on respirable particle size, (ii) dust mite allergen aerosolization, (iii) quantification and verification of accuracy dust mite allergen concentration, (iv) quantification of respirable particle size and number, and (v) quantification and correlation analysis between particle size and number and dust mite allergen concentration.
[0074] In accordance with one particular embodiment, an EEC is an enclosed space in which airborne particulates, in this case the dust mite allergen, are kept within strict limits. It is a room designed to full Level II Clean Room specifications. In this example, it is a 125 m 2 room with a seating capacity of 60 subjects. Humidity and temperature are tightly controlled with thermostatic and hygrometric feedback systems. Heating, ventilation and cooling are adjusted to maintain at least 6.5 air exchanges per hour. The room is supplied with clean fresh air via eight ceiling mounted vents. Both air inlets and outlets are fitted with High Efficiency Particulate Air filters (HEPA). This prevents contaminants from being introduced into the controlled environment from the outside. The room is under a slightly positive pressure relative to adjoining areas to ensure no entry of particulate contaminants from these exterior areas into the chamber. In addition, a small directly connected airlock chamber is attached to the chamber which is enclosed on both sides by doors to minimize any transient changes in environmental factors or airborne particulates upon entry or exit from the chamber.
[0075] The walls and ceiling of the chamber are covered with a statically dissipative paint which acts to reduce dust mite powder build up on the walls of the chamber and limit this as a dust powder source or reservoir. The floor of the chamber is covered with smooth, resilient, sheet flooring with few seams. The flooring and ceiling curves upward to meet the walls to form rounded corners and baseboards, such that dust collection is minimized. These floor specializations allow the floor to act as a reservoir for settled dust—particularly the largest dust particles (those larger than 25 μm with approximate 8′ settling times of 20 s). Unlike typical clean room standards, dust mite allergen bearing particles larger than 0.3 μm will accumulate (since HEPA filters on chamber air outlets will permit passage of particles <0.3 mm). However, as described in the experimental protocol below, airborne particle numbers and allergen content will be estimated in real-time and particle aerosolization parameters adjusted accordingly to maintain constant airborne allergen concentrations and particle exposures, which do not exceed daily PM10 or PM2.5 EPA standards. Furthermore, the large particles which will accumulate in the floor reservoir are difficult to re-suspend and therefore will not contribute appreciably to airborne particulate levels.
[0076] At least one fan is placed in the chamber to create turbulent airflow to prolong dust aerosolization. The number and placement of fans is based on individual chamber characteristics and are determined from measurement of dust mite allergen and particle size and number at various points in the chamber. The aerosol generator is placed behind a wall in the chamber to prevent subject observation of its operation. Additionally, this wall promotes laminar flow about the aerosol generator.
[0077] The particle allergen levels can be measured using a volumetric sampler with a glass fiber filter and then using ELISA to quantify the amount of allergen. The particle size and number within the chamber or even within a particular area of the chamber can be quantified using a laser particle counter, for example. Preferably, this can be conducted on a real-time basis. In turn, correlation analysis is carried out to correlate the particle size and number information with the dust mite allergen concentration information obtained using ELISA to yield an estimate of the allergen concentration for the EEC (or an area within the EEC). In this regard, the correlation is essentially used as a calibration means such that the allergen concentration can be estimates for areas of an EEC by collecting particle count information. This can be done substantially in “real-time”, and greatly reduces the number of costly ELISA analyses required. FIG. 2 generally illustrates the steps for this correlation analysis.
[0078] FIG. 3 illustrates a general approach “algorithm” for aerosolizing dust mite powder into an EEC to achieve a desired average dust mite allergen concentration, e.g., 50 to 200 ng/m 3 , or preferably 80±50 ng/m 3 . Mill dust mite powder is aerosolized in an EEC. There are two key variables for the control of the dust mite allergen concentration: variable one is the aerosol generation; and variable two is the room dynamics. Variable one depends on, for example, the settings used for the aerosol generator if that is the means used to aerosol the powder into the chamber. Variable two, the room dynamics, depends on, inter alia, the number, speed and placement of fans, the HVAC specifications, and the size and shape of the room.
[0079] An equilibration period is required so that the allergen concentration in the chamber environment reaches a steady state, e.g. after 2 or 3 hours. Once this is achieved, the allergen concentration and particle count information can be assessed. If either the concentration range (i.e. less than 80 or greater than 130 ng/m 3 , for example) or the particle counts are not achieved, then the aerosol generation is adjusted accordingly. If they are within the appropriate range, then spatial uniformity within the EEC is addressed by collecting air samples throughout the chamber. If the allergen concentration within the chamber is not reasonably homogenous, then the room dynamics are altered accordingly. For example, the number of fans and their locations can be altered to obtain spatial uniformity within the chamber.
[0080] Particle exposures for PM10 and PM2.5 are generally adhered to such that if particle exposures are too high, the aerosol generator settings are altered. If the dust mite allergen concentration and particle numbers are acceptable, then spatial uniformity within the EEC was addressed by collecting air samples throughout the chamber. Preferably, both the allergen concentration and the particle count analyses are conducted at different locations within the chamber, and move periodically.
[0081] As an example, the present invention can be implemented to develop a clinical model to evaluate relative potency of inhaled steroids with mild experimental exacerbation of asthma induced in dust mite allergic asthmatic subjects in an environmental exposure chamber. Preferably, during such a study a chamber in accordance with the present invention maintains the level of dust mite airborne allergen uniformly controlled between 50-120 ng/m3. Such a study would employ an EEC and methodologies required to aerosolize dust mite allergen in a controlled environment such that allergen and particle concentrations are maintained generally homogeneously across the room.
[0082] In general, in order to demonstrate equivalence of a second entry inhaled steroid product, it is known that a pharmacokinetic study design is not appropriate, because the drug is locally acting and the systemic levels detected are not necessarily indicative of the topical dose delivered to the pulmonary mucosa. Factors such as particle size and delivery device greatly affect the amount of drug delivered to the lung versus the amount swallowed orally. As a result, a pharmacodynamic response study needs to be used to show therapeutic equivalence. The study design used must be able to reliably show possible differences in relative potency between the test and reference formulations.
[0083] It is known that daily low dose allergen challenge in mild to moderate asthmatics induces a measurable reduction in lung function with reduction of FEV1 over a period of 4 to 5 days. Consequently, in accordance with the present invention, an asthma investigation model can be implemented with continuous allergen challenge in an EEC, as opposed to repeated daily low dose allergen challenge.
[0084] Such a clinical equivalence study is designed to assess the deterioration of asthma in an EEC asthma model following a short course of oral steroids with two different inhaled doses. This approach has the advantage that the baseline is the inverse of previous study models in that the starting point is best possible control with a short course of oral steroid. Because of this, baseline can be achieved at the end of each period with another course of oral steroid and a crossover study can be done with no detectable carry-over.
[0085] This modelling approach comprises a number of advantages, including: (i) controlled allergen exposure results in reduced variability of data produced; (ii) with the lower variability, the sample size will be lower; (iii) the length of the study is generally significantly less than is typical which results in better retention; (iv) observed dosing and lung function measurements results in 100% compliance and very reliable data; and (v) extraneous factors such as seasonal influences and risk of upper respiratory infections which will influence primary endpoint are minimized as the patients are confined.
[0086] For example, an EEC is a room (1600 sq. ft.) built to Level II Clean Room specifications where a specially designed dust feeder is used to release spent dust mite feces particles. The air flow and air circulation throughout the room is specially designed to ensure stable levels of ambient dust mite of approximately 100 ng/m 3 . In milled spent dust mite particles, the majority of Der p1 has been found in particles sized 5 to 10 microns, as discussed above. This size range allowed tight control of allergen aerosolization (little re-suspension), and was in the range of respirable particle size that is important in the etiology of asthma. Preferably, the EEC maintains this level indefinitely.
[0087] As described above, the airborne dust mite levels in the EEC can be measured using a volumetric sampler with a glass fiber filter. The levels of allergen are then measured using an ELISA assay to quantify the amount of allergen per meter cube in the air sampled.
[0088] The model is developed in two phases, as an example: (i) phase one involves the graduated exposure to dust mite allergen in the EEC with healthy mild asthmatics with increased time over seven stages; and (ii) once safety of exposure to dust mite in the EEC has been established, in phase two 12 subjects will be enrolled in a double blind cross-over study to establish the sensitivity of the model to ascertain the difference between two doses of a standard inhaled steroid.
[0089] Phase one will be run in several stages to ensure subject safety. The initial assessment will be limited to a single subject with low level allergen challenge (e.g., 25 ng/m 3 ) of up to 8 hours under careful observation. The time will be increased depending on the tolerance of the subject. Once safety has been established at a low level of allergen exposure, the same procedure will be repeated at moderate level (e.g., 50 ng/m 3 ) of allergen exposure.
[0090] For phase two, the study will be conducted as a double blind three way cross-over design with placebo and two doses of oral steroid per day. There will be a qualifying period where subjects will be exposed to house dust mite allergen Der p1 in the EEC for a period of time to ensure that there is deterioration of asthma with exposure (the exact length of exposure will be determined from data obtained from phase one). Following the qualifying period, subjects will be randomized to one of the two steroid doses or placebo. The treatment will be administered once per day in the morning under direct supervision. At the start of each period, subjects will receive a 2 to 3 day course of oral or inhaled steroid at home, to achieve complete control of their asthma. At the end of the course, the subjects will be admitted to the EEC and will be exposed to Der p1 antigen level of approximately 100 ng/m 3 . Subjects will be continuously in the EEC for a period of 7 days, while being continuously monitored with a physician or paramedic present. While sleeping, subjects will be visually observed for signs of respiratory distress.
[0091] Preferably, subjects will be screened according to reasonable inclusion and exclusion criteria.
[0092] The EEC will be equipped for overnight stay with beds; washroom and shower facilities will be available just outside the EEC. During the stay in the EEC subjects will have various measurements taken at pre-determined intervals, e.g., spirometry measuring FEV1, FEF 25-75 etc., every hour for the first 6 hours then every four hours while awake.
EXAMPLE
[0093] Cultured spent dust mite cultures were acquired from a supplier (in this case INDOOR Biotechnologies Inc. of Charlottesville, Va., U.S.A.). These cultures were conditioned such that dust mite culture particles are size reduced with the majority of the particles to be less than 25 μm, and generally in the range of 5-15 μm. Particle size reduction was achieved with ballmilling under low humidity conditions (or other inert gas conditions) suitable for hygroscopic powders. Milled dust mite cultures were stored at room temperature and desiccated to prevent clumping.
[0094] Milled dust mite cultures were aerosolized with an aerosol generator within an EEC, as described above, with the dust mite particle aerosolization maintained with generation of turbulent flow within the chamber by at least one fan placed strategically in the chamber.
[0095] The number of fans and their position within the chamber which are required for maintenance and spatial distribution of dust mite allergen is determined by examining the airborne dust mite allergen and particle numbers, in the manner described above. The airborne dust mite allergen concentration, at least initially, is determined by the setting on the aerosol generator such that the rate of aerosolization must be adjusted to obtain ideal dust mite allergen bearing particle release. Airborne dust mite allergen concentration was determined by collecting air samples during the course of the study using high volume air samplers and analyzing these samples using ELISA. Specifically in this case, the dust mite allergen Der p 1 was measured.
[0096] The numbers of airborne particles in each size range of 0.5, 1, 2, 5, 10, and 25 μm was determined using LASAIR II™ particle counter (manufactured by Particle Measuring Systems of Boulder, Colo., U.S.A.). FIG. 4 illustrates the particle counts obtained in the EEC for different milled dust mite particle sizes.
[0097] FIG. 5A illustrates the particle count profile for 5.0 μm particles. The particle count initially increased when the aerosol generator was turned on at approximately 11:20. After an equilibration period of 2.5 h, the average particle count could be obtained over 1 hour (2:30-3:30).
[0098] FIG. 5B illustrates the particle count profile for 10.0 μm particles. The particle count for 10 μm particles followed the same time profile as for 5 μm particles, however there were approximately 20-fold fewer particles aerosolized for 10 μm particles compared to 5 μm particles.
[0099] One objective in these studies was to obtain airborne dust mite allergen concentrations of 80±50 ng/m 3 and to obtain spatial uniformity for this targeted airborne dust mite allergen at a patient seated eye level, which is generally 48″ above chamber floor. FIG. 6 illustrates that (using the experimental algorithm as discussed with reference to FIG. 3 ) the spatial uniformity throughout an EEC can be achieved within the etiologically relevant dust mite allergen exposure range. In this case, the mean dust mite allergen concentration (“[DMA]”) was 85.4±5.7 ng/m 3 with a maximum value of 115 ng/m 3 and a minimum value of 50.7 ng/m 3 . The allergen concentration values were connected with volumetric smoothing (created using PSI-PLOT™, v.7.01, Poly Software International of Pearl River, N.Y., U.S.A.).
[0100] Another objective was that these airborne dust mite allergen concentrations were to be achieved without exceeding the PM10 and PM2.5 EPA particle exposure guidelines. Calculations over the course of a 6-hour exposure demonstrated that levels were well below the recommended levels for PM10 and PM2.5, with 12.30±0.51 ng/m 3 and 1.86±0.30 ng/m 3 recorded, respectively.
[0101] Finally, as this was for the purposes of investigating the asthma response to dust mite allergen, the allergen should be carried primarily on disease-relevant sized particles of 5 to 10 μm. In this case, there was a strong correlative relationship between airborne dust mite allergen concentration and the average particle counts for the 5 and 10 μm sized particles in the dust mite preparation. FIGS. 7 to 10 demonstrate this point graphically.
[0102] In particular, FIG. 7 illustrates a strong covariation between aerosolized particle number and dust mite allergen concentration for both 5 μm (indicated with “▴”) and 10 μm particles sizes (indicated with “▪”), with r2=0.99 for both. These correlations were significant (p<0.05). Using this correlation, the airborne dust mite allergen concentration could be accurately estimated from particle counts for 5 and 10 μm size particles.
[0103] FIG. 8 illustrates the covariation between particle number and dust mite allergen concentration for 0.5 μm particles revealed r2=0.67, which were not significant.
[0104] FIG. 9 illustrates the covariation between particle number and dust mite allergen concentration for 1 μm (indicated with “▪”) and 2 μm particles (indicated with “▴”) revealed r2=0.64 and 0.92, respectively, which were both not significant.
[0105] Finally, FIG. 10 illustrates the covariation between particle number and dust mite allergen concentration for the largest (25 μm) particles revealed r2=0.67, which was not significant.
[0106] FIG. 11A summarizes the results of FIGS. 7 to 10 by demonstrating that the strongest correlation exists between the 5 and 10 μm sized particles and the dust mite allergen. This correlation is likely at least in part due to the biophysical properties of the milled dust mite particles such that more dust mite allergen is carried on larger particles. In FIG. 11B , the settling time is compared to particle size. In FIG. 11C , particle size is correlated with surface area (given in μm2). Clearly, the optimization of all FIGS. 11A , 11 B and 11 C occur for particles having a diameter of 5 to 10 microns.
[0107] Retrospective analyses of experiments demonstrate that the dust mite allergen concentration, measured by ELISA, was not significantly different from those estimated using 5 and 10 μm particle count calibrations, and hence in this well-defined system using milled dust mite cultures the airborne dust mite allergen concentration could be accurately estimated from particle numbers specifically for disease-relevant particles sized 5 and 10 μm, being 82.7±11.5 ng/m 3 and 75.0±20.4 ng/m 3 , respectively.
[0108] These studies indicate that these methods can be used to achieve a well controlled level of airborne dust mite allergen exposure in a natural setting that is more representative of typical dust mite allergen exposures in the household and elsewhere. These methods can be used to estimate and monitor dust mite allergen exposure in substantially real-time, on a minute-byminute basis. This is important for the development of an EEC model in which long-standing, low level exposures will be required to study asthma in a safe and well-tolerated manner.
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The present invention comprises a method, materials and apparatus for investigating asthma in humans using dust mite allergen. The dust mite allergen is prepared to be of a controlled size such that particles are respirable, effectively aerosolized, and deliver a significant amount of allergen. The dust mite allergen is applied in a controlled manner within an environmental exposure chamber to elucidate the etiological links between dust mite allergen concentration and asthma response in humans. The environmental exposure chamber is specially-designed to promote homogeneity of allergen concentration. Preferably, the dust mite allergen preparation comprises particles having an average diameter of less than 25 microns, and more preferably 5-10 microns. Correlation between aerosolized particle count and allergen concentration enables “real-time” allergen concentration estimates without the use of expensive and time-consuming assay techniques.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Nonprovisional patent application Ser. No. 13/198,214, filed Aug. 4, 2011; which is a continuation of U.S. Nonprovisional patent application Ser. No. 13/089,482, filed Apr. 19, 2011, now U.S. Pat. No. 8,022,093; which is a divisional of U.S. Nonprovisional patent application Ser. No. 12/752,642, filed Apr. 1, 2010, now U.S. Pat. No. 7,956,048; which claims the benefit of U.S. Provisional Patent Application Ser. Nos. 61/165,638, filed Apr. 1, 2009; 61/167,297, filed Apr. 7, 2009; 61/171,894, filed Apr. 23, 2009; 61/177,019, filed May 11, 2009; 61/180,961, filed May 26, 2009; 61/223,685, filed Jul. 7, 2009; and 61/266,364, filed Dec. 3, 2009, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to polymorphs of Eltrombopag and Eltrombopag ethanolamine salt, preparation of these polymorphs and pharmaceutical compositions comprising them.
BACKGROUND OF THE INVENTION
Eltrombopag, (Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxylic acid is a compound having the following chemical structure:
It is a small-molecule, non-peptide thrombopoitin (TPO) receptor agonist that stimulates the proliferation and differentiation of megakaryocytes. Eltrombopag is marketed under the trade name Promacta® by GlaxoSmithKline and Ligand Pharmaceuticals as a bisethanolamine salt of the following chemical structure:
for the treatment of conditions leading to thrombocytopenia.
Eltrombopag is disclosed in U.S. Pat. Nos. 7,332,481 and 7,160,870; WO patent application 01/89457; and in EP patent No. 1294378.
Eltrombopag bisethanolamine salt is disclosed in US 2006/0178518 (corresponding to WO 03/098992).
Polymorphism, the occurrence of different crystal forms, is a property of some molecules and molecular complexes. A single molecule may give rise to a variety of polymorphs having distinct crystal structures and physical properties like melting point, thermal behaviours (e.g. measured by thermogravimetric analysis—“TGA”, or differential scanning calorimetry—“DSC”), x-ray diffraction pattern, infrared absorption fingerprint, and solid state NMR spectrum. One or more of these techniques may be used to distinguish different polymorphic forms of a compound.
Discovering new polymorphic forms and solvates of a pharmaceutical product can provide materials having desirable processing properties, such as ease of handling, ease of processing, storage stability, and ease of purification or as desirable intermediate crystal forms that facilitate conversion to other polymorphic forms. New polymorphic forms and solvates of a pharmaceutically-useful compound or salts thereof can also provide an opportunity to improve the performance characteristics of a pharmaceutical product. It enlarges the repertoire of materials that a formulation scientist has available for formulation optimization, for example by providing a product with different properties, e.g., better processing or handling characteristics, improved dissolution profile, or improved shelf-life. For at least these reasons, there is a need for additional polymorphs of Eltrombopag and Eltrombopag ethanolamine salt.
SUMMARY OF THE INVENTION
The present invention provides crystalline forms of Eltrombopag, Eltrombopag bisethanolamine and monoethanolamine salts, and processes for preparing them.
In one embodiment the present invention encompasses crystalline Eltrombopag designated form I characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 4.0, 7.3, 7.7, 12.1 and 16.1° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 1 ; a solid state 13 C NMR spectrum having peaks at 166.9, 155.4, 134.1, 125.7 and 111.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 35 ; and any combination thereof.
In another embodiment the present invention encompasses crystalline Eltrombopag designated form III characterized by data selected from a group consisting of: powder XRD pattern having peaks at 9.2, 11.2, 12.2 and 14.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 3 ; a solid state 13 C NMR spectrum having peaks at 170.6, 128.7, 124.2 and 113.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 36 ; and any combination thereof.
In yet another embodiment the present invention encompasses crystalline Eltrombopag designated form V characterized by data selected from a group consisting of: powder XRD pattern having peaks at 5.9, 8.2, 10.5 and 12.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 7 ; a solid state 13 C NMR spectrum having peaks at 142.0, 131.6, 114.9 and 67.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 37 ; and any combination thereof.
In one embodiment the present invention encompasses crystalline Eltrombopag designated form XVI characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 7.1, 9.5, 13.9, 21.2 and 25.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 20 ; a solid state 13 C NMR spectrum having peaks at 168.7, 156.7, 127.6 and 112.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 38 ; and any combination thereof.
In another embodiment the present invention encompasses the use of any one, or combination, of the above described crystalline forms of Eltrombopag to prepare Eltrombopag ethanolamine salt, or a formulation thereof.
In yet another embodiment the present invention encompasses a process for preparing Eltrombopag ethanolamine salt comprising preparing any one, or combination, of the above described crystalline forms of Eltrombopag by the processes of the present invention and converting them to Eltrombopag bisethanolamine salt.
In yet another embodiment the present invention encompasses crystalline Eltrombopag bisethanolamine salt designated form II characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 9.3, 11.8, 13.2 and 17.7° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 24 ; a solid state 13 C NMR spectrum having peaks at 174.9, 147.1, 135.4 and 58.7±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 39 ; and any combination thereof.
In one embodiment the present invention encompasses the use the below described crystalline form of Eltrombopag bisethanolamine salt to prepare for the manufacture of a medicament for the treatment of conditions leading to thrombocytopenia.
In another embodiment, the present invention encompasses a pharmaceutical composition comprising at least one of the below described polymorphs of Eltrombopag monoethanolamine and Eltrombopag bisethanolamine salt and at least one pharmaceutically acceptable excipient.
In yet another embodiment the present invention encompasses the use of any one, or combination, of the below described crystalline forms of Eltrombopag monoethanolamine salt to prepare Eltrombopag bisethanolamine salt, and or formulation comprising thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a powder XRD pattern of crystalline Eltrombopag designated form I.
FIG. 2 shows a DSC thermogram of crystalline Eltrombopag designated form I.
FIG. 3 shows a powder XRD pattern of crystalline Eltrombopag designated form III.
FIG. 4 shows a DSC thermogram of crystalline Eltrombopag designated form III.
FIG. 5 shows a powder XRD pattern of crystalline Eltrombopag designated form IV.
FIG. 6 shows a DSC thermogram of crystalline Eltrombopag designated form IV.
FIG. 7 shows a powder XRD pattern of crystalline Eltrombopag designated form V.
FIG. 8 shows a DSC thermogram of crystalline Eltrombopag designated form V.
FIG. 9 shows a powder XRD pattern of crystalline Eltrombopag designated form VI.
FIG. 10 shows a powder XRD pattern of crystalline Eltrombopag designated form VII.
FIG. 11 shows a powder XRD pattern of crystalline Eltrombopag designated form VIII.
FIG. 12 shows a DSC thermogram of crystalline Eltrombopag designated form VIII.
FIG. 13 shows a powder XRD pattern of crystalline Eltrombopag form IX.
FIG. 14 shows a powder XRD pattern of crystalline Eltrombopag form X.
FIG. 15 shows a powder XRD pattern of crystalline Eltrombopag form XI.
FIG. 16 shows a powder XRD pattern of crystalline Eltrombopag form XII.
FIG. 17 shows a powder XRD pattern of crystalline Eltrombopag form XIII.
FIG. 18 shows a powder XRD pattern of crystalline Eltrombopag form XIV.
FIG. 19 shows a powder XRD pattern of crystalline Eltrombopag form XV.
FIG. 20 shows a powder XRD pattern of crystalline Eltrombopag form XVI.
FIG. 21 shows a DSC thermogram of Eltrombopag form XVI.
FIG. 22 shows a powder XRD pattern of amorphous Eltrombopag bisethanoamine salt.
FIG. 23 shows a DSC thermogram of amorphous Eltrombopag bisethanolamine salt.
FIG. 24 shows a powder XRD pattern of crystalline Eltrombopag bisethanolamine salt designated form II.
FIG. 25 shows a DSC thermogram crystalline Eltrombopag bisethanolamine salt designated form II.
FIG. 26 shows a powder XRD pattern of crystalline Eltrombopag bisethanolamine salt designated form III.
FIG. 27 shows a DSC thermogram crystalline Eltrombopag bisethanolamine salt designated form III.
FIG. 28 shows a powder XRD pattern of crystalline Eltrombopag bisethanolamine salt designated form I.
FIG. 29 shows a powder XRD pattern of crystalline Eltrombopag mono-ethanolamine salt designated form H.
FIG. 30 shows a powder XRD pattern of crystalline Eltrombopag mono-ethanolamine salt designated form E.
FIG. 31 shows a powder XRD pattern of crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) form I.
FIG. 32 shows a powder XRD pattern of crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) form I.
FIG. 33 shows a powder XRD pattern of crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) form II.
FIG. 34 shows a powder XRD pattern of crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) form II.
FIG. 35 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag designated form I.
FIG. 36 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag designated form III.
FIG. 37 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag designated form V.
FIG. 38 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag designated form XVI.
FIG. 39 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag bisethanolamine salt designated form II.
FIG. 40 shows a solid state 13 C NMR spectrum of crystalline Eltrombopag bisethanolamine salt designated form I.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to polymorphs of Eltrombopag, Eltrombopag ethanolamine salt, preparation of these polymorphs and pharmaceutical compositions thereof. In particular, the present application provides crystalline forms of Eltrombopag having high chemical purity, which can be used to prepare Eltrombopag salt in high chemical purity.
The present application provides Eltrombopag in a crystalline form, which is exceptionally attractive for making pharmaceutical formulations, as compared to the amorphous forms disclosed in the prior art, which generally demonstrate low purity.
As used herein, and unless stated otherwise, XRPD peaks preferably refer to those measured using Cu radiation at 1.54 angstroms.
As used herein, the term “Room temperature” refers to a temperature between about 20° C. and about 30° C. Usually, room temperature ranges from about 20° C. to about 25° C.
As used herein, the term “Overnight” refers to a period of between about 15 and about 20 hours, typically between about 16 to about 20 hours.
A crystal form may be referred to herein as being characterized by graphical data “as depicted in” a Figure. Such data include, for example, powder X-ray diffractograms and solid state NMR spectra. The skilled person will understand that such graphical representations of data may be subject to small variations, e.g., in peak relative intensities and peak positions due to factors such as variations in instrument response and variations in sample concentration and purity, which are well known to the skilled person. Nonetheless, the skilled person would readily be capable of comparing the graphical data in the Figures herein with graphical data generated for an unknown crystal form and confirm whether the two sets of graphical data are characterizing the same crystal form or two different crystal forms.
A crystal form (or polymorph) may be referred to herein as substantially free of any other crystalline (or polymorphic) forms. As used herein in this context, the expression “substantially free of any other forms” will be understood to mean that the crystalline form contains 20% or less, 10% or less, 5% or less, 2% or less, or 1% or less of any other forms of the subject compound as measured, for example, by XRPD. Thus, polymorphs of Eltrombopag and Eltrombopag ethanolamine salt described herein as substantially free of any other polymorphic forms would be understood to contain greater than 80% (w/w), greater than 90% (w/w), greater than 95% (w/w), greater than 98% (w/w), or greater than 99% (w/w) of the subject polymorphic form of Eltrombopag. Accordingly, in some embodiments of the invention, the described polymorphs of Eltrombopag and Eltrombopag ethanolamine salt may contain from 1% to 20% (w/w), from 5% to 20% (w/w), or from 5% to 10% (w/w) of one or more other crystal forms of Eltrombopag.
The present invention provides crystalline Eltrombopag.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of: powder XRD pattern having peaks at 4.0, 7.3, 7.7, 12.1 and 16.1° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 1 ; a solid state 13 C NMR spectrum having peaks at 166.9, 155.4, 134.1, 125.7 and 111.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 35 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form I.
The above form I of Eltrombopag can be further characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 8.8, 14.6, 17.6, 24.3 and 26.8° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 2 ; a solid state 13 C NMR spectrum having peaks at 141.4, 130.4, 119.8 and 117.8 f 0.2 ppm; and any combination thereof.
The above crystalline Eltrombopag form I is an anhydrous form.
As used herein, and unless stated otherwise, the term “anhydrous” in relation to crystalline Eltrombopag relates to a crystalline Eltrombopag which contains not more than 1% (w/w) of either water or organic solvents as measured by TGA.
Crystalline Eltrombopag form I has advantageous properties selected from at least one of: chemical purity, flowability, solubility, morphology or crystal habit, stability—such as storage stability, stability to dehydration, stability to polymorphic conversion, low hygroscopicity, low content of residual solvents. Particularly, the crystalline Eltrombopag form I of the present invention has advantageous chemical purity, thermo-dynamical stability and solubility and it is non-hygroscopic in relative humidity (“RH”) of 80%, 100% at room temperature, for a period of at least 10 months.
As used herein the term non-hygroscopic in relation to crystalline Eltrombopag refers to less than 0.2% (w/w) absorption of atmospheric water to the crystalline Eltrombopag in the above specified conditions, as measured by TGA.
As used herein the term “thermo-dynamical stability” in relation to crystalline Eltrombopag form I refers to less than 20%, 10%, 5%, 1%, or 0.5% conversion of crystalline Eltrombopag form Ito any other solid state form of Eltrombopag under heating up to temperature of 200° C. at a heating rate of 10° C./minute, as measured by XRPD. In some embodiments, the conversion is 1%-20%, 1%-10% or 1%-5%.
Preferably, crystalline Eltrombopag form I of the present invention is substantially free of any other polymorph forms.
The above form I can be prepared by a process comprising crystallizing Eltrombopag from glacial acetic acid or suspending crystalline Eltrombopag form III, characterized by data selected from a group consisting of powder XRD pattern having peaks at 9.2, 11.2, 12.2 and 14.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 3 ; a solid state 13 C NMR spectrum having peaks at 170.6, 128.7, 124.2 and 113.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 36 ; and any combination thereof, or crystalline Eltrombopag form XVI characterized by data selected from a group consisting of: powder XRD pattern having peaks at 7.1, 9.5, 13.9, 21.2 and 25.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 20 ; a solid state 13 C NMR spectrum having peaks at 168.7, 156.7, 127.6 and 112.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 38 ; and any combination thereof, in glacial acetic acid.
Typically, the process comprises providing a solution or a suspension of Eltrombopag in glacial acetic acid and precipitating to obtain a suspension comprising the form I; wherein in case where a suspension is provided, the starting Eltrombopag is crystalline Eltrombopag form III or crystalline Eltrombopag form XVI.
Typically, when a solution is provided, glacial acetic acid is used in an amount sufficient for dissolving Eltrombopag. The solution or the suspension of Eltrombopag and glacial acetic acid can be provided by combining Eltrombopag or crystalline Eltrombopag form III and glacial acetic acid, and heating the combination. The combination can be heated to a temperature from about 96° C. to about 118°, preferably it is heated to a temperature from about 114° C. to about 118° C. After the solution or the suspension is formed, it is cooled to provide a suspension in which Eltrombopag form I precipitates. Suitable cooling temperature is from about 40° C. to about 0° C., from about room temperature to about 0° C., or from about 23° C. to about 0° C.
The above process for preparing Eltrombopag form I can further comprise recovery of the obtained Eltrombopag form I. The recovery process may comprise, for example, filtering the crystallizing form, washing and drying. Washing can be done with a mixture of methanol and water. Drying can be done under vacuum, at a temperature such as about 35° C. to about 60° C., over a period of about 2 hours to about 12 hours.
The above described process preferably provides Eltrombopag form I in chemical purity of at least about 99%, at least about 99.5%, or at least about 99.8%, area percent as measured by HPLC.
In certain embodiments, the above described process for preparing Eltrombopag form I can be used to purify Eltrombopag and thus produce chemically pure Eltrombopag salt. In preferred embodiments, the present invention provides a process of purification of Eltrombopag, comprising crystallizing Eltrombopag or suspending crystalline Eltrombopag form III or crystalline Eltrombopag form XVI in glacial acetic acid. In particular, the above chemically pure Eltrombopag form I can be purified from (Z)-methyl 3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxylate of (referred as “EPT impurity 1”) the following formula:
and (Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)-hydrazinyl)-2′-hydroxybiphenyl-3-carboxamide (referred as “EPT impurity 2”) of the following formula:
In preferred embodiments, each of the above impurities in the purified Eltrombopag can be present in an amount from about 0% to about 0.1%, from about 0.01% to about 0.1%, from about 0.01% to about 0.07%, or from about 0.01% to about 0.05%, as measured by HPLC.
Eltrombopag form I can also be prepared by a process comprising suspending a mixture of crystalline Eltrombopag form I and crystalline Eltrombopag form III in a mixture of acetone and water.
The above process comprises combining the mixture of crystalline Eltrombopag form I and form III and acetone to obtain a first suspension, which is heated prior to the addition of water. The first suspension can be heated to a temperature of about reflux temperature, preferably, about 57° C., which results in a second suspension. The second suspension is then combined with water to form a suspension. The suspension can be cooled prior to recovering crystalline form I. Suitable cooling temperature is about room temperature.
The above process for preparing Eltrombopag form I can further comprise recovery of the obtained Eltrombopag form I. The recovery process may comprise, for example, filtering the crystallized form and drying. Drying can be done under vacuum, for example at pressure of about 5 mBar. Drying can be done, for example, at a temperature of about 50° C., for a period of about 1 hour.
Crystalline Eltrombopag form I can be used to prepare other forms of Eltrombopag and Eltrombopag ethanolamine salt, in particular crystalline Eltrombopag designated form V characterized by data selected from a group consisting of: powder XRD pattern having peaks at 5.9, 8.2, 10.5 and 12.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 7 . In certain embodiments, the present invention provides a process for preparing crystalline Eltrombopag form V, comprising preparing crystalline Eltrombopag form I by a process comprising crystallizing or suspending Eltrombopag form I in glacial acetic acid and converting it to crystalline Eltrombopag form V by a process comprising crystallizing Eltrombopag form V from a mixture of tetrahydrofuran (“THF”) and water.
In another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 9.2, 11.2, 12.2 and 14.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 3 ; a solid state 13 C NMR spectrum having peaks at 170.6, 128.7, 124.2 and 113.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 36 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form III.
The above form III of Eltrombopag can be further characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 5.3, 16.1, 22.4 and 24.3° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 4 ; a solid state 13 C NMR spectrum having peaks at 155.0, 141.0, 136.6 and 133.6±0.2 ppm; and any combination thereof.
The above crystalline Eltrombopag form III is a hydrate.
Crystalline Eltrombopag form III has advantageous properties selected from at least one of: chemical purity, flowability, solubility, morphology or crystal habit, stability—such as storage stability, stability to dehydration, stability to polymorphic conversion, low hygroscopicity, low content of residual solvents. Particularly, the crystalline Eltrombopag form III of the present invention have advantageous chemical purity and morphology of irregular particle shape which provide the bulk product with excellent flowability properties that are of benefit for pharmaceutical formulations, and it is non-hygroscopic in relative humidity (“RH”) of 80%, 100% at room temperature, for a period of at least 10 months.
Preferably, crystalline Eltrombopag form III of the present invention is substantially free of any other polymorph forms.
The above form III can be prepared by a process comprising reacting crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) form I and crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“Pyrazole”) from 1 in methanol to obtain Eltrombopag from III.
The above described process preferably provides Eltrombopag form III in chemical purity of at least about 98%, preferably at least about 98.5, area percent as measured by HPLC.
Crystalline pyrazole form I is characterized by data selected from a group consisting of an X-ray powder diffraction having peaks at 10.72, 12.93, 17.95, 20.96, and 26.01° 2θ±0.2° 2θ; a PXRD pattern described in FIG. 31 ; and any combination thereof. This pyrazole crystalline Form can be further characterized by a PXRD having peaks at 9.7, 14.36, 17.09, 23.14 and 27.84° 2θ±0.2° 20.
Crystalline BPCA form I is characterized by data selected from a group consisting of: X-ray powder diffraction having peaks at 8.51, 14.87, 19.66, 26.19 and 32.66° 2θ±0.2° 2θ; a PXRD pattern described in FIG. 32 ; and any combination thereof. This BPCA crystalline Form can be further characterized by a PXRD having peaks at 12.35, 16.80, 17.53, 21.97 and 25.18° 2θ±0.2° 20.
The above form III can also be prepared by a process comprising dissolving Eltrombopag in ethyl acetate and cooling to precipitate crystalline Eltrombopag form III. Typically, the process comprises providing a solution of Eltrombopag in ethyl acetate and precipitating to obtain a suspension comprising the form III. The solution of Eltrombopag and ethyl acetate can be provided by combining Eltrombopag and ethyl acetate and heating the combination. The combination can be heated to a temperature from about 57° C. to about 77°, about 73° C. to about 77° C., or about 77° C. After the solution is formed, it can be cooled to provide a suspension in which Eltrombopag form III precipitates. Cooling is to a temperature such as about 0° C. to about −5° C., or about 0° C.
The above process for preparing Eltrombopag form III can further comprise recovery of the obtained Eltrombopag form III. The recovery process may comprise, for example, filtering the crystalline form and drying. Drying can be done at a temperature such as about room temperature, for example about 22° C., for a period of about overnight.
Crystalline Eltrombopag form III can be used to prepare other forms of Eltrombopag and Eltrombopag ethanolamine salt, in particular crystalline Eltrombopag form I. In certain embodiments, the present invention provides a process for preparing crystalline Eltrombopag form I, comprising preparing crystalline Eltrombopag form III by reacting crystalline BPCA form I and crystalline pyrazole form Ito obtain crystalline Eltrombopag from III and converting the obtained crystalline Eltrombopag from III to crystalline Eltrombopag form I by a process comprising crystallizing or suspending Eltrombopag form III in glacial acetic acid. The process can further comprise re-crystallizing Eltrombopag form III obtained from the reaction in ethyl acetate prior to converting it to crystalline Eltrombopag form I.
In yet another embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 5.5, 9.6, 14.5, 16.5 and 19.3° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 5 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form IV.
The above form IV of Eltrombopag can be further characterized by data selected from a group consisting of a powder XRD pattern having peaks at 8.4, 11.0, 13.1, 21.1 and 22.0° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 6 ; and any combination thereof.
The above form IV can be prepared by a process comprising suspending crystalline Eltrombopag form I in a mixture of methanol and water. The process can comprise combining the crystalline Eltrombopag form I and a mixture of methanol and water, to obtain a first suspension. A suitable ratio of methanol and water in the mixture can be, for example, about 1:3 V/V. The first suspension is then heated, providing the suspension, prior to recovering the form IV. Example for heating temperature can be about 80° C.
The above process for preparing Eltrombopag form IV can further comprise recovery of the obtained Eltrombopag form IV. The recovery process may comprise, for example, cooling the heated suspension, for example, to a temperature of about room temperature, e.g. about 22° C., filtering the crystalling form, washing, e.g., with methanol, and drying. Drying can be air drying, for a period such as about overnight.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of a powder XRD pattern having peaks at 5.9, 8.2, 10.5 and 12.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 7 ; a solid state 13 C NMR spectrum having peaks at 142.0, 131.6, 114.9 and 67.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 37 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form V.
The above form V of Eltrombopag can be further characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 5.3, 9.2, 14.0, 23.5 and 25.0° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 8 ; a solid state 13 C NMR spectrum having peaks at 171.9, 155.4, 136.3 and 121.3±0.2 ppm; and any combination thereof.
The above crystalline Eltrombopag form V is a tetrahydrofuran/water solvate.
Crystalline Eltrombopag form V has advantageous properties selected from at least one of: chemical purity, flowability, solubility, morphology or crystal habit, stability—such as storage stability, stability to dehydration, stability to polymorphic conversion, and low hygroscopicity. Particularly, the crystalline Eltrombopag form V of the present invention has advantageous chemical purity and it is non-hygroscopic in relative humidity (“RH”) of 80%, 100% at room temperature, for a period of at least 10 months.
Preferably, crystalline Eltrombopag form V of the present invention is substantially free of any other polymorph forms.
The above form V can be prepared by a process comprising crystallizing the Eltrombopag from a mixture of tetrahydrofuran (“THF”) and water. Typically, the crystallization comprises providing a solution of Eltrombopag in THF and adding water to obtain a suspension comprising the form V. The solution of Eltrombopag and THF can be provided by combining Eltrombopag and THF. To aid in dissolution, the combination can be heated, for example to a temperature of about 60° C. to about reflux temperature. After the solution is formed, water or a mixture of water and methanol, e.g. in a ratio of about 1:1 V/V, is added, for example in a dropwise manner, to the solution, providing a suspension comprising the crystalline Eltrombopag form V. The precipitated Eltrombopag form V can then be recovered. The recovery process may comprise, for example, filtering the crystalline form, washing and drying. Washing can be done with either water or a mixture of THF and water. Drying can be done under vacuum, for instance, at pressure of about 5 mBar, at a temperature of about 50° C., for a period such as about 1 hour.
The above process of Eltrombopag can further comprise purification of Eltrombopag prior to the crystallization. Said purification comprises suspending or crystallizing Eltrombopag from glacial acetic acid. Typically, the purification step provide crystalline Eltrombopag from I.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of powder XRD pattern having peaks at 5.9, 8.8, 10.3 and 11.7° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 9 ; and any combination thereof. This crystalline form of Eltrombopag can be designated form VI.
The above form VI of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 8.4, 14.7, 16.2, 23.5 and 24.8° 2θ±0.2° 20.
The above form VI can be prepared by a process comprising heating crystalline Eltrombopag form V to a temperature from about 115° C. to about 125°, from about 118° to about 122° C., or from about 120° C. Heating can be done at a rate of 10° C. per minute. The above process can be done under nitrogen. After heating, the sample is cooled, for example to a temperature of about 20°, at a cooling rate of, for example, about 10° C./min.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of: powder XRD pattern having peaks at 7.6, 9.4, 15.0 and 16.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 10 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form VII.
The above form VII of Eltrombopag can be further characterized by a powder XRD pattern having peaks at about 7.3, 12.5, 18.8, 22.5 and 26.0° 2θ±0.2° 20.
The above form VII can be prepared by a process comprising heating crystalline Eltrombopag form V to a temperature from about 200° C. to about 220° C., from about 211° C. to about 215° C., or from 213° C. Heating can be done at a rate of 10° C. per minute. The above process can be done under nitrogen. After heating, the sample is cooled, for example to a temperature of about 20°, at a cooling rate of about 10° C./min.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by data selected from a group consisting of: powder XRD pattern having peaks at 9.0, 13.2, 16.0 and 24.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 11 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form VIII.
The above form VIII of Eltrombopag can be further characterized by data selected from a group consisting of a powder XRD pattern having peaks at 5.3, 11.0, 17.0, 19.1 and 28.2° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 12 ; and any combination thereof.
The above form VIII can be prepared by a process comprising suspending crystalline Eltrombopag form IV in a mixture of dichloromethane and water. The process comprises combining crystalline Eltrombopag form IV and a mixture of dichloromethane and water and adding water to obtain Eltrombopag form I. The process may further comprise basifying and then acidifying the suspension, prior to recovering the crystalline form. Basifying can be done by adding a base to the suspension. Examples for base can be an inorganic base like an alkali metal base, such as sodium hydroxide. Acidifying is done by adding an acid to the basified suspension. Suitable acid can be an inorganic acid, for example, hydrochloric acid.
The Eltrombopag form VIII can then be recovered. The recovery process may comprise separating the phases, filtering Eltrombopag form VIII from the organic phase and drying, e.g under vacuum. Drying can be done at a pressure of about 5 mBar, for example at a temperature of about 50° C., over a period of about ½ hour.
In yet another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 4.5, 14.2, 17.4 and 18.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 13 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form IX.
The above form IX of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 8.8, 10.9, 13.4 and 26.7° 2θ±0.2° 2θ.
The above form IX can be prepared by a process comprising crystallizing Eltrombopag from THF. The crystallization comprises providing a solution of Eltrombopag in THF and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and THF; and heating the combination, for instance to a temperature at which a solution is formed. Precipitation can be achieved by cooling the solution to obtain a suspension comprising the crystalline form. The cooling temperature can be about room temperature, or about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid, for example at a temperature of about room temperature.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of powder XRD pattern having peaks at 6.9, 13.8, 20.4 and 24.7° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 14 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form X. The above form X of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 8.2, 13.2, 16.3 and 25.3° 2θ±0.2° 2θ.
The above form X can be prepared by a process comprising crystallizing Eltrombopag from DMSO. The crystallization comprises providing a solution of Eltrombopag in DMSO and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and DMSO; and heating the combination, for example, to a temperature at which a solution is formed. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. A suitable cooling temperature is a temperature, for example, of about room temperature, or about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid, for example at a temperature of about room temperature.
In another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: a powder XRD pattern having peaks at 3.5, 10.5, 14.0 and 28.4° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 15 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XI. The above form XII of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 4.1, 8.1, 12.1 and 16.2° 2θ±0.2° 2θ.
The above form XI can be prepared by a process comprising crystallizing Eltrombopag from acetone. The crystallization comprises providing a solution of Eltrombopag in acetone and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and acetone; and heating the combination, for instance, to a temperature at which a solution is formed. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. A suitable cooling temperature, for example, is a temperature of about room temperature, or about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid. Maintaining can be done at about room temperature.
In yet another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 4.6, 7.6, 8.9 and 16.2° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 16 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XII. The above form XII of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 10.4, 13.3, 14.1, 15.1 and 23.9° 2θ±0.2° 2θ.
The above form XII can be prepared by a process comprising crystallizing Eltrombopag from methoxybenzene. The crystallization comprises providing a solution of Eltrombopag in methoxybenzene and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and methoxybenzene; and heating the combination, for instance, to a temperature at which a solution is formed. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. A suitable cooling temperature, for example, is a temperature of about room temperature, about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid, for instance at a temperature of about room temperature.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 3.9, 7.8, 11.7 and 12.4° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 17 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XIII. The above form XIII of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 15.5, 20.5, 23.0 and 25.0° 2θ±0.2° 2θ.
The above form XIII can be prepared by a process comprising crystallizing Eltrombopag from diethyl ether. The crystallization comprises providing a solution of Eltrombopag in diethyl ether and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and diethyl ether; and heating the combination, for instance, to a temperature at which a solution is formed. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. A suitable cooling temperature is, for example, about room temperature, about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid. Maintaining can be done at about room temperature.
In another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 5.0, 10.7, 19.0 and 21.4° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 18 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XIV. The above form XIV of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 4.0, 7.9, 9.1 and 15.1° 2θ±0.2° 2θ.
The above form XIV can be prepared by a process comprising crystallizing Eltrombopag from ethyl acetate. The crystallization comprises providing a solution of Eltrombopag in ethyl acetate and precipitating the crystalline form. The solution can be provided by combining Eltrombopag and ethyl acetate; and heating the combination, for example, to a temperature at which a solution is formed. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. The cooling temperature can be a temperature such as about room temperature, e.g. about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise filtering the crystalline form and maintaining the recovered solid. Maintaining can be done at about room temperature.
In yet another embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 11.5 12.0, 12.5 and 20.9° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 19 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XV. The above form XV of Eltrombopag can be further characterized by a powder XRD pattern having peaks at 4.0, 8.1, 9.4, 16.2 and 27.8° 2θ±0.2° 2θ.
The above form XV can be prepared by a process comprising heating crystalline Eltrombopag form X to a temperature from about 155° C. to about 163°, or from about 160°. A suitable heating rate can be a rate of about 10° C. per minute. Heating can be done, for example, under nitrogen.
In one embodiment the present invention encompasses crystalline Eltrombopag characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 7.1, 9.5, 13.9, 21.2 and 25.5° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 20 ; a solid state 13 C NMR spectrum having peaks at 168.7, 156.7, 127.6 and 112.8±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 38 ; and any combination thereof. This crystalline form of Eltrombopag is designated herein as form XVI.
The above form XVI of Eltrombopag can be further characterized by data selected from a group consisting of a powder XRD pattern having peaks at 5.9, 11.2, 15.4, 17.4 and 26.2° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 21 ; a solid state 13 C NMR spectrum having peaks at 146.4, 140.7, 136.3 and 117.3±0.2 ppm; and any combination thereof.
The above crystalline Eltrombopag form XVI is a monohydrate form.
Crystalline Eltrombopag form XVI has advantageous properties selected from at least one of: chemical purity, flowability, solubility, morphology or crystal habit, stability—such as storage stability, stability to dehydration, stability to polymorphic conversion, low hygroscopicity, low content of residual solvents. Particularly, the crystalline Eltrombopag form XVI of the present invention have advantageous chemical purity, it is non-hygroscopic in relative humidity (“RH”) of 80%, 100% at room temperature, for a period of at least 5 months and it is highly crystalline and has enhanced powder flowability.
Preferably, crystalline Eltrombopag form XVI of the present invention is substantially free of any other polymorph forms.
The above form XVI can be prepared by a process comprising reacting crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) form II and crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“Pyrazole”) from II in methanol to obtain Eltrombopag from XVI. BCPA form II can be obtained, for example, from Topharman Shangai Co., Ltd, Batch No: 090921BPCA. Pyrazole form II can be obtained, for example, from Topharman Shangai Co., Ltd, Batch No: 090805PYRAZOL.
Crystalline Eltrombopag form XVI of the present invention can be used to prepare other forms of Eltrombopag and Eltrombopag ethanolamine salt, in particular crystalline Eltrombopag form I. In certain embodiments, the present invention provides a process for preparing crystalline Eltrombopag form I, comprising preparing crystalline Eltrombopag form XVI by reacting crystalline BPCA form H and crystalline pyrazole form II to obtain crystalline Eltrombopag from XVI and converting the obtained crystalline Eltrombopag from XVI to crystalline Eltrombopag form I by a process comprising crystallizing or suspending Eltrombopag form XVI in glacial acetic acid.
The present invention describes crystalline forms of Eltrombopag intermediates 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) and 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”).
Crystalline pyrazole form II is characterized by a PXRD pattern as depicted in FIG. 33 .
Crystalline BPCA form II is characterized a PXRD pattern described in FIG. 34 .
The present invention provides a process for preparing Eltrombopag and Eltrombopag ethanolamine salt, comprising a) providing crystalline Eltrombopag form III or crystalline Eltrombopag form XVI; b) converting the crystalline Eltrombopag form III or crystalline Eltrombopag form XVI obtained in step (a) to crystalline Eltrombopag form I; c) converting the crystalline Eltrombopag form I obtained in step (b) to crystalline Eltrombopag form V; and optionally d) converting the crystalline Eltrombopag form V obtained in step (c) to Eltrombopag ethanolamine salt. Each of the described steps in this said process can be done according to the processes described above, for each of the described polymorph.
The above process provides Eltrombopag ethanolamine salt in high chemical purity of at least 99%, 99.5%, 99.9 or 99.95%, as measured by HPLC.
Each of the above described polymorphs of Eltrombopag can be used to prepare pharmaceutical formulations.
The present invention provides a pharmaceutical formulation comprising any one, or combination, of the above described polymorphs of Eltrombopag, and at least one pharmaceutically acceptable excipient.
Each of the above described crystalline forms of Eltrombopag can also be used to prepare Eltrombopag bisethanolamine or monoethanolamine salts, by reacting any one, or combination, of the above polymorphs of Eltrombopag and ethanolamine.
The process for preparing Eltrombopag ethanolamine salt can comprise preparing any one, or combination, of the above polymorphs of Eltrombopag and converting them to Eltrombopag bisethanolamine or monoethanolamine salt.
In one embodiment the present invention encompasses amorphous Eltrombopag bisethanolamine salt. The amorphous Eltrombopag bisethanolamine salt can be characterized by a PXRD pattern as depicted in FIG. 22 . The amorphous Eltrombopag bisethanolamine salt can be further characterized by a DSC thermogram as depicted in FIG. 23 .
The above amorphous Eltrombopag bisethanolamine salt can be prepared by a process comprising grinding Eltrombopag bisethanolamine salt in the absence of a solvent, i.e., dry grinding.
In another embodiment the present invention encompasses crystalline Eltrombopag bisethanolamine salt characterized by data selected from a group consisting of: powder XRD pattern having peaks at 9.3, 11.8, 13.2 and 17.7° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 24 ; a solid state 13 C NMR spectrum having peaks at 174.9, 147.1, 135.4 and 58.7±0.2 ppm; a solid state 13 C NMR spectrum as depicted in FIG. 39 ; and any combination thereof. This crystalline form of Eltrombopag bisethanolamine salt is designated herein as form II.
The above form II of Eltrombopag bisethanolamine salt can be further characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 8.1, 15.2, 22.6 and 26.1° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 25 ; a solid state 13 C NMR spectrum having peaks at 156.7, 130.4, 126.4 and 113.9±0.2 ppm; and any combination thereof.
Crystalline Eltrombopag bisethanolamine form II has advantageous properties selected from at least one of: chemical purity, flowability, solubility, morphology or crystal habit, stability—such as storage stability, stability to dehydration, stability to polymorphic conversion, low hygroscopicity, low content of residual solvents. Particularly, the crystalline Eltrombopag bisethanolamine form II of the present invention has advantageous chemical purity and it is highly soluble in water.
In a preferred embodiment, the above form II is polymorphically pure. As used herein the term polymorphically pure form II corresponds to composition containing Eltrombopag bisethanolamine salt form II and not more than about 10% by weight, not more than 5%, in particular, not more than 1% preferably 1%-10%, 1%-5%, in particular 1% or less by weight, of form I of bisethanolamine salt characterized by a PXRD pattern having peaks at 7.5, 8.3, 14.0 and 23.0° 2θ±0.2° 2θ, designated form I of bisethanolamine salt.
The amount of Eltrombopag bisethanolamine salt form I and form II in the composition can be measured by PXRD. For example, the amount of form I can be measured by any one of the peaks at 7.5, 8.3 and 14.0° 2θ±0.2° 2θ; and the amount of form II can be measured by any one of the peaks at 9.3, 11.8 and 13.2° 2θ±0.2° 2θ.
The above form II of Eltrombopag bisethanolamine salt can be prepared by a process comprising grinding amorphous Eltrombopag bisethanolamine salt in the presence of methyl tert-butyl ether (MTBE). A sufficient amount of MTBE should be added to obtain Form II. Preferably, to maximize yield, as much MTBE as possible should be added without transforming the solid into a paste. See, e.g., Example 25.
In one embodiment the present invention encompasses crystalline Eltrombopag bisethanolamine salt characterized by data selected from a group consisting of: powder XRD pattern having peaks at 4.1, 6.5, 15.2 and 18.1° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 26 ; and any combination thereof. This crystalline form of Eltrombopag bisethanolamine salt is designated herein as form III.
The above form III of Eltrombopag bisethanolamine salt can be further characterized by data selected from a group consisting of: a powder XRD pattern having peaks at 11.9, 13.5, 14.6 and 17.7° 2θ±0.2° 2θ; a DSC thermogram as depicted in FIG. 27 ; and any combination thereof.
The above form III of Eltrombopag bisethanolamine salt can be prepared by a process comprising slurrying amorphous Eltrombopag bisethanolamine salt in cumen, i.e., isopropylbenzene. Slurrying can be done for a period of about a day. The form III can than be recovered from the slurry, for example, by drying, e.g. by air drying.
The present invention describes crystalline Eltrombopag bisethanolamine salt characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 7.5, 8.3, 14.0 and 23.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 28 ; a solid state 13 C NMR spectrum as depicted in FIG. 40 ; and any combination thereof. This crystalline form of Eltrombopag bisethanolamine salt is designated herein as form I. The above form I of Eltrombopag bisethanolamine salt can be further characterized by a powder XRD pattern having peaks at 5.7, 11.4, 17.2 and 26.7° 2θ±0.2° 2θ.
In a more preferred embodiment, the above form I is polymorphically pure. As used herein the term polymorphically pure form I corresponds to composition containing Eltrombopag bisethanolamine salt form I and not more than about 10% by weight, not more than 5%, particularly, not more than 1% by weight, of form II of bisethanolamine salt characterized by a PXRD pattern having peaks at 9.3, 11.8, 13.2 and 17.7° 2θ±0.2° 2θ, designated form H of bisethanolamine salt.
The amount of Eltrombopag bisethanolamine salt form I and form II in the composition can be measured by PXRD. For example, the amount of form I can be measured by any one of the peaks at 7.5, 8.3 and 14.0° 2θ±0.2° 2θ; and the amount of form II can be measured by any one of the peaks at 9.3, 11.8 and 13.2° 2θ±0.2° 2θ.
The above form I of Eltrombopag bisethanolamine salt can be prepared by a process comprising reacting Eltrombopag and ethanolamine in a solvent selected from a group consisting of: ethanol, methanol, tetrahydrofuran (THF), and a mixture of THF and water. The process comprises providing a reaction mixture of Eltrombopag and ethanolamine in the solvent and precipitating the crystalline form.
The reaction mixture can be provided by combining Eltrombopag or a suspension of Eltrombopag in the solvent and ethanolamine or a solution of ethanolamine in the solvent, wherein the solvent of Eltrombopag and ethanolamine can be same or different. The suspension of Eltrombopag and the solution of ethanolamine can be heated prior to the combining step, for example to a temperature such as reflux temperature. For example, when using ethanol and methanol as solvents for Eltrombopag and for ethanolamine the suspension of Eltrombopag and the solution of ethanolamine are heated, and when using THF or a mixture of THF and water the combination step is done at a temperature of about room temperature, i.e., without heating the suspension of Eltrombopag and the solution of ethanolamine.
After the reaction mixture is provided it can be further maintained, for example at the same temperature of the combination step, over a period of about 30 minutes to about 45 minutes. Precipitation is achieved, for example, by cooling the reaction mixture to obtain a suspension comprising the crystalline form. Cooling can be to a temperature in a range from about room temperature to about 0° C., over a period of about 0.5 hour to about 19 hours. For example, when using ethanol cooling is done for about 1.5 hours to about 2 hours and when using methanol cooling is done over a period of about 0.5 hour to about 19 hours. The Eltrombopag bisethanolamine form I can then be recovered.
The recovery can comprise, for example, filtering the obtained solid from the suspension, washing and drying. Washing can be done with the solvent used in the suspension of Eltrombopag or the solution of ethanolamine. Drying can be done under vacuum, at pressure such as about 5 mBar. Drying can be done at a temperature from about 20° C. to about 50° C., for example, over a period of about 1.5 hours to about 18 hours. Optionally, the drying can be done at two steps, e.g., drying at a temperature of about 20° C. and then further drying at a temperature of about 50° C. The process for crystallizing Eltrombopag bisethanolamine form I from methanol can be done subsequent to the synthesis of Eltrombopag, without recovering Eltrombopag from the reaction mixture in which it is formed.
The synthesis can be done, for example, by a process comprising combining hydrochloric acid, methanol, 2′,3′-dihydroxybiphenyl-3-carboxylic acid (BPCA) and sodium nitrite to obtain a first solution, adding sulfamic acid to obtain a reaction mixture and further adding pyrazole to obtain a solution. The first solution can be cooled, for example to a temperature from about 5° C. to about 0° C. The first solution can be maintained prior to the addition of sulfamic acid, for example at a temperature from about 5° C. to about 0° C. The sulfamic acid can be dissolved in water prior to its addition to the first solution. After the addition of sulfamic acid, the obtained reaction mixture can be maintained, for instance, with stirring, at a temperature from about 5° C. to about 25° C., over a period of about 45 minutes. Then, 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) is added to the reaction mixture and the solution is formed. The solution can be maintained, for example, with stirring, at a temperature of about room temperature, over a period of about 10 minutes to about 15 minutes.
The solution, comprising Eltrombopag, can then be used to prepare Eltrombopag bisethanolamine form I. The process comprises combining the solution and ethanolamine to obtain a suspension from which the crystalline form precipitates. The suspension can be maintained, e.g. upon stirring, over a period of about 45 minutes. The Eltrombopag bisethanolamine form I can then be recovered, for example, by filtering the obtained solid from the suspension.
The present invention also encompasses crystalline Eltrombopag bisethanolamine form I having low ethanol content of less than about 0.5% (5000 ppm) by weight, less than 0.25% (2500 ppm) by weight, or less than about 0.24% (2400 ppm) by weight.
The crystalline Eltrombopag bisethanolamine form I having low ethanol content can be prepared by a process comprising a) providing a mixture of ethanolamine in ethanol; b) heating the mixture to a temperature from about 65° C. to about reflux temperature; c) adding solid Eltrombopag to the mixture; d) heating to reflux; and optionally e) recovering crystalline Eltrombopag bisethanolamine form I.
The present invention also provides crystalline Eltrombopag mono-ethanolamine salt. Eltrombopag mono-ethanolamine salt can be illustrated by the following chemical structure:
In one embodiment the present invention encompasses crystalline Eltrombopag mono-ethanolamine salt characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 4.9, 6.9, 15.1 and 23.0° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 29 ; and any combination thereof. This crystalline form of Eltrombopag mono-ethanolamine salt is designated herein as form H. The above form H of Eltrombopag mono-ethanolamine salt can be further characterized by a powder XRD pattern having peaks at 9.9, 12.7, 24.0 and 27.1° 2θ±0.2° 2θ.
The above form H can be prepared by a process comprising crystallizing Eltrombopag mono-ethanolamine from a solvent selected from a group consisting of 1-butanol or 1-pentanol. The crystallization comprises providing a solution of Eltrombopag bisethanolamine salt in either 1-butanol or 1-pentanol and precipitating the crystalline form. The solution can be provided by combining Eltrombopag bisethanolamine salt and 1-butanol or 1-pentanol; and heating the combination, to temperature such as about 40° C. to reflux, or about 70° C. Precipitation can be achieved, for example, by cooling the solution to obtain a suspension comprising the crystalline form. A suitable cooling temperature is a temperature, for example, of about room temperature, or about 22° C. The obtained crystalline form can then be recovered from the suspension. The recovery can comprise, for instance, filtering the crystalline form and maintaining the isolated solid, for example at a temperature of about room temperature.
In another embodiment the present invention encompasses crystalline Eltrombopag mono-ethanolamine salt characterized by a data selected from a group consisting of: powder XRD pattern having peaks at 10.5, 13.4, 19.5 and 21.7° 2θ±0.2° 2θ; a PXRD pattern as depicted in FIG. 30 ; and any combination thereof. This crystalline form of Eltrombopag mono-ethanolamine salt is designated herein as form E. The above form E of Eltrombopag mono-ethanolamine salt can be further characterized by a powder XRD pattern having peaks at 8.3, 14.1, 18.3, 25.5 and 26.4° 2θ±0.2° 2θ.
The above crystalline Eltrombopag mono-ethanolamine form E can be prepared by a process comprising drying amorphous Eltrombopag bisethanolamine. The drying process comprises exposing amorphous Eltrombopag bisethanolamine to 2,2,2 trifluoroethanol and further exposing to air. Exposing amorphous Eltrombopag bisethanolamine to 2,2,2trifluoroethanol can be done for a period of about 7 days. Exposing amorphous Eltrombopag bisethanolamine to air is done, for example, for a period of about 24 hours, at a temperature of about 25° C.
The above described crystalline forms of Eltrombopag monoethanolamine and Eltrombopag bisethanolamine salts can be used to prepare pharmaceutical formulations, by any method known in the art.
The present invention provides a pharmaceutical formulation comprising any one, or combination, of the above described polymorphs of Eltrombopag bisethanol-amine and Eltrombopag monoethanolamine salt, and at least one pharmaceutically acceptable excipient.
A. PXRD Method
Samples, after being powdered in a mortar and pestle, are applied directly on silicon plate holder. The X-ray powder diffraction pattern was measured with Philips X'Pert PRO X-ray powder diffractometer, equipped with Cu irradiation source=1.54184 {acute over (Å)} ({acute over (Å)}ngstrom), X'Celerator (2.022° 2Θ) detector. Scanning parameters: angle range: 3-40 deg., step size 0.0167, time per step 50 s or 100 s, continuous scan. The accuracy of peak positions was defined as ±0.2 degrees due to experimental differences like instrumentation and sample preparations.
Scanning parameters were as follows:
Scan range Time per step/s EBP acid form I 3-40 50 III 4-40 100 IV 4-40 100 V 4-40 100 VI 3-40 100 VII 3-40 100 VIII 3-40 50 IX 3-40 50 X 3-40 50 XI 3-40 50 XII 3-40 50 XIII 3-40 50 XIV 3-40 50 XV 3-40 50 XVI 3-40 37 EBP bisetanolamine salt form I 3-40 50 II 3-40 50 III 3-40 50 EBP monoetanolamine salt form H 3-40 50 E 3-40 50
B. DSC Method
DSC analysis was performed on Q 1000 MDSC TA instruments with heating rate of 10° C./min, under nitrogen flow of 50 ml/min. Standard aluminum, closed pan (with hole) was used, sample mass was about 1-5 mg.
C. GC Method
(i) Equipment
Apparatus: Capillary Gas Chromatography instrument equipped with autosampler, split/splitless injector and flame-ionization detector
Capillary column: DB-WAX (USP G14), 30 m×0.53 mm, 1 μm or demonstrated equivalent Suitable data acquisition system Analytical balance 0.01 mg
(ii) Reagents and Standards
All reagents and standards are chromatographic grade. If chromatographic grade is not available, A.C.S. grade or any suitable grade that is available can be used.
Dimethylsulfoxide (DMSO), p.a. Tetrahydrofurane, p.a. Methanol, p.a. Ethanol, p.a. Acetic acid, p.a.
GC Conditions
Column temperature: 50° C. isothermal for 5 minutes
50° C.→230° C. at 20° C./min 230° C. isothermal for 40 minutes
Injector temperature: 250° C. Detector temperature: 280° C. Detector: FID Carrier: He (or N 2 ) at 4 mL/min (const. pressure at about 10 psi) Split ratio: 2:1
(iii) Preparation of Solutions:
Blank solution (B): Place DMSO into a vial.
Working standard solution (WS): Place a portion of DMSO into a 10 mL volumetric flask. Weigh, on a balance with 0.01 mg precision, about 150 mg (190 μL) of methanol, about 36 mg (41 μL) of tetrafuran standard, about 250 mg (316 μL) of ethanol standard and about 250 mg (316 μL) of acetic acid standard in the volumetric flask. Dilute to volume with DMSO and mix well. Standard solution (STD): Place a portion of DMSO into a 100 mL volumetric flask. Pipette 1.0 mL of above prepared working standard solution (WS) and dilute to volume and mix well. Pipette standard solution (STD) into a vial. Test solution (T): Weigh, on a balance with 0.01 mg precision, about 250 mg of sample into a 5 mL volumetric flask and dilute to volume. Pipett solution into vial.
D. Solid State 13 CNMR Method
13 C NMR at 125 MHz using Bruker Avance II+ 500
SB probe using 4 mm rotors Magic angle was set using KBr Homogeneity of magnetic field checked using adamantane Parameters for Cross polarization optimized using glycine Spectral reference set according to glycine as external standard (176.03 ppm for low field carboxyl signal)
EXAMPLES
Example 1
Preparation of Crude Eltrombopag
3′-Amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) Form I (90 g, 392.6 mmol), was added slowly with stirring at room temperature to a solvent mixture of tech. methanol (1.8 L) and 4 M hydrochloric acid (0.245 L, 981.5 mmol) in 3 L reactor. The resulting red solution was stirred for thirty minutes. The solution was then cooled to 0-5° C. and a cold solution of sodium nitrite (27 g, 391.3 mmol) in 90 mL of water was added over twenty minutes such that the reaction mixture temperature did not rise above 10° C. The reaction mixture was stirred for one hour at 5-10° C. Sulfamic acid (4 g, 41.2 mmol) in 90 mL of water was added at 5° C. and the resulting mixture was stirred for additionally one hour at the same temperature. The reaction mixture was warmed to room temperature and triethylamine (ca 104 mL) was added to adjust pH 7-8. 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) form I (72 g, 357.8 mmol), was added in one portion to the reaction mixture and the resulting mixture was stirred for additionally two hours at room temperature. Hydrochloric acid (4M, ca 140 mL) was slowly added with stirring over twenty minutes to adjust pH to 1.8. A solid precipitated and was collected by filtration, washed with of mixture MeOH:water (1:1, 100 mL) and dried at 40° C./0 bar in vacuum oven for about 18 hours giving 151 g of crude orange to brown crystals of Eltrombopag crude (XRPD: form III with small percentage (less than 10%) of form I. (HPLC: 98.5%, Yield=95.4%)
Example 2
Preparation of Crystalline Eltrombopag Form I
A mixture of Eltrombopag Form I and Form III (500 mg) was suspended in acetone (30 mL) and heated to 57° C. Water (10 mL) was added and the resulting suspension was left to cool to reach a temperature of 22° C. The precipitate was filtered and dried for 1 h at 50° C./5 mbar to yield 314 mg.
Example 3
Preparation of Crystalline Eltrombopag Form I
A mixture of Eltrombopag Form I and Form III, (230 mg) was dissolved in 25 mL of glacial acetic acid (99.5%) while heating. The hot solution was then filtered and left to crystallize while cooling in an ice bath. The obtained product was collected by filtration and dried at 35° C. under vacuum. 139 mg of bright orange product was obtained.
Example 4
Preparation of Crystalline Eltrombopag Form I
Eltrombopag Form III (96 mg) was dissolved in 10 mL of glacial acetic acid (99.5%) while heating to boiling point of glacial acetic acid (118° C.). The hot solution was then filtered and left to crystallize while cooling to room temperature (23° C.). The obtained product was collected by filtration and dried at 35° C., under vacuum. 40 mg of bright orange product was obtained.
Example 5
Preparation of Chemically Pure Crystalline Eltrombopag Form I
Eltrombopag form III (24.42 g, HPLC purity: 98%) was suspended in 470 ml of glacial acetic acid (>99.5%) in a 1 L reactor. The suspension was stirred for five hours under reflux, then cooled to 40° C. and stirred for one hour at the same temperature. Crystals formed and were filtrated off, washed with 100 mL of methanol:water (1:1) and dried at 60° C./0 mbar for twelve hours yielding 20.49 g orange solid of Eltrombopag form I (Yield=88%; HPLC purity: 99.94%).
Example 6
Preparation of Chemically Pure Crystalline Eltrombopag Form I—Large Scale
Crude Eltrombopag (151 g, HPLC purity: 98.5%) was suspended in 2.9 L of glacial acetic acid in 3 L reactor. The suspension was stirred for five hours under reflux and cooled to 40° C. Crystals formed and were filtrated off, washed with 200 mL of methanol:water (1:1) and dried at 60° C./0 mbar overnight yielding 133 g orange solid of pure 3′-{N′-[1-(3,4-Dimethylphenyl)-3-methyl-5-oxo-1,5-dihydro-pyrazol-4-ylidene]hydrazino}-2′-hydroxybiphenyl-3-carboxylic acid (HPLC: 99.8%; XRPD: form I) (Yield=88%). PXRD analysis provided the diffractogram as shown in FIG. 1 . DSC analysis provided the thermogram as shown in FIG. 2
Example 7
Preparation of Crystalline Eltrombopag Form III
Eltrombopag (210 mg) was dissolved in 15 mL of EtOAc while heating at reflux (77° C.). The hot solution was then filtered and left to crystallize while cooling in an ice bath (0-5° C.). The obtained product was collected by filtration and dried overnight at 22° C. 82 mg of bright orange product was obtained. PXRD analysis provided the diffractogram as shown in FIG. 3 . DSC analysis provided the thermogram as shown in FIG. 4 .
Example 8
Preparation of Crystalline Eltrombopag Form IV
Eltrombopag (500 mg) Form I was suspended in MeOH/water mixture 1:3 (40 mL) and heated to 80° C. The suspension was left to cool to 22° C. The precipitate was filtered, washed with MeOH and air dried on air over night to yield 321 mg. PXRD analysis provided the diffractogram as shown in FIG. 5 .
Example 9
Preparation of Crystalline Eltrombopag Form V
A mixture of Eltrombopag Form I and Form III (500 mg) was dissolved in THF (10 mL) and mixture of water/MeOH (1:1, 10 mL) was added dropwise. The precipitate was filtered and dried for 2 h at 50° C./5 mbar to yield 340 mg.
Example 10
Preparation of Crystalline Eltrombopag Form V
A mixture of Eltrombopag Form I and Form III (500 mg) was dissolved in THF (10 mL) and water (10 mL) was added dropwise. The solution was stirred 1 hour during which a precipitate was formed. The precipitate was filtered, washed with THF/water (1:1, 10 mL) and dried for 2 h at 50° C./5 mbar to yield 423 mg.
Example 11
Preparation of Crystalline Eltrombopag Form V
Eltrombopag (8.65 g) was dissolved in THF (50 mL) with heating to reflux. Water (50 mL) was added dropwise and the solution was stirred for 1 hour at 22° C. during which a precipitate was formed. The precipitate was filtered, washed with water and dried for 2 h at 50° C./5 mbar to yield 7.70 g. PXRD analysis provided the diffractogram as shown in FIG. 7 . DSC analysis provided the thermogram as shown in FIG. 8
Example 12
Preparation of Crystalline Eltrombopag Form V
Eltrombopag Form VIII (1.092 g) was dissolved in 6.4 mL of THF while heating at 60° C. When a clear solution was obtained, 6.4 ml of H 2 O was added and reaction mixture was stirred for 1 hour at 22° C. A solid precipitated and was filtered, washed with H 2 O, and dried at 50° C. under vacuum, 1 hour. 1.023 g of bright orange product was obtained.
Example 13
Preparation of Crystalline Eltrombopag Form VI
Eltrombopag Form V (2 mg) was placed in aluminum sample pan with a small hole on lid under nitrogen pouring at a flow rate of 35 ml/min. The sample was equilibrated at 20° C., heated with heating rate of 10° C. per minute up to 120° C. The sample was cooled with a rate of 10° C./min up to 20° C. The prepared sample was measured by XRPD and a unique pattern was obtained. PXRD analysis provided the diffractogram as shown in FIG. 9 .
Example 14
Preparation of Crystalline Eltrombopag Form VII
Eltrombopag Form V (2 mg) was placed in aluminum sample pan with a small hole on lid under nitrogen pouring at a flow rate of 35 ml/min. The sample was equilibrated at 20° C., heated with heating rate of 10° C. per minute up to 213° C. The DSC was calibrated with indium. The sample was cooled at a rate of 10° C./min up to 20° C. Prepared sample was measured by XRPD and a unique pattern was obtained. PXRD analysis provided the diffractogram as shown in FIG. 10 .
Example 15
Preparation of Crystalline Eltrombopag Form VIII
Eltrombopag Form IV (500 mg) was suspended in dichloromethane (10 mL) and water (5 mL). The suspension was basified with NaOH, 1M (2.5 mL) and then acidified with HCl, 1M (2.5 mL). The solid was filtered off and dried in a vacuum oven for ½ h on 50° C./5 mbar. PXRD analysis provided the diffractogram as shown in FIG. 11 . DSC analysis provided the thermogram as shown in FIG. 12 .
Example 16
Preparation of Eltrombopag Ethanolamine According to US 2006/0178518 A1, Example 1
Eltrombopag crude orange solid (1 g) was stirred in 16.75 ml of THF at approximately 30° C. Water (2.0 ml) was added slowly so as to maintain a temperature greater then 28° C. When addition was complete, the temperature was returned to 30° C. and the solution filtered through a glass fiber pad (2× Whatman GFC filters) to remove particulate matter. The filter was washed through with THF (2.0 ml) which was added to the filtrate. The filtrate was allowed to cool to room temperature. Ethanolamine (0.324 g, 2.35 mol. equiv.) was dissolved in IMS (26 ml) at 22° C. and stirred under a nitrogen atmosphere at 22° C. The filtrate containing the free acid was added to the ethanolamine solution over 20 to 30 minutes. The resulting dark red suspension was stirred for 3 hours and the solid isolated by filtration and dried at 50° C. in a vacuum oven over night to yield 1.22 g (96%) of the title compound.
Example 17
Preparation of Crystalline Eltrombopag Form IX
Eltrombopag form I (15-20 mg) was dissolved in THF (2 mL) with heating and left at 22° C. Obtained crystals were analyzed by XRD powder analysis. PXRD analysis provided the diffractogram as shown in FIG. 13 .
Example 18
Preparation of Crystalline Eltrombopag Form X
Eltrombopag form I (15-20 mg) was dissolved in DMSO (2 mL) with heating and left at 22° C. Obtained crystals were analyzed by powder XRD analysis. PXRD analysis provided the diffractogram as shown in FIG. 14 .
Example 19
Preparation of Crystalline Eltrombopag Form XI
Eltrombopag form I (15-20 mg) was dissolved in acetone (6 mL) with heating, filtered and left at 22° C. Obtained crystals were analyzed by powder XRD. PXRD analysis provided the diffractogram as shown in FIG. 15 .
Example 20
Preparation of Crystalline Eltrombopag Form XII
Eltrombopag form I (15-20 mg) was dissolved in methoxybenzene (anisol) (6 mL) with heating. Solution was left at 22° C. Obtained crystals were analyzed by powder XRD. PXRD analysis provided the diffractogram as shown in FIG. 16 .
Example 21
Preparation of Crystalline Eltrombopag Form XIII
Eltrombopag form I (15-20 mg) was dissolved in diethyl ether (6 mL), with heating, filtered and left at 22° C. Obtained crystals were analyzed by powder XRD. PXRD analysis provided the diffractogram as shown in FIG. 17 .
Example 22
Preparation of Crystalline Eltrombopag Form XIV
Eltrombopag form I (15-20 mg) was dissolved in ethyl acetate (6 mL) with heating, filtered and left at 22° C. Obtained crystals were analyzed by powder XRD. PXRD analysis provided the diffractogram as shown in FIG. 18 .
Example 23
Preparation of Crystalline Eltrombopag Form XV
Eltrombopag form X (2 mg) was placed in a DSC and was heated to a temperature of 160° C., under N 2 . The prepared sample was measured by XRPD. PXRD analysis provided the diffractogram as shown in FIG. 19 .
Example 24
Preparation of Amorphous Eltrombopag Bisethanolamine Salt
About 0,1 g of Eltrombopag bisethanolamine was grinded in Fritsch, Pulverisette 7, ball mill. Sample was grinded in 12 mL agate container with 7 agate balls (10 mm in diameter) with speed rate of 650 rpm. Amorphous sample was obtained after 1 h, 2 h and 3 hours of dry grinding. XRPD and DSC are given in FIG. 22 and FIG. 23 .
Example 25
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form II
About 0.1 g of amorphous Eltrombopag bisethanolamine was grinded with additional 0.5 ml of methyl tert-butyl ether in Fritsch, Pulverisette 7, ball mill. Sample was grinded in 12 mL agate container with 6 agate balls (10 mm in diameter) with speed rate of 700 rpm. Crystalline sample was obtained after 1 h of grinding. Continuing the experiment, additional 0.5 ml of methyl tert-butyl ether was added in the same container after 1 hour and again after 2 hours of grinding in order to enhance material crystallinity. Raw data for XRPD and DSC measurements of the sample obtained after 3 hours of grinding are given in FIGS. 24 and 25 , respectively.
Example 26
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form III
About 0.2 g of amorphous Eltrombopag bisethanolamine was slurried with about 3 ml of cumen solvent for about one day. The resulting red suspension was dried in the air at ambient temperature of about 25° C. Raw data for XRPD and DSC measurements of the sample obtained are given in FIGS. 24 25 , respectively.
Example 27
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag (2.48 g) was suspended in 50 ml of ethanol. The reaction mixture was refluxed and 3.4 ml of ethanolamine was added dropwise to the suspension. The mixture was refluxed for 45 minutes and was cooled down to 0° C. over 1.5 hr. The resulting crystals were filtered off. 2.9 g of purple crystals was obtained. Yield 91.0%
Example 28
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Ethanolamine (3.1 ml) was added to 55 ml of absolute ethanol and refluxed. 2.27 g of eltrombopag was added portionwise over 10 minutes. The resulting mixture was refluxed for 30 minutes and then was cooled down to 0° C. over 1.5 hr. The resulting suspension was stirred at 20° C. overnight. Crystals formed and were filtered off. 2.75 g of purple crystals was obtained. Yield 94.8%.
Example 29
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Methanolic HCl acid (22 ml, 1.25 M), 50 ml methanol and 2.5 g BPCA (2′,3′-dihydroxybiphenyl-3-carboxylic acid) were stirred and cooled down to 0-5° C. at which point 0.770 g NaNO 2 (dissolved in 3 ml water) was added dropwise. The resulting solution was stirred at 0-5° C. for 30 min., and then 2 ml of conc. HCl acid were added dropwise. The resulting solution was stirred at 0-5° C. for 30 min. followed by addition of 40 mg sulfamic acid (dissolved in 3 ml water). The resulting reaction mixture was stirred for 45 min at 5-25° C. followed by addition 2.2 g of 1-(3,4-dimethylphenyl)-3-methyl-1,2-dihydropyrazol-5-one. The resulting solution was stirred for 10-15 min at room temperature and 4 ml of ethanolamine was added. The resulting suspension was stirred for 45 min, followed by filtration. 4.56 g of purple powder was obtained. Yield 74.15%
Example 30
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag (1.0 g; 2.26 mmol) was dissolved in THF (17 mL) at room temperature. Water (2 mL) and additional THF (2 mL) were added and the solution was filtered. Ethanolamine (0.32 mL; 5.31 mmol) was dissolved in ethanol, p.a. (26 mL) and stirred under N 2 atmosphere. Eltrombopag solution was added dropwise to the ethanolamine/ethanol mixture over 25-30 minutes. The resulting reaction mixture was stirred for 3 hours under N 2 atmosphere. The precipitate was filtered and dried for 3 h at 50° C./5 mbar to yield 1.01 g (79%) of dark brown solid.
Example 31
Preparation of crystal Eltrombopag Bisethanolamine Salt Form I
Eltrombopag (1.0 g; 2.26 mmol) was dissolved in THF (30 mL) with stirring at room temperature and under N 2 atmosphere. Ethanolamine (1.4 mL; 23 mmol) was added to the THF solution and the resulting reaction mixture was stirred under N 2 atmosphere for 1.5 h. A precipitate formed and was filtered, washed with THF (2×2 mL) and dried for 3 h at 50° C./5 mbar to yield 1.20 g (94%) of purple brown solid.
Example 32
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag (9 g; 20 mmol) was dissolved in THF (270 mL) with stirring at RT and under N 2 atmosphere. Ethanolamine (3.0 mL; 50 mmol) was added to the THF solution and the resulting reaction mixture was stirred under N 2 atmosphere for 1.5 h. A precipitate formed and was filtered, washed with THF and dried for 3 h at 20° C./5 mbar and for 18 h at 50° C./5 mbar to yield 10.0 g (89%) of purple brown solid.
Example 33
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag (1.67 g; 3.78 mmol) was dissolved in THF (30 mL) and the solution filtered. Ethanolamine (2.28 mL; 37.8 mmol) was dissolved in ethanol, p.a. (50 mL) and heated to reflux. When the ethanol started to distill, the THF solution was added dropwise into the ethanolamine solution over 20 minutes via an addition funnel. The addition was additionally washed with THF (2×1.7 mL). The resulting reaction mixture was refluxed for 0.5 h under N 2 atmosphere. The heating was discontinued and the stirring was continued for 5 h. A precipitate formed and was filtered, washed with EtOH (2×4 mL) and dried for 18 h at 22° C./5 mbar and for 2 h at 50° C./5 mbar to yield 1.4 g (66%) of golden brown solid.
Example 34
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag form III (1.0 g; 2.26 mmol) was suspended in MeOH (20 mL) and heated to reflux. Ethanolamine (1.36 mL; 22.6 mmol) was added to the resulting suspension and the resulting reaction mixture was stirred at reflux for 0.5 h. The heating was discontinued and the reaction mixture reached 25° C. in 2 hours with stirring. The suspension was cooled to 0° C. and stirred for 0.5 h. The precipitate was filtered, washed with cold MeOH (2×5 mL) and dried for 15 h at 50° C./5 mbar to yield 1.06 g (83%) of purple crystals.
Example 35
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
Eltrombopag form I (5.7 g; 12.9 mmol) was suspended in MeOH (114 mL) and heated to reflux. Ethanolamine (7.8 mL; 129 mmol) was dissolved in MeOH (28.5 mL) and added dropwise to the Eltrombopag suspension over 5 minutes. The resulting reaction mixture was stirred at reflux for 0.5 h and at r.t. for 19 h. The precipitate was filtered, washed with MeOH (100 mL) and dried for 2 h at 50° C./5 mbar to yield 5.39 g (74%) of purple crystals.
Example 36
Preparation of Crystalline Eltrombopag Bisethanolamine Salt Form I
A mixture of Eltrombopag form I and form V (3.5 g; 7.92 mmol) was suspended in EtOH (70 mL) and heated to reflux. Ethanolamine (4.8 mL; 79.6 mmol) was dissolved in EtOH (17.5 mL) and added dropwise to the Eltrombopag suspension over 15 minutes. The resulting reaction mixture was stirred at reflux for 0.5 h, cooled to 0° C. in 1.5 h and stirred for additional 0.5 h. The precipitate was filtered, washed with EtOH (3×10 mL) and dried for 1.5 h at 50° C./5 mbar to yield 3.71 g (83%) of purple crystals.
Example 37
Preparation of Crystalline Eltrombopag Mono-Ethanolamine Salt Form H
Eltrombopag bisethanolamine (15-20 mg) was dissolved in 5 mL of 1-butanol with heating to 70° C. and left to crystallize at 22° C. Precipitate was analysed.
Example 38
Preparation of Crystalline Eltrombopag Mono-Ethanolamine Salt Form H
Eltrombopag (15-20 mg) bisethanolamine was dissolved in 5 mL of 1-pentanol with heating to 70° C. and then was left to crystallize at 22° C. A precipitate formed and was separated by filtration and analysed. PXRD analysis provided the diffractogram as shown in FIG. 29 .
Example 39
Preparation of Crystalline Eltrombopag Mono-Ethanolamine Salt Form E
Amorphous Eltrombopag bisethanolamine (0.5 g) was placed in a desiccator containing the atmosphere of 2, 2, 2-trifluoroethanol. After 7 days, a yellow to orange sample was removed from the desiccator and air dried at temperature of about 25° C. for about 24 hours. PXRD analysis provided the diffractogram as shown in FIG. 30 .
Example 40
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
Ethanolamine, (1.0 mL; 16.6 mmol) was dissolved in n-propyl acetate at room temperature. Eltrombopag (1.5 g; 3.39 mmol) was dissolved in THF (20 mL) at room temperature, the resulting solution filtered into an addition funnel and added thereby into the ethanolamine solution. The addition funnel was additionally washed with THF (10 mL). The reaction mixture was stirred at room temperature for 1 h. A solid formed and was filtered and the reactor washed with THF (30 mL). The precipitate was washed with THF (10 mL) and dried at 50° C./5 mbar for 2.5 h to yield 1.78 g (93%) of purple solid EBP olamine.
Example 41
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
Eltrombopag, Form V, (50 mg) was dissolved with heating in 1,4-dioxane (3 mL). Ethanolamine was added (0.05 mL) and the flask was closed and left at room temperature. A precipitate formed and was analyzed by XRPD.
Example 42
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
Amorphous Eltrombopag ethanolamine was slurried with tert-butylmethyl ether (TMBE) over the period of 1 hour. Eltrombopag bisethanolamine form II and amorphous were detected. The mixture was further slurried and Eltrombopag bisethanolamine Form I was also detected. After 3 days of slurrying a stable suspension of Eltrombopag bisethanolamine Form I and II was obtained, with higher amount of form II then form I.
Example 43
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
A mixture of Form II and Form I of eltrombopag bisethanolamine was prepared by slow crystallisation of amorphous Eltrombopag bisethanolamine in atmosphere of 1-octanol over the period of about 12 days.
Example 44
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
A mixture of Form II and Form I of eltrombopag bisethanolamine was prepared by solvent drop grinding of amorphous Eltrombopag bisethanolamine with 1-octanol. About 0.1 g of amorphous Eltrombopag olamine was ground with additional few drops of 1-octanol in Fritsch, Pulverisette 7, ball mill. The sample was ground in 12 mL agate container with 6 agate balls (10 mm in diameter). After 2 hours of grinding (700 rpm) Form II was detected.
Example 45
Preparation of Crystalline Form II of Eltrombopag Bisethanolamine in a Mixture with Form I of Eltrombopag Bisethanolamine
Eltrombopag bisethanolamine form II in a mixture with amorphous Eltrombopag bisethanolamine was obtained by very strong grinding of amorphous EBP with a few drops of water after three hours of grinding. About 0.1 g of amorphous Eltrombopag bisethanolamine was ground with an additional 0.5 ml of water in Fritsch, Pulverisette 7, ball mill. The sample was ground in 12 mL agate container with 6 agate balls (10 mm in diameter). Duration of grinding: 1 h (650 rpm)+1 h (800 rpm)+1 h (800 rpm)→XRPD.
Example 46
Preparation of Pure Crystalline Form II of Eltrombopag Bisethanolamine
Pure Form II of eltrombopag bisethanolamine was prepared by slow crystallization of amorphous Eltrombopag bisethanolamine in an atmosphere of TMBE over the period of 1 month and more at room temperature.
Example 47
Preparation of Crystalline Eltrombopag Form XVI
Crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid form II (50 g, 218 mmol, PXRD pattern at FIG. 34 ) (Supplier: Topharman Shangai Co., Ltd; Batch No: BPCA: 090921BPCA) was added to a solvent mixture of methanol (1 L) and hydrochloric acid, 4 M (137 mL) in a 1 L reactor with stirring at room temperature (cca 22° C.). The resulting solution was stirred for ½ h and then cooled to 0-5° C. A refrigerated solution of sodium nitrite (15 g, 217 mmol) in water (50 mL) was added to the reaction mixture over 20 min (maintaining the reaction temperature below 10° C.) and the stirring was continued for 1 h. A Solution of sulfamic acid (2.22 g, 23 mmol) in water (50 mL) was added to the reaction mixture and stirred for 1 h at 5° C. The resulting reaction mixture was heated to room temperature and triethylamine (cca 80 mL) was added to adjust to pH 7-8. Crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) form II (44 g, 218 mmol, PXRD pattern at FIG. 33 ) (Supplier: Topharman Shangai Co., Ltd; Batch No: 090805PYRAZOL) was added in one portion to the reaction mixture and stirred for 2 h at room temperature, maintaining the pH 7-8. Hydrochloric acid (4 M, cca 40 mL) was added to adjust the pH to 1.8 over 20 minutes with stirring. The precipitated solid was filtered, washed with mixture of MeOH:water (1:1, 60 mL) and dried at 40° C./5 bar for about 18 h to yield 100 g (90%) of EBP as a bright orange powder. PXRD analysis provided the diffractogram as shown in FIG. 20 . DSC analysis provided the thermogram as shown in FIG. 21
Example 48
Preparation of crystalline 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (“BPCA”) form I according to IPCOM000180992D
A solution of 2′-hydroxy-3′-nitrobiphenyl-3-carboxylic acid (800 g, 3.2 mol) in methanol (5 L) was hydrogenated over 5 Pd/C (160 g) at room temperature for 8 hours. The reaction mixture was filtered, concentrated and slurried in THF (2.5 L) to give 3′-amino-2′-hydroxybiphenyl-3-carboxylic acid (690 g, 50.5%) as a brown solid. PXRD analysis provided the diffractogram as shown in FIG. 32 .
Example 49
Preparation of crystalline 1-(3,4-dimethylphenyl)-3-methyl-1H-pyrazol-5-ol (“pyrazole”) form I according to IPCOM000180992D
2-(3,4-Dimethylphenyl)hydrazinium chloride (900 g, 5.21 mol), ethyl acetoacetate (678 g, 5.21 mol), sodium acetate (428 g, 5.21 mol) and glacial acetic acid (10 L) were stirred at 118° C. for about 24 hours. The resulting mixture was cooled and concentrated, and the residue was dissolved in dichloromethane (10 L) and carefully washed with saturated sodium bicarbonate (3×3 L). The organic layer was concentrated to afford a solid. The solid was dissolved in ethanol (450 mL) under reflux. Petroleum ether (7.2 L) was slowly added, and the resulting mixture was cooled and filtered to afford the title compound (748 g, 71%). PXRD analysis provided the diffractogram as shown in FIG. 31 .
Example 50
Preparation of Eltrombopag Bisethanolamine Form I with Low Content of Ethanol
Ethanolamine (24 mL, 0.4 mol) was mixed with ethanol (600 mL) in a 1 L reactor. The mixture was heated to 65° C. and Eltrombopag cryst (40 g, 0.08 mol) was added. The resulting reaction mixture was heated to reflux and stirred for half an hour. The suspension was then cooled to 25° C. A precipitate formed and was filtered off and washed with ethanol (100 mL). The solid was then dried at 50° C./5 mbar to weight loss<0.5% giving 42 g dark purple crystal of EBP olamine (XRPD: form I) (Yield=92%; GC residual EtOH=0.24%).
Example 51
Preparation of (Z)-methyl 3′-(2-(1-(3,4=dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxylate (ETP impurity 1)
Pure 3′-{N′-[1-(3,4-Dimethylphenyl)-3-methyl-5-oxo-1,5-dihydro-pyrazol-4-ylidene]hydrazino}-2′-hydroxybiphenyl-3-carboxylic acid (Eltrombopag) (20 g, 0.045 mol) was suspended in a mixture of MeOH/THF=1/1 (400 mL). The suspension was heated to reflux and sulfuric acid (5 mL) was added drop wise. The reaction mixture was refluxed overnight, cooled to room temperature and evaporated to obtain an oily residue. Water (200 ml) was added to the and a thick suspension was formed. EtOAc (200 ml) was added to form a 2-phase system and the layers were separated. The organic layer was left for half an hour at room temperature resulting in formation of orange crystals. The crystals were filtered, washed with 2×20 mL EtOAc and dried in a vacuum oven at 35° C./0 bar for 2 hours, giving 17.17 g of (Z)-methyl 3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxylate (Yield: 83.3%); (HPLC: >95%)
Example 52
Preparation of ((Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxamide (ETP impurity 2)
Step a: Preparation of (Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carbonyl chloride
Thionyl chloride (5 mL, 68.5 mmol) was added to a solution of pure 3′-{N′-[1-(3,4-Dimethylphenyl)-3-methyl-5-oxo-1,5-dihydro-pyrazol-4-ylidene]hydrazino}-2′-hydroxybiphenyl-3-carboxylic acid (Eltrombopag form I) (5 g, 11 mmol) in dry THF (75 mL) followed by addition of DMF (0.5 mL) at room temperature in three-necked flask. The reaction mixture was stirred for one hour and additional thionyl chloride (5 mL, 68.5 mmol) and DMF (0.5 mL) were added. The precipitation of acyl chloride started in half an hour and heptane (90 mL) was added. The thick reaction suspension was stirred for further half an hour, filtrated and washed with 2×50 mL of heptane yielding 5 g of (Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carbonyl chloride (Yield: 96%); (HPLC: 95%), that was immediately used for the next step.
Step b: Preparation of Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2-hydroxybiphenyl-3-carboxamide (ETP impurity 2)
(Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carbonyl chloride (5 g, 10.9 mmol) was added portion wise (over one hour) to an NH 3 /NMP solution (120 mL) and the resulting reaction mixture was cooled to 0° C. The cooled reaction mixture was stirred for one hour, then warmed to room temperature and EtOH (50 mL) was added followed by drop wise addition of 4 M HCl (100 mL). The resulting orange suspension was stirred for half an hour, filtered, washed with 2×50 mL EtOH. The filtered orange crystals were suspended in EtOAc (50 mL) and refluxed for 4 hours, then cooled to room temperature and 20 mL of MeOH/H 2 O (1/1) were added. the resulting orange suspension was filtrated, washed with MeOH/H 2 O=1/1 (30 mL) and dried in vacuum oven (0 bar/50° C.) for four hours giving 2.54 g of fluorescent orange crystals of Z)-3′-(2-(1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1H-pyrazol-4(5H)-ylidene)hydrazinyl)-2′-hydroxybiphenyl-3-carboxamide (Yield: 50.9%; HPLC purity: 98%).
Example 53
Preparation of Eltrombopag Form I from Eltrombopag Form VI
Eltrombopag acid, form XVI (27.3 g) was suspended in 525 mL of glacial acetic acid. The suspension was heated to reflux and stirred for two and a half hours at reflux. The suspension was then cooled to 40° C. The crystals formed in the process were filtered off and washed with methanol:water (1:1, 100 mL), and vacuum dried at 50° C. overnight. The process provided 22.08 g of an orange solid of Eltrombopag acid form I (Yield=80.9%).
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New polymorphs of Eltrombopag and Eltrombopag ethanolamine salt have been obtained and characterized. These polymorphs and pharmaceutical compositions comprising them are useful, for example, in treating conditions leading to thrombocytopenia.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/652,600, filed May 29, 2012, entitled “Reducing driver distraction in spoken dialogue”, the disclosure of which is hereby incorporated by reference and the priority of which is hereby claimed pursuant to 37 CFR 1.78(a) (4) and (5)(i).
BACKGROUND
[0002] A driver of a motor vehicle may become distracted under certain conditions, which are typically characterized by increased mental workload. A related situation occurs in a vehicle capable of autonomous operation, where the nominal driver may lose situation awareness, which may be unsafe under certain anticipated workload conditions requiring driver response. Automated spoken and multimodal dialogue systems are becoming more common in motor vehicles and can be a factor in reducing potential distraction and/or reduced situation awareness of the driver.
[0003] It is thus desirable to have methods for reducing driver distraction and/or reducing driver situation unawareness while engaging in spoken dialogue with an automated dialogue system. This goal is met by the present invention.
SUMMARY
[0004] Embodiments of the invention provide systems and methods for reducing user distraction associated with automated dialogue by monitoring user workload, by providing extended system dialogue acts to compensate for distraction, and by modifying the reward that assesses dialogue performance in order to optimize automated dialogue responsiveness that decreases user distraction associated with automated dialogue.
[0005] In a similar fashion, additional embodiments of the invention provide systems and methods for reducing user situation non-awareness associated with automated dialogue in an autonomous vehicle or similar system. According to embodiments of the invention, the terms “situation non-aware” and “situation non-awareness” connote at least a partial unawareness of the full situation in which the autonomous motor vehicle is operating. The driver may have some awareness of the situation, but is potentially lacking the full awareness that a situation-aware driver would be expected to have. A situation-aware driver has sufficient cognitive capacity directed to the driving task of taking control of the vehicle when necessary. A driver with impaired situation-awareness lacks information to take responsible control of the vehicle should the need arise.
[0006] Embodiments of the invention may be applied advantageously in a broad range of situations where a human user participates in automated dialogue while operating, or supervising the operation of, apparatus or systems. In certain circumstances the human user may be faced by a high workload burden and may become distracted from the operation of the apparatus or systems. In cases where the user is supervising or overseeing the operation of apparatus or systems, the user may have a heavy anticipated workload and become non-aware of the present situation and factors thereof that could affect the operation which the user is supervising.
[0007] For clarity of illustration, the present disclosure details certain embodiments of the invention which are applicable to the non-limiting example of a user who is a driver of a motor vehicle. The case of users who are supervising or overseeing the operation of apparatus or systems is likewise illustrated herein by the non-limiting example of a user who is nominally a driver of an autonomous motor vehicle. It is understood, however, that embodiments of the present invention are broadly applicable to other and more general cases as well. In another non-limiting example, a user who operates an industrial process system and/or supervises the operation of an industrial process system can also benefit from embodiments of the present invention.
Distraction and Situation Non-Awareness
[0008] In order to safely and effectively handle a motor vehicle, the driver must continually receive sensory input from many different sources, and respond appropriately and in a timely fashion to those inputs. There is a component of the accumulated workload which is associated with the driver's participation in automated dialogues, and this factor is addressed in the present disclosure.
[0009] If the cognitive workload in managing the inputs and responses exceeds a certain level, the driver may become distracted from the task of driving, with potentially serious consequences. A person who is nominally the “driver” of an autonomous vehicle, however, does not have the same ongoing responsibilities. The term “autonomous vehicle” herein denotes a vehicle which has one or more automated systems for performing one or more common driving tasks without direct driver involvement. Examples of systems for autonomous vehicles include, but are not limited to: autopilot systems for aircraft and ships; and cruise control systems and automated lane-centering systems for automobiles and trucks. Although such systems can alleviate considerable workload from the pilot or driver, they may not necessarily be able to handle all situations which may arise. Thus, a trained human operator, designated as the nominal “pilot” or “driver” supervises or oversees the operation of the autonomous vehicle, and is intended to be able to take over partial or full control in the event that a situation arises which the automated system cannot fully handle. In the non-limiting example of a cruise-control system, the driver may have to intervene by applying the brake, should traffic conditions suddenly change
[0010] The driver of an autonomous vehicle may be relieved of much of the driving workload, but must nevertheless remain alert to the present situation at all times, and must remain ready to intervene as necessary. Thus, in place of the workload itself, the driver of an autonomous vehicle has an anticipated workload. The anticipated workload may be similar in some respects to the actual workload handled by an actual driver, and in some cases may even exceed the workload of actual driving, such as in a case where sudden intervention is required. According to certain embodiments of the invention, if the driver is situation non-aware and the anticipated workload exceeds a certain level, then the potential for serious consequences exists.
[0011] Therefore, according to certain embodiments of the invention, an increase in anticipated workload for the driver of an autonomous vehicle can lead to a potentially-dangerous condition if the driver is situation non-aware, paralleling the case where an increase in workload for the driver of a regular vehicle can lead to a condition of driver distraction.
[0012] FIG. 1 conceptually illustrates the regimes of interest according to certain embodiments of the present invention. A regime set 100 applies to the driver of a regular vehicle, and a regime set 130 applies to the driver of an autonomous vehicle. Basic regimes 151 pertain to measurement. In a regime 101 the workload associated with driving is measured for the driver of a regular vehicle, and in a regime 131 the anticipated workload associated with driving an autonomous vehicle is measured. Secondary regimes 153 pertain to control of automated dialogues. In a regime 103 the workload associated with automated dialogue in a regular vehicle can be controlled, and in a regime 133 the workload associated with automated dialogue in an autonomous vehicle can be controlled. Optimization regimes 155 provide latitude for adjusting the control of regimes 153 . A regime 105 provides latitude to keep the combined driving workload 101 and automated dialogue workload 103 below a distraction threshold 110 . According to an embodiment of the invention, distraction threshold 110 is a conceptual threshold rather than an operational threshold. In this embodiment, the system seeks to reduce distraction based on past experience actualized in a learning phase (as discussed below), in place of measuring the distraction directly.
[0013] In a region 107 below threshold 110 the driver is not distracted, whereas in a region 109 above threshold 110 the driver is distracted. Likewise, a regime 135 provides latitude to keep the combined driving anticipated workload 131 and automated dialogue workload 133 below a situation non-awareness threshold 140 . In a region 137 below threshold 140 the driver is situation-aware, whereas in a region 139 above threshold 140 the driver is situation non-aware.
Reducing Distraction and Situation Non-Awareness
[0014] According to certain embodiments of the invention, an offline learning process is used to develop a new dialogue policy for an automated dialogue system using a training database of example dialogues. The new dialogue policy is developed through a learning process which confers penalties for creating dialogues which empirically create distraction/situation non-awareness. (In these embodiments, the term “penalty” denotes a negative reward.) Then, in dialogue-time situations, the new dialogue policy reduces workload/anticipated workload if the dialogue is similar to dialogue examples seen in the training process exceeding a threshold.
[0015] In this fashion, embodiments of the invention can optimize the automated dialogue to reduce the levels of distraction/situation non-awareness.
[0016] Therefore, according to an embodiment of the invention there is provided a method for reducing user distraction associated with interaction with an automated dialogue system, the method comprising:
receiving, by a processor, a user workload parameter; responsively to the user workload parameter, controlling the automated dialogue system to perform a system dialogue turn that reduces the user workload associated with interacting with the automated dialogue system, wherein the system dialogue turn includes a dialogue act selected from a group consisting of: a workload-reducing dialogue act; and a regular dialogue act modified by a workload-reducing dialogue modification.
[0021] Also, according to another embodiment of the invention, there is provided a method for reducing user situation non-awareness associated with an automated dialogue system, the method comprising:
receiving, by a processor, a user anticipated workload parameter; responsively to the user anticipated workload parameter, controlling the automated dialogue system to perform a system dialogue turn that reduces the user workload associated with interacting with the automated dialogue system, wherein the system dialogue turn includes a dialogue act selected from a group consisting of: a workload-reducing dialogue act; and a regular dialogue act modified by a workload-reducing modification.
[0026] In addition, according to a further embodiment of the invention, there is provided a dialogue system for reducing user distraction associated with interaction with automated dialogue, the system comprising:
a dialogue control unit; a storage device containing a dialogue policy; a workload estimation unit operative to: receive a workload parameter indicative of a user workload; and compute a workload estimate; and input the workload estimate into the dialogue control unit.
[0033] Moreover, according to still another embodiment of the invention, there is provided a dialogue system for reducing user situation non-awareness associated with interaction with automated dialogue, the system comprising:
a dialogue control unit; a storage device containing a dialogue policy; an anticipated workload estimation unit operative to: receive an anticipated workload parameter indicative of an anticipated user workload; and compute an anticipated workload estimate; and input the anticipated workload estimate into the dialogue control unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The subject matter disclosed may best be understood by reference to the following detailed description when read with the accompanying drawings in which:
[0041] FIG. 1 illustrates operational regimes for reducing driver distraction and situation non-awareness, according to certain embodiments of the invention.
[0042] FIG. 2A conceptually illustrates a system according to certain embodiments of the invention, for reducing user distraction in real time.
[0043] FIG. 2B conceptually illustrates a system according to certain embodiments of the invention, for reducing user situation non-awareness in real time.
[0044] FIG. 3A conceptually illustrates a system according to certain embodiments of the invention, for offline policy learning to reduce user distraction.
[0045] FIG. 3B conceptually illustrates a system according to certain embodiments of the invention, for offline policy learning to reduce user situation non-awareness.
[0046] FIG. 4A is a flowchart of a method according to certain embodiments of the invention, for reducing user distraction in real time.
[0047] FIG. 4B is a flowchart of a method according to certain embodiments of the invention, for reducing user situation non-awareness in real time.
[0048] FIG. 5 is a flowchart of a method according to specific embodiments of the invention, for reducing driver distraction in real time.
[0049] For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.
DETAILED DESCRIPTION
[0050] FIG. 2A conceptually illustrates a system according to certain embodiments of the invention, for reducing distraction in real time for a driver of a regular motor vehicle. An input stage 201 receives speech audio and/or multimodal input to a speech and multimodal understanding unit 203 , which outputs processed user dialogue acts 205 into a dialogue control unit 207 . In response, dialogue control unit 207 outputs system dialogue acts 209 into a speech and multimodal generation unit 211 for generating speech audio and/or multimodal output 213 . In these embodiments, one or more workload parameters 221 are input into a workload estimation unit 223 which outputs a workload measure 225 into dialogue control unit 207 . A workload-responsive dialogue policy 235 is available to dialogue control unit 207 for responding to high workload situations with appropriate workload-reducing system dialogue acts 209 . Workload estimates may be prepared according to factors including, but not limited to: vehicle parameters, such as steering, brakes, and safety systems; road conditions, such as road bends and traffic; weather conditions, such as rain and fog; time of day; and driver attributes, such as eye, head, and hand movements.
[0051] According to certain embodiments of the invention, a workload estimation may be obtained from factors including, but not limited to:
vehicle parameters, such as:
steering, brakes, safety systems
road conditions, such as
road-bends or traffic
weather conditions, such as
heavy-rain or fog
time of day driver attributes, such as movement of
eyes head, and hands
[0067] In another embodiment of the invention, workload can be estimated according to a user model. These different embodiments regarding workload estimation can be combined together or used separately.
[0068] Further embodiments of the invention provide an estimate of future workload, which may be useful for adjusting dialogue policy to reduce future driver distraction. In these embodiments, workload may be predicted according to factors including, but not limited to:
road conditions weather conditions, and time of day
[0072] According to these embodiments, to prepare workload-responsive dialogue policy 235 , a driver distraction input 231 is used as penalties 233 in a learning process, as described below. The output of the learning process is used to create dialogue policy 235 . Dialogue policy 235 thus bridges between the learning process—shown in FIG. 2A conceptually as an off-line creation phase 236 of dialogue policy 235 —and the interactive dialogue system—shown in FIG. 2A conceptually as a dialogue-time application 237 of dialogue policy 235 .
[0073] FIG. 2B conceptually illustrates a system according to certain embodiments of the invention, for reducing situation non-awareness in dialogue time for a driver of an autonomous motor vehicle. As before, an input stage 201 receives speech audio and/or input to a speech and multimodal understanding unit 203 , which outputs processed user dialogue acts 205 into a dialogue control unit 207 . In response, dialogue control unit 207 outputs system dialogue acts 209 into a speech and multimodal generation unit 211 for generating speech audio and/or multimodal output 213 . In these embodiments, one or more anticipated workload parameters 251 are input into an anticipated workload estimation unit 253 which outputs an anticipated workload measure 255 into dialogue control unit 207 . An anticipated workload-responsive dialogue policy 285 is available to dialogue control unit 207 for responding to high anticipated workload situations with appropriate workload-reducing system dialogue acts 209 .
[0074] Anticipated workload is the cognitive workload the driver would incur should it become necessary to take over control of the vehicle. If the driver is participating in an automated dialogue, this may impact situation awareness, particularly in an environment of high anticipated workload. According to certain embodiments of the invention, an anticipated workload estimate may be obtained from factors including, but not limited to:
vehicle parameters, such as:
steering, brakes, safety systems
road conditions, such as
road-bends or traffic
weather conditions, such as
heavy-rain or fog
time of day
[0086] According to these embodiments, a prediction of anticipated workload may be useful for adjusting the dialogue policy to increase future situation awareness, and anticipated workload may be predicted according to factors including, but not limited to:
road conditions weather conditions, and time of day
[0090] According to these embodiments, to prepare anticipated workload-responsive dialogue policy 285 , a driver situation non-awareness input 281 is used as penalties 283 in a learning process, as described below. The output of the learning process is used to create dialogue policy 285 . Dialogue policy 285 thus bridges between the learning process—shown in FIG. 2B conceptually as an off-line creation phase 286 of dialogue policy 285 —and the interactive dialogue system—shown in FIG. 2B conceptually as a dialogue-time application 287 of dialogue policy 285 .
[0091] FIG. 3A conceptually illustrates a system according to certain embodiments of the invention, for offline policy learning to reduce driver distraction. User dialogue acts 301 are input into a user model 303 , the output of which are a set of beliefs 305 that are used as input to workload-responsive dialogue policy 235 , which has been formulated through an off-line policy learning process 307 . The new policy developed through this process is therefore sensitive to the beliefs. As also illustrated in FIG. 2A , policy 235 is used to govern dialogue control unit 207 to output system dialogue acts 209 in response to the beliefs and workload estimate 225 .
[0092] Policy learning process 307 receives input from an interaction log 309 with reward/penalty 331 input to guide the learning process in creating a policy that meets the desired goal of reducing driver distraction. Input to reward/penalty 331 includes penalties according to a driver distraction assessment 321 . Driver distraction assessment 321 can be obtained from a driver's subjective impression of being distracted. Because the learning process takes place off-line, driver assessments can be obtained after completion of the driving session, in a vehicle or a vehicle simulator, in which the dialogues recorded in interaction log 309 were obtained. According to various embodiments of the invention, an off-line process for policy learning takes place in a laboratory, for which a reward is also assigned off-line. In other embodiments, policy learning takes place in the vehicle itself, or an off-vehicle server, such as at a scheduled time, or after sufficient dialogue is recorded in the dialogue log, in cases where the reward is measured automatically.
[0093] Besides direct feedback from the driver, visual inspection of driver interaction and/or performance-metrics can be used, such as braking response time given the measured headway from a lead vehicle and observation of driver head and eye movement. Driver feedback is typically limited to off-line availability, but automated assessments may be done in real-time during driving sessions. In addition to driver distraction assessment 321 , which involves penalties for distraction, other dialogue metrics 323 can be used, some of which may involve rewards.
[0094] In a similar manner, FIG. 3B conceptually illustrates a system according to certain embodiments of the invention, for offline policy learning to reduce driver situation non-awareness in an autonomous vehicle. User dialogue acts 301 are input into a user model 303 , the output of which are a set of beliefs 305 that are used as input to anticipated workload-responsive dialogue policy 285 , which has been formulated through off-line policy learning process 307 . As also illustrated in FIG. 2B , policy 285 is used to govern dialogue control unit 207 to output system dialogue acts 209 in response to anticipated workload estimate 255 . Also in a similar manner, reward/penalty 343 receives input from a driver situation non-awareness assessment 331 .
[0095] According to certain embodiments of the invention, dialogue-time measurement of driver situation awareness enables policy learning, and driver situation awareness may be obtained in ways including, but not limited to:
as feedback from the driver; by visual inspection of driver interactions; and by measuring driver eye and head movement, e.g.
driver's eyes focused on the road implies a high driver situation awareness; but driver's eyes focused elsewhere than on the road implies a low driver situation awareness.
Driving Modes in an Autonomous Vehicle
[0101] There are two modes for operating an autonomous vehicle: an autonomous mode, where one or more autonomous systems are in control of respective vehicle operating functions; and a driver control mode, where the driver assumes control of the vehicle. Autonomous control can be partial control of vehicle operating functions, a non-limiting example of which is automatic cruise control in a vehicle. According to certain embodiments of the invention, an automated dialogue system in an autonomous vehicle should be able to handle switching between these two modes. According to an embodiment of the invention, this is done by switching between two appropriate dialogue policies; in this embodiment, the learning phase policy parameters are developed separately, and at dialogue time the appropriate policy is selected, consistent with the driving mode. In another embodiment of the invention, there is a combined dialogue policy that supports both modes, and at dialogue time the mode is input to the policy along with both workload and anticipated workload estimates, and with penalty for driver distraction and penalty for driver situation non-awareness.
Method
[0102] FIG. 4A is a flowchart of a method according to certain embodiments of the invention, for reducing driver distraction during a dialogue.
[0103] In a step 401 a driver workload parameter 403 is received. Then, in a step 405 a system dialogue turn 407 is performed according to workload-responsive dialogue policy 235 . According to these embodiments, system dialogue turn 407 includes a workload-reducing dialogue act 409 and/or a regular system dialogue turn with a workload-reducing modification 411 .
[0104] In a similar manner, FIG. 4B is a flowchart of a method according to other embodiments of the invention, for reducing driver situation non-awareness in an autonomous vehicle during a dialogue.
[0105] In a step 421 a driver anticipated workload parameter 423 is received. Then, in a step 425 a system dialogue turn 427 is performed according to anticipated workload-responsive dialogue policy 285 . According to these embodiments, system dialogue turn 427 includes an anticipated workload-reducing dialogue act 429 and/or a regular system dialogue turn with an anticipated workload-reducing modification 431 .
[0106] According to the above embodiments, workload-reducing and anticipated workload-reducing dialogue turns may have features including, but not limited to: pauses and suggestions for pauses (see below); termination of dialogue and suggestions for terminating dialogue. Workload-reducing and anticipated workload-reducing modifications may have features including, but not limited to: breaking up dialogue turns into simpler sentences; presenting alternatives sequentially, rather than together; and phrasing questions for answering by “yes-no” responses; preferring speech modality to tactile and visual modality (see below).
[0107] Certain embodiments of the invention provide a spectrum of pause handling, and termination ranging as follows by degree of user involvement, which is selectable by the system:
Pause with or without a prompt, until workload is reduced; Prompt the user before pausing and allow the user a limited time to cancel the pause; Suggest pausing as a choice to the user; Pause according to user request; Pause until instructed otherwise; and Terminate the dialogue Prompt the user before terminating and allow the user a limited time to cancel; Suggest terminating the dialogue to the user Terminate upon user request.
[0117] According to related embodiments of the present invention, the difference between pausing a dialogue and terminating the dialogue is that a paused dialogue may be resumed at a later time from the point at which the dialogue was paused, whereas a terminated dialogue is stopped and may not be resumed (but may be restarted). The terms “suspend”, “suspending”, “suspension”, etc., herein denote that a dialogue has been interrupted by either being paused or being terminated. Whether or not a suspended dialogue may be later resumed depends on whether the dialogue was paused or terminated, but in either case the dialogue is interrupted at the time the suspension goes into effect.
[0118] FIG. 5 is a flowchart of a method according to specific embodiments of the invention. In a step 501 a hazard warning 503 is received. Hazard warning 503 can be signaled by a variety of presently-known methods, including, but not limited to: detection of a hazard ahead by an on-board radar system; and hazard notification by a navigational system, based on road condition information supplied to the navigational system. In a related embodiment, the hazard warning includes a warning of a braking condition of another vehicle ahead of the vehicle. In a step 505 , in response to hazard warning 503 , the dialogue is immediately suspended via an immediate dialogue suspension action 507 .
[0119] The method illustrated in FIG. 5 may also be considered as a special case of the method illustrated in FIG. 4A , wherein user workload parameter 403 includes hazard warning 503 that a hazard has been detected, and system dialogue turn 407 includes immediate dialogue suspension action 507 . In this case, immediate dialogue suspension action 507 is included in workload-reducing dialogue act 409 or in workload-reducing dialogue modification 411 . In a related embodiment, workload estimation 223 ( FIG. 2A ) includes hazard warning 503 . In another related embodiment, workload estimation 223 includes immediate dialogue suspension action 507 .
[0120] The method illustrated in FIG. 5 may additionally be considered as a special case of the method illustrated in FIG. 4B , wherein user anticipated workload parameter 423 includes hazard warning 503 that a hazard has been detected, and system dialogue turn 427 includes immediate dialogue suspension action 507 . In this case, immediate dialogue suspension action 507 is included in anticipated workload-reducing dialogue act 429 or in anticipated workload-reducing dialogue modification 431 . In a related embodiment, anticipated workload estimation 253 ( FIG. 2B ) includes hazard warning 503 . In another related embodiment, anticipated workload estimation 253 includes immediate dialogue suspension action 507 .
[0121] According to embodiments of the invention, a dialogue may be simplified by one or more of the following:
Breaking up compound requests for information to requests for separate single items of information; Presenting alternatives separately in sequential sentences rather than together in a single sentence; and Presenting questions in low-level or yes/no answer form.
[0125] According to other embodiments of the invention, a prediction of upcoming increased workload can trigger the speeding up of a dialogue. For example, if the driver is approaching an area of congested traffic or other abnormal driving conditions, the automated dialogue system can receive a prediction that workload will soon increase, and may decide to accelerate an ongoing dialogue so that the dialogue will complete before the workload increases. A dialogue may be speeded up by one or more of the following:
Reducing the number of prompts by aggregating information in fewer prompts; Presenting information visually, rather than aurally; and Using implicit confirmation rather than explicit confirmation. For example, if the driver requested information on nearby Chinese restaurants, the dialogue system could respond with an implicit confirmation such as “What price range Chinese restaurant do you seek?” rather than first asking for explicit confirmation that the request was for Chinese restaurants.
Computer Product
[0129] A computer product according to the above method embodiments includes a set of executable commands for performing the one or both of the above methods on a computer, wherein the executable commands are contained within a tangible computer-readable non-transitory data storage medium including, but not limited to: computer media such as magnetic media and optical media; computer memory; semiconductor memory storage; flash memory storage; data storage devices and hardware components; and the tangible non-transitory storage devices of a remote computer or communications network; such that when the executable commands of the computer product are executed, the computer product causes the computer to perform one or both of the above methods.
[0130] In these embodiment, a “computer” is any data processing apparatus for executing a set of executable commands to perform a method of the present invention, including, but not limited to: personal computer; workstation; server; gateway; router; multiplexer, demultiplexer; modulator, demodulator; switch; network; processor; controller; digital appliance, tablet computer; mobile device, mobile telephone; any other device capable of executing the commands
[0131] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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Methods and systems for reducing driver distraction and situation non-awareness related to a dialogue of an automated dialogue system in a vehicle. For a dialogue policy learning session, driver distraction is introduced as an input into a penalty assigner that assesses dialogue quality, and dialogue acts are extended to include dialogues and dialogue act presentation styles which reduce driver workload related to dialogues. The automated dialogue system policy is developed during the learning process by optimizing the penalties, so that automated dialogue workload is reduced in response to increased workload or anticipated workload on the driver. Methods and systems are presented for responding to both actual workload in regular vehicles as well as anticipated workload in autonomous vehicles.
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BACKGROUND OF THE INVENTION
This invention relates generally to prefabricated walls, and more particularly to a prefabricated, free-standing wall having oppositely facing, exterior panels.
It is not uncommon for the interior of business establishments, especially stores, to be renovated or redecorated and, upon occasion, to require the addition of new walls to the pre-existing structure. In the past, prefabricated walls were little more than inflexible simulations of ordinary floor-to-ceiling walls and thus were ill-suited for modern, free-form office designs. In addition, they generally lacked the internal strength to support merchandise display shelves or racks typically found on ordinary store walls. The prefabricated walls disclosed in U.S. Pat. No. 1,462,208 to Mayo issued July 17, 1923 and U.S. Pat. No. 3,017,672 to Vaughan issued Jan. 23, 1962 are examples of the earlier prefabricated walls and represent the closest prior art known to the inventor. While both the Mayo and Vaughan prefabricated walls are constructed from a plurality of panels set side by side in upper and lower channelled brackets, neither wall includes structural features which would permit it to stand on its own without joining other walls or a ceiling or to support display devices.
One popular alternative to erecting a prefabricated wall was to bring in a crew and build a conventional stud wall on location. Although sturdier than some prefabricated walls, conventional stud walls required far more time and effort on the job site. The costs of construction were high both in terms of labor and time during which the area under construction was unproductive. The present wall preferably utilizes certain of the features disclosed in my copending application Ser. No. 178,148 filed Aug. 14, 1980 entitled CURTAIN WALL to which further reference will be made hereinafter, and additionally provides a free-standing wall which has sufficient strength and stability to support merchandise for display.
SUMMARY AND OBJECTS OF THE INVENTION
The present prefabricated wall comprises a lower, horizontally extending sill member that has longitudinally coextensive, upwardly opening, medial and first and second lateral channels; a plurality of load-bearing vertical frame members, each having a horizontal foot section at its lower end secured within the medial channel of the sill member and a horizontal head section at its upper end; an upper, horizontally extending cap member that has longitudinally coextensive, downwardly opening, medial and first and second lateral channels disposed in co-planar relationship to corresponding channels of the sill member, the medial channel of the cap housing the head sections of the vertical frame members; and a plurality of wall panels removably positioned in side by side relation within each of the lateral channels of the cap and sill members. A leveling apparatus is also provided in the present invention and preferably comprises a floor-mounted base member that has a plurality of externally threaded, upwardly extending anchoring posts; a plurality of internally threaded leveling columns variably mounted on the posts in horizontal alignment with one another; and a leveling column receiving, downwardly-opening channel on the lower sill member of the wall.
The primary object of the present invention is to provide a free-standing wall that can support merchandise display shelves or racks.
Another object of the present invention is to provide a prefabricated wall that can be quickly and easily assembled on location.
Further objects of the present invention will become apparent with reference to the following drawings and description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prefabricated wall according to the present invention;
FIG. 2 is a top plan view of the wall;
FIG. 3 is an enlarged, fragmentary perspective view, partially in section, of the leveling device, lower sill, vertical frame members and other features of the wall;
FIG. 4 is an enlarged, horizontal sectional view through the outer panels and vertical frame members in a straight section of the wall;
FIG. 5 is a similar view of a ribbed section of the wall;
FIG. 6 is a similar view of an angled section of the wall;
FIG. 7 is a vertical sectional view taken along the line 7--7 in FIG. 4; and
FIG. 8 is an enlarged, vertical sectional view of the leveling device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIGS. 1 and 2, the present prefabricated wall, generally designated 10, is free-standing and is preferably formed with a plurality of angularly related, relatively adjoining sections 11, 12, 13, 14, 15 and 16 having oppositely facing exterior surfaces 17 and 18. If desired, the wall could be perfectly straight and supported at its ends 19 and 20 by other structures; however, it is preferable to include relatively short, opposing, buttressing sections or ribs 13 and 14 at intervals of twenty feet or less along the length of a straight section of the wall.
The internal structure of a straight wall section 12 is illustrated in FIGS. 3, 4, and 7. A plurality of vertical frame members 21 which provide structural support for the wall lie in spaced apart relation therewithin. Each frame member 21 is provided with a horizontal foot 22 and a horizontal head 23 welded or otherwise rigidly attached to its lower and upper ends, respectively. Ordinarily, the vertical frame members and horizontal feet and heads are fashioned from hollow, rectangular shafts or rods of metal. Preferably, the vertical members 21 lying within the straight sections are arranged in pairs and share an elongated foot 22, head 23 and intermediate horizontal connector (not shown). Separate pairs of vertical members may be spaced approximately 48"-60" apart along a typical straight wall section.
A horizontally extending lower sill 24 houses the frame feet 22 within a longitudinally coextensive, upwardly opening medial channel 25. A horizontally extending upper cap 26 (FIG. 7) houses the frame heads 23 within a substantially similar but downwardly opening medial channel 25. The feet 22 and heads 23 may be bevelled at their free ends 27 to provide access to suitable fastening means 28 by which they are attached to their respective medial channels 25 in the sill and cap members. The fastening means 28 in the sill 25 preferably form part of a leveling apparatus described below. Both the sill 24 and cap 26 include first and second lateral channels 29 and 30 lying on opposite sides of and coextensive with their respective medial channels 25. Preferably, the sill and cap are extruded aluminum and have medial channels raised or offset from the lateral channels, as indicatd in FIG. 7. In this manner, the sill member 24 may be provided with a downwardly opening channel 31 immediately below its upwardly opening, medial channel 25, with a common closed end 32 therebetween. Similarly, the upper cap may include an upwardly opening channel 33 immediately above its downwardly opening medial channel 25 and common closed end 34.
Preferably, the sill 24 is installed, as indicated in FIGS. 3, 7 and 8, upon a leveling apparatus which comprises a floor-mounted base 35 and a plurality of anchoring posts 36 and leveling columns 37. The base or platform 35 is formed from longitudinally extending, relatively narrow planks of wood or other material laid end to end and rigidly secured to the floor to form the template upon which the present wall may be constructed. The base, in effect, follows the contour of the floor. The anchoring posts 36 are externally threaded, are rigidly fastened to the base, and extend upwardly therefrom. The leveling columns 37 are internally threaded to engage the posts 36. Thus, by simply turning the columns 37 in either a clockwise or counterclockwise direction, one may lower or raise them relative to the base 35 and anchoring posts 36 and establish a level, horizontal plane.
The downwardly-opening channel 31 of the sill receives the leveling columns 37, and the closed end 32 of the sill rests thereupon. The free ends of the anchoring posts 36 extend through openings in the closed end 32 and are secured by suitable fastening means 28 either to the medial channel 25 or to the foot sections 22 of the frame members lying therein. Thus, where the floor dips, a space 38 may form between the sill 25 and base 35 (FIG. 7).
As indicated in FIG. 1, the opposing external surfaces 17 and 18 of the wall are formed from a plurality of panels 39 standing within the lateral channels of the cap 26 and sill 24. These panels 39 are fabricated and assembled within the sill and cap channels in a manner disclosed in my copending application, Ser. No. 178,148 filed Aug. 14, 1980 and entitled CURTAIN WALL. As indicated in FIGS. 3 and 4, the panels 39 are held in position and separated by vertically extending, horizontally spaced-apart studs 40 whose upper and lower end portions extend into the lateral channels of the cap and sill members, respectively. The channels, in turn, are provided at longitudinally spaced intervals with stud-locating fingers 41 which detachably engage the upper and lower end portions of the studs 40. As illustrated in FIG. 7, the outer lips 42 of the lateral channels of the sill member are shorter than the outer lips 43 of the lateral channels of the cap member. Thus, during assembly of the wall, the upper ends of the studs 40 may be first lifted into the stud-locating fingers 41 of the cap, the lower ends of the studs are swung over the outer lip 42 of the sill and then inserted into the sill's stud locating fingers, without releasing the upper ends of the studs from contact with the upper fingers 41. In a similar manner, the exterior panels 39 may be inserted into the lateral channels of the cap and sill and into abutment along their lateral edges 39A and 39B, with the panel-separating webs 40A and 40B, respectively, of the studs. As illustrated in FIG. 1, the exterior panels may provide the wall with a mirrored surface 44 or with less reflective material 45. In addition, shelf-supporting brackets 46 and other merchandise display appendages may be attached to the studs 40 in the manner described in my previously cited patent application.
In order to be substantially free of supporting or stabilizing attachments to other walls or a ceiling, the free standing wall 10 may have a number of angularly related, relatively adjoining sections. FIG. 5 illustrates a 90° joint between wall sections 15 and 16 in FIGS. 1 and 2. And, except for changes in angularity, a substantially identical arrangement of the wall's structural components can be used to construct the obtuse joint between wall sections 11 and 12. Referring to FIG. 5, one will note that three vertical frame members 21A-C are welded or otherwise secured to two relatively adjoining angularly related foot sections 22A and 22B. The angularly adjoining foot sections in turn, are set within the medial channels of and reinforce the adjoining sill sections 24A and 24B. The adjoining cap sections which are supported by the vertical members 21A-C are similarly connected and reinforced by angularly adjoined head sections (not shown). As with the straight foot 22, the angular foot sections 22A and 22B include bevelled end surfaces 27 that provide access to suitable attachment means 28. The angular head sections are similarly constructed.
An alternative or additional manner of making the wall self-stabilizing is to provide relatively opposing, stabilizing ribs or buttresses 13 and 14 at intervals between straight wall sections 12 and 15, as indicated in FIGS. 1, 2 and 6. Although substantially similar in construction to the straight wall sections 12 and 15, the ribs 13 and 14 are relatively attenuated structures that are joined to the straight sections by a cross-like configuration of vertical members and adjoining foot and head sections. As illustrated in FIG. 6, each of the adjoining sill sections 24D-G includes an outlying vertical frame member 21D-G and an associated foot section 22D-G. In addition, at the intersection of the various sill members, the foot sections are welded or otherwise attached together and a fifth vertical frame member 21H extends upwardly therefrom. A similar pattern of head sections joins the vertical frame members 21D-H and adjoining cap members (not shown).
The ribs 13 and 14 terminate in end caps or plates 47 which cover the ends of the sill 24 and the cap 26 and which have substantially flat external surfaces and a number of longitudinally coextensive, inwardly-projecting spines 48. In addition to their cosmetic function, the end caps 47 provide support to the ends of the external panels 39. Preferably, the innermost spines 48 are positioned to fit tightly against the walls of the medial channels of the sill and cap members, and the outlying spines help suppor the external panels. The end caps 47 may also be used at the free ends 19 and 20 of the wall or as framing pieces for a doorway 49 (FIG. 1).
In operation, the present free-standing wall may be rapidly assembled on site because its various components are fashioned to the required specifications before shipment from the manufacturer. The vertical frame members, for instance, may be joined with their respective horizontal feet and heads in the various configurations outlined above; the cap and sill members may be properly mitered; and the anchoring posts may be set within the pre-cut sections of the base at the factory. On location, the following, somewhat simplified, assembly procedure may be used: the base sections are laid out and secured to the floor; the leveling columns are adjusted to bring their top surfaces into a common horizontal plane; the sill sections are placed on the columns and anchoring posts; the vertical frame members are positioned and their feet are fastened to the medial channels of the sill sections; the cap sections are fastened to the heads of the frame members; the studs and exterior walls are positioned within the lateral channels of the cap and sill sections; and the merchandise display appendages are inserted into the studs.
This description of the preferred embodiment, of course, is not intended to unduly limit the breadth of the invention or the scope of the following claims.
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A prefabricated wall features coplanar triple-channelled upper cap and lower sill members joined in vertically spaced relation by vertical frame members rigidly fastened in the medial channels of the cap and sill members, and exterior panels removably carried in the lateral channels of the sill and cap members in covering relation to the vertical frame members. The sill member also includes an underlying channel which houses an adjustable leveling device upon which the sill is mounted.
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BACKGROUND OF INVENTION
[0001] Apparatuses used for melt spinning of synthetic threads are known from German Patent Application 195 40 907 A1, for example.
[0002] To this end, a polymer melt is fed to a spin beam from a melt source, for example an extruder or a polymerization unit. Inside the spin beam the melt is fed to usually one, or, by use of a distributor, multiple, metering pumps, which distribute the melt at a defined volumetric flow rate to spin cans in which the filaments are formed. The elements of the spin beam, that is, the distributor, metering pumps, piping, and spin cans, are all heated together and are enclosed by insulation.
[0003] Occasionally the physical characteristics of the polymers used for the melt spinning are altered under the influence of temperature and time. Polyamide 6.6, for example, tends to undergo post-polycondensation, resulting in an unmeltable hardening of the material and thus to deposits, or, in extreme cases, to plugging, in the lines. For this reason, in the design of spin beam special attention is given to a uniform, short residence time of the melt in the spin beam, and to a very uniform temperature. The residence time of the melt can be made uniform by mechanically optimizing the flow in the lines. Uniform temperature of the spin beam is achieved by heating, using a heat transfer medium contained as a liquid/gas mixture in the spin beam. Heat is transferred to the cold locations by condensation of the gaseous portion of the fluid on same, so that a very uniform temperature corresponding to the boiling point of the heat transfer medium is achieved within the spin beam. It is also known to use oil as heat transfer medium, or electrical heating.
[0004] Despite the above-described constructive measures, spinning of polyamide 6.6 is not regarded favorably by manufacturers of synthetic fibers. If post-polycondensed polymer forms, resulting in plugging of the lines, the spin beam must be completely disassembled and the plugged elements regenerated in an external furnace, i.e.; pyrolytically cleaned at temperatures of 450 to 550° C. This situation may occur in particular upon unit shutdowns, or when there is insufficient polymer throughput. However, even without the occurrence of an unexpected operating state it may be necessary to regenerate the spin beam at certain time intervals.
[0005] The cost of regeneration deters small, inexperienced synthetic fiber manufacturers from processing critical polymers such as polyamide 6.6.
[0006] The design of a spin beam must take into account ease of disassembly and the ability to dismantle into small units. Appropriate flanges on piping, using sealants, must be provided.
BRIEF SUMMARY OF INVENTION
[0007] The object of the present invention, therefore, is to further refine an apparatus for spinning according to the prior art, thus allowing the spin beam to be regenerated without costly disassembly.
[0008] This object is achieved by the invention by providing the spin beam with regeneration heating, either permanently installed or temporarily attachable to the spin beam, which heats the spin beam to the required pyrolysis temperature as needed. The advantage of the invention lies in the fact that the regeneration process can thus take place without costly disassembly of the spin beam. The spin beam may be constructed as a single unit so that removable flanges and other leak hazards are not necessary, resulting in a spin beam with a more economical and simple design.
[0009] In the case of a spin beam heated by a heat transfer medium, it is usually not possible with this heating principle to achieve the pyrolysis temperature required for the regeneration process. For this reason separate regeneration heating is provided for the regeneration process in the form of electrical resistance heating, a hot air blower, or the like.
[0010] To carry out the regeneration process, the regeneration heating is able to heat the melt-conducting components to temperatures above the operating temperature. This temperature is preferably in the range of 450 to 550° C., which thermally destroys the organic deposits.
[0011] If the spin beam is heated by an electrical heating unit, the unit can simultaneously be put to practical use as regeneration heating, and is capable of heating the spin beam to the regeneration temperature.
[0012] The thermal destruction of the organic deposits generates gases and vapors in the spin beam. For this reason, in one preferred refinement of the invention means are provided for exhausting the generated gases and vapors. In one particularly preferred refinement the exhausted gases and vapors are filtered.
[0013] For the case in which the spin beam is heated using a heat transfer medium, in one advantageous refinement of the invention means are provided to drain off the heat transfer medium for the duration of the regeneration process, and to store it outside the spin beam which is heated to regeneration temperature. In one particularly advantageous refinement of the invention, means are provided to remove the vapors produced by evaporation of the heat transfer medium during the regeneration process.
[0014] One exemplary embodiment is described in greater detail below, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0015] [0015]FIG. 1 shows a section through an apparatus for spinning melt-spun filament yarns according to the present invention;
[0016] [0016]FIG. 2 shows a section through a variant of an apparatus for spinning melt-spun filament yarns according to the present invention; and
[0017] [0017]FIG. 3 shows a section through another variant of an apparatus for spinning melt-spun filament yarns according to the present invention.
DETAILED DESCRIPTION
[0018] [0018]FIG. 1 illustrates in sectional view an inventive apparatus for spinning. A polymer melt is fed from an extruder 1 via a melt feed line 2 to spin beam 3 . Instead of extruder 1 , a direct polycondensation reactor may be used here as the source for the polymer melt. Inside spin beam 3 , melt feed line 2 is apportioned to two spinning pumps 4 . Spinning pumps 4 distribute the polymer melt, metered via distribution lines 5 , to the individual spinning cans, not shown, which are accommodated in spinning can receivers 6 . The filaments for forming the thread are extruded from the polymer melt in these spinning cans. The number of spinning can receivers 6 as well as the number of spinning pumps 4 are chosen here by way of example.
[0019] Inside spin beam 3 , a cavity 7 is formed so that it may be filled with a heat transfer medium. This heat transfer medium circulates through an operational heating means 8 . 3 via an inlet 8 . 1 and an outlet 8 . 2 . Spin beam 3 is thus heated to operating temperature by operational heating means 8 . 3 , an operating temperature of 250 to 330° C. being common.
[0020] The use of oil or diphyl as heat transfer medium is known. Diphyl is advantageous here since it is present in spin beam 3 in the liquid and the gaseous phase, so that cold components of spin beam 3 are heated in a targeted manner by the heat of condensation produced by condensation of the gaseous diphyl. For the sake of brevity the operational heating of melt feed line 2 , which cooperates with operational heating 8 . 3 or is operated separately, is not illustrated here.
[0021] Although the length of divided feed line 2 , as well as the length of each distribution line 5 to the particular spinning can receiver 6 , is the same for every branch, and therefore the residence time of the melt in the melt-conducting parts of spin beam 3 is equal for each spinning can receiver 6 , degradation of the polymer can occur in spite of the uniform temperature in spin beam 3 .
[0022] For this reason, in FIG. 1 spin beam 3 is provided with regeneration heating by which spin beam 3 can be heated to a regeneration temperature above the operating temperature.
[0023] In this case the regeneration heating is a hot air blower comprising hot air exhaust 10 , filter 12 , blower 13 , regeneration heating means 14 , and hot air feed 9 .
[0024] To carry out the regeneration heating process, the heat transfer medium contained in cavity 7 can be transferred into a collection reservoir 8 . 4 . The regeneration heating causes hot air to flow through cavity 7 , which is now filled only with air, long enough to heat the components inside spin beam 3 to the regeneration temperature. To this end, blower 13 directs the air through regeneration heating means 14 which heats the air flowing through. The hot air is led via hot air feed 9 through spin beam 3 , and is returned via hot air exhaust 10 . Any vapors formed from the residues of the heat transfer medium are collected by filter 12 . Parallel to the above-described path of the hot air through spin beam 3 , in the example in FIG. 1 a second hot air duct 11 is provided which heats melt feed line 2 , likewise to the regeneration temperature.
[0025] Control means 15 detect the temperature in spin beam 3 by use of a temperature sensor 19 , and, based on a comparison of set point and actual values, controls blower 13 and regeneration heating means 14 .
[0026] During the regeneration process the spinning cans, not shown here, are removed from spinning can receivers 6 so that the openings in distribution lines 5 are open. An opening 2 . 1 is provided in melt feed line 2 through which compressed air can be blown into the melt feed line system. Alternatively, melt feed line 2 is connected via opening 2 . 1 to an exhaust device 2 . 2 by which the gases generated during the regeneration process are exhausted and filtered.
[0027] Residues in melt feed line 2 and distribution lines 5 which could not be completely removed by the regeneration process, i.e.; the polymer chains of which were not fully broken up to the gaseous form, are discharged by flushing the lines with polymer—not including the spinning packets used—following the regeneration process.
[0028] The regeneration heating may be permanently connected to the spin beam 3 . However, it is also possible and practical for economic reasons to design filter 12 , blower 13 , regeneration heating means 14 , and control means 15 to be removable so that they can be attached as needed to hot air feed 9 and hot air exhaust 10 of the spin beam 3 to be regenerated. Thus, a manufacturer of chemical fibers need have only one regeneration heating system on hand for a plurality of spin beams.
[0029] Although heating with heat transfer medium is illustrated in FIG. 1 as the operational heating system, the spin beam according to the invention also encompasses other embodiment forms of the operational heating system, such as (electrical) trace heating of the melt-conducting components, for example. These are known in the art. The same also applies to the figure which follows.
[0030] [0030]FIG. 2 shows a variant of spin beam 3 illustrated in FIG. 1. In this case, regeneration heating means 16 are based on additional electrical heating of spin beam 3 . Although hot air does not flow through the cavity in the spin beam here, a collection reservoir 8 . 4 for the heat transfer medium is nevertheless provided, since as a rule the heat transfer media used are not heat-resistant in the regeneration temperature range. Residues of the heat transfer medium remaining in spin beam 3 evaporate during the regeneration process and are discharged by an exhaust means 20 .
[0031] The spin beam is typically well insulated from the outside, whereas the interior components conduct heat relatively well. In this manner, and by the heat radiation inside spin beam 3 , a sufficiently uniform heat distribution is achieved, the requirements for uniformity of temperature being less stringent for the regeneration process than for the spinning operation. The number of regeneration heating means 16 and their particular location are deduced from the design of spin beam 3 , and can be appropriately designed by one skilled in the art. Regeneration heating means 16 are designed as heating coils, heating rods, etc., and transfer the heat by means of heat conduction or heat radiation. Here as well, regeneration heating means 16 may be either permanently installed in spin beam 3 or designed to be interchangeable. With regard to heating rods in particular, it is possible to use these in openings in spin beam 3 which are provided specifically for this purpose and which are closed by stoppers during normal operation.
[0032] [0032]FIG. 3 shows a further variant of the apparatus according to the invention for spinning 3 . In contrast to the examples illustrated in the previous figures, heating of spin beam 3 during normal spinning operations (operational heating) is provided not by a heat transfer medium, but rather by heating means 17 to the individual melt-conducting parts, the heating means being designed here as trace heating. This may be electrical resistance heating, for example. Heating means 17 are controlled by control means 18 which include temperature regulation, for example. Control means 18 are provided with a separate operating mode in which the heating means can be operated at a higher regeneration temperature, so that the regeneration process can be simultaneously carried out using the operational heating means.
[0033] List of Reference Numbers
[0034] [0034] 1 . Extruder
[0035] [0035] 2 . Melt feed line
[0036] [0036] 2 . 1 Opening
[0037] [0037] 2 . 2 Exhaust means
[0038] [0038] 3 . Spin beam
[0039] [0039] 4 . Spinning pump
[0040] [0040] 5 . Distribution line
[0041] [0041] 6 . Spinning can receiver
[0042] [0042] 7 . Cavity
[0043] [0043] 8 . 1 Heat transfer medium inlet
[0044] [0044] 8 . 2 Heat transfer medium outlet
[0045] [0045] 8 . 3 Operational heating means
[0046] [0046] 8 . 4 Collection reservoir
[0047] [0047] 9 . Hot air feed
[0048] [0048] 10 . Hot air exhaust
[0049] [0049] 11 . Second hot air duct
[0050] [0050] 12 . Filter
[0051] [0051] 13 . Blower
[0052] [0052] 14 . Regeneration heating means
[0053] [0053] 15 . Control means
[0054] [0054] 16 . Regeneration heating means
[0055] [0055] 17 . Heating means
[0056] [0056] 18 . Control means
[0057] [0057] 19 . Temperature sensor
[0058] [0058] 20 . Exhaust means
[0059] The disclosure in German Patent Application 102 58 261.0 of Dec. 13, 2002 is incorporated herein by reference. This German Patent Application describes the invention described hereinabove and claimed in the claims appended hereinbelow and provides the basis for a claim of priority for the instant invention under 35 U.S.C. 119.
[0060] While the invention has been illustrated and described as embodied in a spin beam, it is not intended to be limited to the details shown, since various modifications and changes may be made without departing in any way from the spirit of the present invention.
[0061] 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.
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An apparatus for spinning melt-spun filament yarns including a spin beam is disclosed. A polymer melt fed to a spin beam is distributed within the spin beam to a plurality of spinning cans mounted on the spin beam. To reduce costs to the manufacturer for ensuring ease of disassembly of the spin beam, as well as to avoid the need for disassembling the spin beam and having a furnace on hand, the spin beam is provided with an integrated or removably attachable regenerative heater by which the melt-conducting components of the spin beam can be heated to a regeneration temperature of between about 450 to 550° C. to pyrolytically remove the deposits.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Applications Ser. No. 60/290,141 filed May 10, 2001, the teachings of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to communication systems. More particularly, the present invention relates to a system and method for estimating path loss between wireless stations in an IEEE 802.11 wireless local area network (WLAN) and for using this value to more accurately adjust the transmit power level and/or transmission rate of each station.
2. Description of the Invention
In general, there are two variants of wireless local area networks (WLAN): infrastructure-based and ad hoc-type. In the former network, communication typically takes place only between the wireless nodes, called stations (STAY), and the access point (AP), whereas communication takes place between the wireless nodes in the latter network. The stations and the AP, which are within the same radio coverage, are known as a basic service set (BSS).
The IEEE 802.11 standard specifies the medium access control (MAC) and physical characteristics for a wireless local area network (WLAN) to support physical layer units. The IEEE 802.11 standard is defined in International Standard ISO/IEC 8802-11, “Information Technology—Telecommunications and information exchange area networks”, 1999 Edition, which is hereby incorporated by reference in its entirety.
Currently, the IEEE 802.11 does not provide any mechanism for providing dynamic transmit power control (TPC) between wireless stations within a BSS. Typically, each 802.11 STA uses a fixed transmission power level for all the frame transmissions throughout its lifetime. However, a new standard, IEEE 802.11h contemplates implementing the dynamic transmit power control (TPC). Accordingly, the present invention provides an improved TPC mechanism that can be implemented within the firmware of the proposed 802.11h MAC implementation without much complexity.
SUMMARY OF THE INVENTION
The present invention is directed to a system and method of estimating path loss by a communication receiver to determine accurate transmission power control (TPC) or to adjust transmission rate in a wireless local area network (WLAN).
According to an aspect of the present invention, a method for determining the transmission power level and/or transmission rate between a plurality of stations located within the coverage area of a basic service set (BSS) in a wireless local area network (WLAN) is provided. The method includes the steps of: measuring total received signal power of an incoming frame; calculating a path loss based on the difference between the measured received signal power and the transmit power level extracted from the incoming frame and adjusting the transmit power level or the transmission rate of the receiving station according to the said calculated path loss.
Another aspect of the present invention provides a method for determining the transmission power level and/or transmission rate between a plurality of stations located within the coverage area of a basic service set (BSS) in a wireless local area network (WLAN), each station having a means for transmitting a signal and a means for receiving a signal. The method includes the steps of: transmitting a first frame from a transmitting station to a receiving station; measuring the receive power level of said received first frame by the receiving station; extracting the transmit power level from the received first frame by the receiving station; calculating a path loss based on the difference between the measured received signal power and the extracted transmit power level from the first frame; and, adjusting the transmit power level and/or the transmission rate of a future frame transmitted by the receiving station based on the calculated path loss information received therein. The path loss information is determined based on the proportionate weight of the calculated path loss information and, one or more, previously calculated path loss information.
Another aspect of the present invention provides an apparatus with a power measurement circuit for determining the transmission power level between a plurality of stations located within the coverage area of a basic service set (BSS) in a wireless local area network (WLAN). The apparatus includes a receiver circuit for demodulating an incoming signal; a power measurement circuit for measuring the received signal power of the incoming signal received therein; a processor, coupled to the power measurement circuit, for calculating path loss information based on the difference between the received signal power and the transmit power level extracted from the incoming frame; a memory, coupled to the processor, for storing the calculated path loss information for a predetermined time period for a subsequent retrieval; and, a transmitter circuit coupled to the processor
The foregoing and other features and advantages of the invention will be apparent from the following, more detailed description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram illustrating the architecture of a wireless communication system whereto embodiments of the present invention are to be applied;
FIG. 2 illustrates a simplified block diagram of an access point and each station within a particular basic service set (BSS) according to the embodiment of the present invention;
FIG. 3 illustrates the format of an 802.11 frame, including the modification of the SERVICE field, that can be used to transmit information between stations according to an embodiment of the present invention;
FIG. 4 is a flow chart illustrating the operation steps of selectively adjusting the power level according to an embodiment of the present invention;
FIG. 5 is a flow chart illustrating the operation steps of updating path loss per frame reception according to an embodiment of the present invention; and,
FIG. 6 is a flow chart illustrating the operation steps of updating path loss prior to a frame transmission according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following description, for purposes of explanation rather than limitation, specific details are set forth such as the particular architecture, interfaces, techniques, etc., in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details.
FIG. 1 illustrates a representative network whereto embodiments of the present invention are to be applied. As shown in FIG. 1 , an access point (AP) 2 is coupled to a plurality of mobile stations (STA i ), which, through a wireless link, are communicating with each other and to the AP via a plurality of wireless channels. A key principle of the present invention is to provide a mechanism to update and estimate the path loss between a transmitting station and a receiving station by the receiving station of a frame. The updated path loss is useful in, but not limited to, saving the battery power, avoiding interference to other systems, adjusting radio coverage and adjusting transmission rate, by transmitting frames at just the right power level and the right transmission rate. IEEE 802.11 Physical Layers (PHYs) define a plurality of transmission rates based different modulations and channel coding schemes so that the transmitter of a frame can choose one of the multiple rates based on the wireless channel condition between the receiver and itself at a particular time. Typically, the lower the transmission rate, the more reliable the transmission. It should be noted that the network shown in FIG. 1 is small for purposes of illustration. In practice most networks would include a much larger number of mobile stations.
Referring to FIG. 2 , the AP and each STA within the WLAN of FIG. 1 may include a system with an architecture that is illustrated in the block diagram of FIG. 1 . Both the AP and STA may include a receiver 12 , a demodulator 14 , a power measurement circuit 16 , a memory 18 , a control processor 20 , a timer 22 , a modulator 24 , and a transmitter 26 . The exemplary system 10 of FIG. 2 is for descriptive purposes only. Although the description may refer to terms commonly used in describing particular mobile stations, the description and concepts equally apply to other processing systems, including systems having architectures dissimilar to that shown in FIG. 2 .
In operation, the receiver 12 and the transmitter 26 are coupled to an antenna (not shown) to convert received signals and transmit desired data into corresponding digital data via the demodulator 14 and the modulator 24 , respectively. The power measurement circuit 16 operates under the control of the processor 20 to determine the path loss by subtracting the received signal strength from the transmission power level (in dBm), which is conveyed in the frame received thereon. The path loss with respect to other stations is estimated and stored in the memory 18 that is coupled to the processor 20 for subsequent retrieval. The estimated path loss with respect to other stations within the same BSS is updated and later used to calculate the transmission power level. The timer 22 is used to eliminate the outdated path loss estimation, which is stored in the memory 18 . In the embodiment, the path loss is updated as it tends to change due to the time-varying nature of the wireless channel as well as the potential mobility of WLAN STAs.
FIG. 3 represents the format of PHY Protocol Data Unit (PPDU) frame that is used to convey the transmission power level information between the stations. As shown in the lowest part of FIG. 3 , the transmission power level (represented by TXPWR — LEVEL) is transmitted in the SERVICE field of the 802.11a/h PPDU frame. The SERVICE field of the 802.11a is slightly modified to include the four-bit TXPWR — LEVEL field. The original SERVICE field format of 802.11a is found in the middle part of FIG. 3 . The TXPWR — LEVEL field is defined from 1 to 16, where each value represents a particular transmission power level. The TXPWR — LEVEL is used to determine the path loss by subtracting the received signal strength via Received Signal Strength Indicator (RSSI) from the transmitted signal power via TXPWR — LEVEL (explained later). After obtaining the path loss by receiving frame(s), the receiving STA can determine both the PHY rates as well as the transmission power intelligently for its future transmission to other STA. Thus, the transmission power level and rate are determined solely up to the transmitting STA's discretion. It should be noted that the transmission power should not exceed the maximum transmission power specified by the AP through a beacon frame; an 802.11h-compliant AP shall broadcast such maximum transmission power via beacon frames periodically. Hence, receiving an erroneous TXPWR — LEVEL, which causes an adverse effect on the system performance, can be avoided. An Extended Hamming Code may be used for the error detection code operation.
Now, the principle of operation steps according to the present invention of updating the path loss to determine the transmission power level is explained hereafter.
Referring to FIG. 4 , the inventive process includes the following steps: in step 100 , a station STA 2 receives a frame. In step 110 , the STA 2 measures the power level of the received frame. Measuring the power level is a well-known art that can be performed in a variety of ways. In step 120 , the STA 2 calculates the path loss, which is the difference between the transmitted power level and the received power level, and updates the path loss information. The path loss PL is updated by giving a different weight to the new and old path loss values, as follows: PL=al*PL — new+a 2 *PL (a 1 +a 2 =1, a 1 ≧0, and a 2 ≧0), wherein PL — new represents the estimated path loss from the new frame reception. The updated path loss is then used to determine the transmitter power required to obtain the desired carrier-to-noise ratio within the BSS. In step 140 , the STA 2 adjusts the transmission power level and/or the transmission rate based on the adjustment level that was determined in step 120 .
Although a limited number of STAs is shown in FIG. 4 for illustrative purposes, it is to be understood that the WLAN can support communications between a much larger number of STAs. Thus, the number of STAs in the figure should not impose limitations on the scope of the invention. In such event, each STA keeps track of the path loss between other STAs within the BSS and to the AP, then each transmitting station may use the path loss estimation to adjust the transmit power level as it transmits a frame to another STA or to the AP. With non-802.11e WLAN, a STA needs to keep track of the path loss with the AP only as the STA must transmit frames to its AP. Here, each transmitting station may want to keep track of the path loss with a selected number of STAs to reduce the complexity. In addition, to prevent using outdated and stale path loss information, the present invention may adopt the path loss information lifetime. To this end, whenever STA 2 updates the path loss estimation with STA 1 by receiving a frame from STA 1 , STA 2 sets a timer for each updated path loss estimation using the timer 22 of FIG. 2 . Hence, the STA 2 will compare the most recent updated time of the frame with the current time when it is to transmit a frame.
FIG. 5 illustrates the principles of updating the path loss adjusting the transmission power level and/or the transmission rate of a frame. In step 200 , upon receiving a frame from another station in step 200 , the newly estimated path loss is calculated and updated in step 220 . Thereafter, the new path loss estimation is compared to determine whether it is different from the previously stored path loss estimation by more than the threshold in step 220 . If so, the receiving station will calculate the path loss according to a particular condition (PL=al*PL — new+a 2 *PL, wherein a 1 +a 2 =1, a 1 ≧0, and a 2 ≧0) in step 240 and will reset the flag PL — var=0. Otherwise, the receiving station will erase the old path loss information and store the new information by setting the flag PL — var=1, which indicates a change in the path loss information in step 230 . Thereafter, the STA 2 will use the stored path loss information received from the STA 1 only if the lifetime of the path loss does not pass the preset threshold and only when PL — var=0. This same method could be used to update path information between AP and a STA. Also, the same method could be used by AP to update path loss information to the STAs.
FIG. 6 illustrates the operation steps of using the path loss information by the transmitting station. To transmit a frame to another station in step 300 , it is determined whether the path loss estimation that is received from the receiving station exists in step 310 . If so, it is determined whether the time of the path loss estimation and current time is less than the preset threshold in step 330 . Otherwise, a new estimation of path loss may be performed via a Request-to-Send (RTS)/Clear-to-Send (CTS) frame exchange. The CTS/RTS frame can measure the path loss without service interruption. The transmitting station could measure the path loss by sending an RTS frame to the supposed receiving STA and receiving the corresponding CTS frame from the said receiving STA. Note that the CTS frame shall include the transmission power level in its SERVICE field as well so that the sender of the RTS frame can estimate the path loss. Alternatively, the transmitting station may use the maximum power level announced by the AP within the BSS via a beacon frame for its frame transmission in step 320 . If the difference is less than the preset threshold and PL — var=0, the station uses the path loss estimation found in step 310 . If the difference is not less than the preset threshold in step 330 , a new estimation of path loss is performed via RTS/CTS, or the station may use the maximum power level announced by the AP within the BSS via the beacon frame in step 340 .
While the preferred embodiments of the present invention have been illustrated and described, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the present invention. In addition, many modifications may be made to adapt to a particular situation and the teaching of the present invention without departing from the central scope. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the present invention, but that the present invention include all embodiments falling within the scope of the appended claims.
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A method and apparatus for determining the transmission power level between a plurality of stations located within the coverage area of a basic service set (BSS) in a wireless local area network (WLAN). The receiving station measures a received signal power from the transmitting station, then the path loss estimation is computed based on the difference between the received signal power and the transmit power level extracted from the incoming signal. The computed path loss is updated according predetermined criteria. Based on the updated path loss information, the transmit power level and/or the transmission rate of a receiving station is adjusted.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 11/093,152, filed Mar. 29, 2005, now U.S. Pat. No. 7,373,462. This application relates to commonly-owned, co-pending U.S. Pat. Nos. 7,386,684; 7,386,685; 7,386,683; 7,386,684; 7,380,071; and 7,383,397 all filed on even date herewith and incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to computer systems having multiprocessor architectures and, more particularly, to a novel multi-processor computer system for processing memory accesses requests and the implementation of cache coherence in such multiprocessor systems.
2. Description of the Prior Art
To achieve high performance computing, multiple individual processors have been interconnected to form multiprocessor computer system capable of parallel processing. Multiple processors can be placed on a single chip, or several chips—each containing one or several processors—interconnected into a multiprocessor computer system.
Processors in a multiprocessor computer system use private cache memories because of their short access time (a cache is local to a processor and provides fast access to data) and to reduce number of memory requests to the main memory. However, managing caches in multiprocessor system is complex. Multiple private caches introduce the multi-cache coherency problem (or stale data problem) due to multiple copies of main memory data that can concurrently exist in the multiprocessor system.
Small scale shared memory multiprocessing system have processors (or groups thereof interconnected by a single bus. However, with the increasing speed of processors, the feasible number of processors which can share the bus effectively decreases.
The protocols that maintain the coherence between multiple processors are called cache coherence protocols. Cache coherence protocols track any sharing of data block between the processors. Depending upon how data sharing is tracked, cache coherence protocols can be grouped into two classes: 1) Directory based and 2) Snooping.
In directory based approach, the sharing status of a block of physical memory is kept in just one location called the coherency directory. Coherency directories are generally large blocks of memory which keep track of which processor in the multiprocessor computer system owns which lines of memory. Disadvantageously, coherency directories are typically large and slow. They can severely degrade overall system performance since they introduce additional latency for every memory access request by requiring that each access to the memory go through the common directory.
FIG. 1 illustrates a typical prior art multiprocessor system 10 using the coherence directory approach for cache coherency. The multiprocessor system 10 includes a number of processors 15 a , . . . , 15 d interconnected via a shared bus 24 to the main memory 20 a , 20 b via memory controllers 22 a , 22 b , respectively. Each processor 15 a , . . . , 15 d has its own private cache 17 a , . . . , 17 d , respectively, which is N-way set associative. Each request to the memory from a processor is placed on the processor bus 24 and directed to the coherency directory 26 . Frequently, in the coherency controller, a module is contained which tracks the location of cache lines held in particular subsystems to eliminated the need to broadcast unneeded snoop request to all caching agents. This unit is frequently labeled “snoop controller” or “snoop filter”. All memory access requests from the I/O subsystem 28 are also directed to the coherency controller 26 . Instead of the main memory, secondary cache connected to the main memory can be used. Processors can be grouped into processor clusters, where each cluster has its own cluster bus, which is then connected to the coherency controller 26 . As each memory request goes through the coherence directory, additional cycles are added to each request for checking the status of the requested memory block.
In a snooping approach, no centralized state is kept, but rather each cache keeps the sharing status of data block locally. The caches are usually on a shared memory bus, and all cache controllers snoop (monitor) the bus to determine whether they have a copy of the data block requested. A commonly used snooping method is the “write-invalidate” protocol. In this protocol, a processor ensures that it has exclusive access to data before it writes that data. On each write, all other copies of the data in all other caches are invalidated. If two or more processors attempt to write the same data simultaneously, only one of them wins the race, causing the other processors' copies to be invalidated.
To perform a write in a write-invalidate protocol based system, a processor acquires the shared bus, and broadcasts the address to be invalidated on the bus. All processors snoop on the bus, and check to see if the data is in their cache. If so, these data are invalidated. Thus, use of the shared bus enforces write serialization.
Disadvantageously, every bus transaction in the snooping approach has to check the cache address tags, which could interfere with CPU cache accesses. In most recent architectures, this is typically reduced by duplicating the address tags, so that the CPU and the snooping requests may proceed in parallel. An alternative approach is to employ a multilevel cache with inclusion, so that every entry in the primary cache is duplicated in the lower level cache. Then, snoop activity is performed at the secondary level cache and does not interfere with the CPU activity.
FIG. 2 illustrates a typical prior art multiprocessor system 50 using the snooping approach for cache coherency. The multiprocessor system 50 contains number of processors 52 a , . . . , 52 c interconnected via a shared bus 56 to the main memory 58 . Each processor 52 a , . . . , 52 c has its own private cache 54 a , . . . , 54 c which is N-way set associative. Each write request to the memory from a processor is placed on the processor bus 56 . All processors snoop on the bus, and check their caches to see if the address written to is also located in their caches. If so, the data corresponding to this address are invalidated. Several multiprocessor systems add a module locally to each processor to track if a cache line to be invalidated is held in the particular cache, thus effectively reducing the local snooping activity. This unit is frequently labeled “snoop filter”. Instead of the main memory, secondary cache connected to the main memory can be used.
With the increasing number of processors on a bus, snooping activity increases as well. Unnecessary snoop requests to a cache can degrade processor performance, and each snoop requests accessing the cache directory consumes power. In addition, duplicating the cache directory for every processor to support snooping activity significantly increases the size of the clip. This is especially important for systems on a single chip with a limited power budget.
What now follows is a description of prior art references that address the various problems of conventional snooping approaches found in multiprocessor systems.
Particularly, U.S. Patent Application US2003/0135696A1 and U.S. Pat. No. 6,704,845B2 both describe replacement policy methods for replacing entries in the snoop filter for a coherence directory based approach including a snoop filter. The snoop filter contains information on cached memory blocks—where the cache line is cached and its status. The U.S. Patent Application US2004/0003184A1 describes a snoop filter containing sub-snoop filters for recording even and odd address lines which record local cache lines accessed by remote nodes (sub-filters use same filtering approach). Each of these disclosures do not teach or suggest a system and method for locally reducing the number of snoop requests presented to each cache in a multiprocessor system. Nor do they teach or suggest coupling several snoop filters with various filtering methods, nor do they teach or suggest providing point-to-point interconnection of snooping information to caches.
U.S. Patent Applications US2003/0070016A1 and US2003/0065843A1 describe a multi-processor system with a central coherency directory containing a snoop filter. The snoop filter described in these applications reduces the number of cycles to process a snoop request, however, does not reduce the number of snoop requests presented to a cache.
U.S. Pat. No. 5,966,729 describes a multi-processor system sharing a bus using a snooping approach for cache coherence and a snoop filter associated locally to each processor group. To reduce snooping activity, a list of remote processor groups “interested” and “not-interested” in particular cache line is kept. Snoop requests are forwarded only to the processor groups marked as “interested” thus reducing the number of broadcasted snoop requests. It does not describe how to reduce the number of snoop requests to a local processor, but rather how to reduce the number of snoop requests sent to other processor groups marked as “not interested”. This solution requires keeping a list with information on interested groups for each line in the cache for a processor group, which is comparable in size to duplicating the cache directories of each processor in the processor group thus significantly increasing the size of chip.
U.S. Pat. No. 6,389,517B1 describes a method for snooping cache coherence to allow for concurrent access on the cache from both the processor and the snoop accesses having two access queues. The embodiment disclosed is directed to a shared bus configuration. It does not describe a method for reducing the number of snoop requests presented to the cache.
U.S. Pat. No. 5,572,701 describes a bus-based snoop method for reducing the interference of a low speed bus to a high speed bus and processor. The snoop bus control unit buffers addresses and data from the low speed bus until the processor releases the high speed bus. Then it transfers data and invalidates the corresponding lines in the cache. This disclosure does not describe a multiprocessor system where all components communicate via a high-speed bus.
A. Moshovos, G. Memik, B. Falsafi and A. Choudhary, in a reference entitled “JETTY: filtering snoops for reduced energy consumption in SMP servers” (“Jetty”) describe several proposals for reducing snoop requests using hardware filter. It describes the multiprocessor system where snoop requests are distributed via a shared system bus. To reduce the number of snoop requests presented to a processor, one or several various snoop filters are used.
However, the system described in Jetty has significant limitations as to performance, supported system and more specifically interconnect architectures, and lack of support for multiporting. More specifically, the approach described in Jetty is based on a shared system bus which established a common event ordering across the system. While such global time ordering is desirable to simplify the filter architecture, it limited the possible system configurations to those with a single shared bus. Alas, shared bus systems are known to be limited in scalability due to contention to the single global resource. In addition, global buses tend to be slow, due to the high load of multiple components attached to them, and inefficient to place in chip multiprocessors.
Thus, in a highly optimized high-bandwidth system, it is desirable to provide alternate system architectures, such as star, or point-to-point implementations. These are advantageous, as they only have a single sender and transmitter, reducing the load, allowing the use of high speed protocols, and simplifying floor planning in chip multiprocessors. Using point to point protocols also allows to have several transmissions in-progress simultaneously, thereby increasing the data transfer parallelism and overall data throughput.
Other limitations of Jetty include the inability to perform snoop filtering on several requests simultaneously, as in Jetty, simultaneous snoop requests from several processors have to be serialized by the system bus. Allowing the processing of several snoop requests concurrently would provide a significant increase in the number of requests which can be handled at any one time, and thus increase overall system performance.
Having set forth the limitations of the prior art, it is clear that what is required is a system incorporating snoop filters to increase overall performance and power efficiency without limiting the system design options, and more specifically, methods and apparatus to support snoop filtering in systems not requiring a common bus.
Furthermore, there is a need for a snoop filter architecture supporting systems using point-to-point connections to allow the implementation of high performance systems using snoop filtering.
There is a further need for the simultaneous operation of multiple snoop filter units to concurrently filter requests from multiple memory writers to increase system performance.
There is further a need to provide novel, high performance snoop filters which can be implemented in a pipelined fashion to enable high system clock speeds in systems utilizing such snoop filters.
There is an additional need for snoop filters with high filtering efficiency transcending the limitations of prior art.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a simple method and apparatus for reducing the number of snoop requests presented to a single processor in cache coherent multiprocessor systems.
It is a further object of the present invention to provide a simple method and apparatus for supporting snoop filtering in multiprocessor system architectures. While prior art has allowed snoop filtering to be used only in bus-based system, the present invention teaches how to advantageously use snoop filtering in conjunction with point to point protocols by permitting several transmissions in-progress simultaneously, thereby increasing the data transfer parallelism and overall data throughput.
In accordance with the present invention, there is provided a snoop filtering method and apparatus for supporting cache coherency in a multiprocessor computing environment having multiple processing units, each processing unit having one or more local cache memories associated and operatively connected therewith. The method comprises providing a snoop filter device associated with each processing unit, each snoop filter device having a plurality of dedicated input ports for receiving snoop requests from dedicated memory writing sources in the multiprocessor computing environment. Each snoop filter device includes a plurality of parallel operating port snoop filters in correspondence with the plurality of dedicated input ports that are adapted to concurrently filter snoop requests received from respective dedicated memory writing sources and forward a subset of those requests to its associated processing unit.
According to the invention, there is provided a snoop filtering method and a snoop filter apparatus associated with a processing unit of a computing environment having multiple processing units for supporting cache coherency in the computing environment, the snoop filter apparatus comprising:
a plurality of inputs, each receiving a snoop request from a dedicated memory writing source in the computing environment;
a snoop filter means provided for each input and adapted to concurrently filter received respective snoop requests from respective dedicated memory writing sources, each snoop filter means implementing one or more parallel operating sub-filter elements adapted for processing received snoop requests and forwarding a subset thereof to the associated processing unit,
whereby as a result of the concurrent filtering, a number of snoop requests forwarded to a processing unit is significantly reduced thereby increasing performance of the computing environment.
In accordance with the present invention, one of said one or more parallel operating sub-filter elements comprises an address range filter means for determining whether an address of a received snoop request is within an address range comprising a minimum range address and a maximum range address.
Furthermore, one of said one or more parallel operating sub-filter elements comprises a snoop cache device adapted for tracking snoop requests received at the snoop filter means and recording addresses corresponding to snoop requests received; and, a snoop cache logic means in one to one correspondence with a respective snoop cache for comparing a received snoop request address against all addresses recorded in the corresponding snoop cache device, and, one of forwarding said received snoop request to the associated processing unit when an address does not match in the respective snoop cache device, or discarding the snoop request when an address match is found in the snoop cache device.
Furthermore, the processing unit has one or more cache memories associated therewith, and the snoop filter means comprises a memory storage means adapted to track cache line addresses of data that have been loaded into a cache memory level of its associated processor and record the cache line addresses. Accordingly, one of the one or more parallel operating sub-filter elements comprises a stream register check means for comparing an address of the received snoop request against corresponding addresses stored in the memory storage means; and, one of forwarding said received snoop request to said processor in response to matching an address in the memory storage means, or otherwise discarding the snoop request.
In one embodiment, the memory storage means comprises a plurality of stream register sets, each stream register set comprising a base register and a corresponding mask register pair, the base register tracking address bits common to all of the cache lines represented by the stream register; and, the corresponding mask register tracking bits representing differences to prior recorded addresses included in its corresponding base register.
Furthermore, each of the one or more parallel operating sub-filter elements generates a signal indicating whether a snoop request is to be forwarded to said associated processor or not forwarded. The snoop filter means further comprising: a means responsive to each signal generated from the sub-filter element for deciding whether a snoop request is to be forwarded or discarded.
Advantageously, the present invention enables snoop filtering to be performed on several requests simultaneously, while in the prior art systems, simultaneous snoop requests from several processors have to be serialized by the system bus. Allowing the processing of several snoop requests concurrently provides a significant increase in the number of requests which can be handled at any one time, and thus increase overall system performance.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the present invention will become apparent to one skilled in the art, in view of the following detailed description taken in combination with the attached drawings, in which:
FIG. 1 depicts a base multiprocessor architecture with the coherence directory for cache coherency according to the prior art;
FIG. 2 depicts a base multiprocessor system using snooping approach for cache coherency according to the prior art;
FIG. 3 depicts a base multiprocessor system using snooping approach for cache coherency using a point-to-point connection described according to the present invention;
FIG. 4 illustrates an alternative embodiment base multiprocessor system using snooping approach for cache coherency using point-to-point connection where snoop filter is placed between the L2 cache and the main memory;
FIG. 5 depicts a high level schematic of a snoop filter block in accordance with a preferred embodiment of the invention;
FIG. 6 is a high level schematic of the snoop block containing multiple snoop filters according to the present invention;
FIG. 7 illustrates a high level schematic of a single snoop port filter according to the present invention;
FIGS. 8( a ) and 8 ( b ) depict high level schematics of two alternative embodiments of the snoop block according to the present invention;
FIG. 9 is a is a high level schematic of the snoop block including multiple port snoop filters according to a further embodiment of the present invention;
FIG. 10 depicts the control flow for the snoop filter implementing snoop cache for a single snoop source according to the present invention;
FIG. 11 depicts a control flow logic for adding a new entry to the port snoop cache in accordance with the present invention;
FIG. 12 depicts a control flow logic for removing an entry from the snoop cache in accordance with the present invention;
FIG. 13 depicts a block diagram of the snoop filter implementing stream registers in accordance with the present invention;
FIG. 14 depicts another embodiment of the snoop filter implementing stream registers filtering approach in accordance with the present invention;
FIG. 15 is a block diagram depicting the control flow for the snoop filter using paired stream registers and masks sets according to the invention; and,
FIG. 16 is a block diagram depicting the control flow for updating two stream register sets and the cache wrap detection logic for the replaced cache lines according to the invention;
FIG. 17 illustrates block diagram of signature filters to provide additional filtering capability to stream registers;
FIG. 18 is the block diagram of filtering mechanism using signature files in accordance with the present invention;
FIGS. 19( a ) and 19 ( b ) depict exemplary cache wrap detection logic circuitry (registers and comparator) for an N-way set-associative cache;
FIG. 20 depicts an exemplary cache wrap detection logic circuitry for an N-way set-associative cache according to a second embodiment of the invention that is based on a loadable counter; and,
FIG. 21 depicts an exemplary cache wrap detection logic circuitry for an N-way set-associative cache according to a third embodiment of the invention that is based on a scoreboard register.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to drawings, and more particularly to FIG. 3 , there is shown the overall base architecture of the multiprocessor system with the use of snooping approach for cache coherency. In the preferred embodiment, the multiprocessor system is composed of N processors 100 a , . . . , 100 n (or CPUs labeled DCU 1 to DCU N ) with their local L1 data and instruction caches, and their associated L2 caches 120 a , . . . , 120 n . The main memory 130 is shared and can be implemented on-chip or off-chip. In the alternative embodiment, instead of main memory, a shared L3 with access to main memory can be used. In the preferred embodiment, the processor cores 100 a , . . . , 100 n are PowerPC cores such as PPC440 or PPC405, but any other processor core can be used, or some combination of various processors in a single multiprocessor system can be used without departing from the scope of this invention. The processor cores 100 a , . . . , 100 n are interconnected by a system local bus 150 .
To reduce the number of snoop requests presented to a processor, and thus to reduce the impact of snooping on processor and system performance, and to reduce power consumed by unnecessary snoop requests, a snoop filter 140 a , . . . , 140 n is provided for each respective processor core 100 a , . . . , 100 n in the multiprocessor system 10 . For transferring snooping requests, the preferred embodiment does not use the system bus 150 , as typically found in prior art systems, but rather implements a point-to-point interconnection 160 whereby each processor's associated snoop filter is directly connected with each snoop filter associated with every other processor in the system. Thus, snoop requests are decoupled from all other memory requests transferred via the system local bus, reducing the congestion of the bus which is often a system bottleneck. All snoop requests to a single processor are forwarded to the snoop filter 140 a , . . . , 140 n , which comprises several sub-filters with the same filtering method, or with several different filtering methods, or any combination of the two, as will be described in greater detail herein. The snoop filter processes each snoop request, and presents only a fraction of all requests which are possibly in the processor's cache to the processor.
For each processor, snoop requests are connected directly to all other processors' snoop filters using a point-to-point interconnection 160 . Thus, several snoop requests (resulting from write and invalidate attempts) from different processors can occur simultaneously. These requests are no longer serialized, as in the typical snooping approach using the system bus, where this serialization is performed by the bus. That is, multiple snoop requests can be processed in the snoop filter concurrently, as will be described herein in further detail. As a processor has only one snoop port, the snoop requests not filtered out by a snoop filter will be serialized in a queue to be presented to the processor. However, the number of requests passed to the processor is much less than the pre-filtered number of all snoop requests, reducing the impact of cache coherence implementation on system performance.
To prevent queue overflowing condition of the queues contained in the snoop filter block, a token-based flow control system is implemented for each point to point link to limit the number of simultaneously outstanding requests. According to the token-based flow control, each memory writer can send the next write request—which also initiates snoop requests to all other processor units and accompanied snoop filter blocks—only if it has tokens available for all ports of the snoop filter blocks it has a direct point-to-point connection. If there are no tokens available from at least one of the remote ports it is connected to, no snoop requests can be sent out from this memory writer until at least one token from the said snoop filter port gets available again.
FIG. 4 illustrates an alternative embodiment of this invention, with a base multiprocessor system using a snooping approach for cache coherency with point-to-point interconnection for snooping requests, wherein the snoop filter is placed between the L2 cache and the main memory 230 . The multiprocessor system according to this embodiment thus comprises N processors 200 a , . . . , 200 n (or CPUs labeled DCU 1 to DCU N ) with their local L1 data and instruction caches, and their associated L2 caches 220 a , . . . , 220 n . The main memory 230 is shared and can be implemented on-chip or off-chip. In the alternative embodiment, instead of main memory, a shared L3 cache with access to main memory can be used. All memory access requests from processors 200 a , . . . , 200 n are transferred via a system local bus 250 . In the embodiment depicted in FIG. 4 , each of the processors in the multiprocessor system is paired with a respective snoop filter 240 a , . . . , 240 n . The point-to-point interconnection 260 is used to transfer snoop requests in the preferred embodiment in order to reduce the congestion of the system bus. In this point-to-point connection scheme 260 , each processor's associated snoop filter is directly connected with each snoop filter associated with every other processor in the system. All snoop requests to a single processor are forwarded to its snoop filter, which processes each snoop request, and forwards only an appropriate fraction of all requests to the processor. In this embodiment, the snoop requests are filtered at the L2 cache level (not at L1, as in the previous embodiment illustrated in FIG. 3 ), but the presented invention is applicable to any cache level, and can be used for other levels of the cache hierarchy without departing from the scope of the invention.
Referring now to FIG. 5 , there is depicted a high level block diagram of the snoop filter device according to the present invention. Snoop requests from all other processors 1 to N in a multiprocessor system are forwarded to the snoop block 310 via dedicated point-to-point interconnection inputs 300 a , . . . , 300 n . The snoop block 310 filters the incoming snoops and forwards the appropriate subset to the processor 320 via the processor snoop interface 340 . In addition, the snoop block 310 monitors all memory access requests from the processor and L1 data cache block 320 to the L2 cache 330 . These are only requests which miss in the L1 cache. The snoop block monitors all read address and control signals 360 and 362 to update its filters accordingly.
FIG. 6 depicts a high level schematic of the snoop block 310 depicted in FIG. 5 . As shown in FIG. 6 , the snoop block 310 includes multiple (“N”) port snoop filters 400 a , . . . , 400 n that operate in parallel, with each dedicated only to one source of N memory writers (processors or a DMA engine sub-system, etc.). Each of the port snoop filters 400 a , . . . , 400 n receive on its dedicated input 410 a , . . . , 410 n snoop requests from a single source which is directly connected point-to-point. As will be described herein, a single port snoop filter may include a number of various snoop filter methods. The snoop block 310 additionally includes a stream register block 430 and snoop token control block 426 . In addition, each port snoop filter 400 a , . . . , 400 n monitors all memory read access requests 412 from its associated processor which miss in the processor's L1 level cache. This information is also provided to the stream register block 430 for use as will be described in greater detail herein.
In operation, the port snoop filters 400 a , . . . , 400 n process the incoming snoop requests and forward a subset of all snoop requests to a respective snoop queue 420 a , . . . , 420 n having one queue associated with each snoop port. A queue arbitration block 422 is provided that arbitrates between all the snoop queues 420 and serializes all snoop requests from the snoop queues 420 fairly. Logic is provided to detect a snoop queue overflow condition, and the status of each queue is an input to a snoop token control unit 426 that controls flow of snoop requests from the remote memory writers. A memory writer—being a processor or a DMA engine—can submit a write to the memory and a snoop request to all snoop filters only if it has a token available from all snoop filters. The only snoop filter from which a processor does not need a token available to submit a write is its own local snoop filter. This mechanism ensures that the snoop queues do not overflow. From the snoop queue selected by arbiter 422 , snoop requests are forwarded to the processor via a processor snoop interface 408 .
FIG. 7 illustrates a high level schematic of a single snoop port filter 400 . The snoop port filter block 400 includes multiple filter units which implement various filtering algorithms. In the preferred embodiment, three snoop filter blocks 440 , 444 , and 448 operate in parallel, each implementing a different snoop filter algorithm. The snoop filter blocks are labeled snoop cache 440 , stream register check unit 444 , and range filter 448 . In one embodiment, each of the parallel snoop filter blocks receives on its input an identical snoop request 410 from a single source simultaneously. In addition, the snoop cache 440 monitors all memory read access requests 412 from the processor which miss in the L1 level cache, and stream registers check unit 444 receives status input 432 from the stream register unit 430 depicted in FIG. 6 .
According to the preferred embodiment, the snoop cache block 440 filters the snoop requests 410 using an algorithm which is based on the temporal locality property of snoop requests, meaning that if a single snoop request for a particular location was made, it is probable that another request to the same location will be made soon. The snoop cache monitors every load made to the local cache, and updates its status, if needed. The stream register check block 444 filters snoop requests 410 using an algorithm that determines a superset of the current local cache content. The approximation of cache content is included in the stream registers block 430 ( FIG. 6 ), and the stream register status 432 is forwarded to each snoop port filter 400 . Based on this status, for each new snoop requests 410 , a decision is made if the snoop address can possibly be contained in the local cache. The third filtering unit in the snoop port filter is the range filter 448 . For this filtering approach, two range addresses are specified, the minimum range address and the maximum range address. The filtering of a snoop request is performed by first determining if the snoop request is within the address range determined by these two range addresses. If this condition is met, the snoop request is discarded; otherwise, the snoop request is forwarded to the decision logic block 450 . Conversely, the request can be forwarded when it falls within the address range and discarded otherwise, without departing from the scope of the invention. Particularly, the decision logic block 450 receives results 456 of all three filter units 440 , 444 and 448 together with the control signals 454 which enable or disable each individual snoop filter unit. Only results of snoop filter units for which the corresponding control signals are enabled are considered in each filtering decision. If any one of the filtering units 440 , 444 or 448 decides that a snoop request 410 should be discarded, the snoop request is discarded. The resulting output of this unit is either to add the snoop request to the corresponding snoop queue 452 , or to discard the snoop request and return a snoop token 458 to the remote processor or DMA unit that initiated the discarded snoop request.
In the preferred embodiment, only the three filtering units implementing the algorithms above described are included in a port snoop filter, but one skilled in the art will appreciate that any other number of snoop filter units can be included in a single port snoop filter, or that some other snoop filter algorithm may be implemented in the port snoop filter, or a combination of snoop algorithms can be implemented, without departing from the scope of the invention.
FIGS. 8( a ) and 8 ( b ) depict high level schematics of two alternative embodiments of the snoop filter block 310 of FIG. 6 . As described herein with respect to FIG. 6 , the snoop block may include multiple snoop filters that can use various filtering approaches, the same filtering approach, or a combination of the two. As shown in FIG. 8( a ), N port snoop filters 460 a , . . . , 460 n operate in parallel, one for each of N remote memory writers. Each of the port snoop filters 460 a , . . . , 460 n receive on its respective input 462 a , . . . , 462 n snoop requests from a single dedicated source which is connected point-to-point. In addition, each snoop filter 460 a , . . . , 460 n monitors all of the local processor's memory load requests 464 which have missed in the L1 level cache. Other signals from other units of the snoop block may also be needed to supply to the port snoop filters, if required by the filter algorithm implemented. The exact signals needed are determined by the one or more snoop filter algorithms implemented in a single port snoop filter 460 . Additionally, it should be understood that all port snoop filters do not have to implement the same set of filtering algorithms.
The port snoop filters 460 a , . . . , 460 n filter the incoming snoops and forward the appropriate unfiltered subset of snoop requests into the respective queues 466 a , . . . , 466 n and the queue arbitration block 468 . Here, the snoop requests are serialized and presented to a next snoop filter 470 , which handles inputs from all remote memory writers. This shared snoop filter 470 processes all snoop request presented and forwards a subset of all requests to the snoop queue 472 . From the snoop queue 472 , snoop requests are forwarded to the processor via the processor snoop interface 474 . It should be understood that it is possible to have multiple or no shared snoop filters 470 instead of the configuration shown in FIG. 8( a ). In the case of multiple shared filters, the filters may be arranged in parallel or in series (in which case the output of one filter is the input to the next, for example). If a filter has inputs from more than one source (i.e., is shared between multiple sources), it has to have its own input queue and an arbiter to serialize snoop requests. A final ordered subset of all snoop requests is placed in the snoop queue 472 , and snoop requests are forwarded to the processor via the processor snoop interface 474 . Optionally, a snoop queue full indication signal 476 is provided that indicates when the snoop queue is full in order to stop some or all remote memory writers from issuing further snoop requests until the number of snoops in the snoop queue falls below a predetermined level.
Similarly, FIG. 8( b ) illustrates another embodiment with an alternative organization of the snoop filters in the snoop block 310 . N port snoop filters 480 a , . . . , 480 n , each receiving only snoop requests from one of N remote memory writers (i.e., excluding the processor where the snoop filter is attached), operate in parallel. Each port snoop filter 480 a , . . . , 480 n receives on its respective input snoop requests 482 a , . . . , 482 n from only a single source, respectively. A shared snoop filter 484 is connected in parallel with the port snoop filter devices 480 a , . . . , 480 n . In an alternative embodiment, more than one shared snoop filter can be attached in parallel. The shared snoop filter 484 handles inputs from all N remote memory writers. Having more than one input, the shared filter 484 has its own input queues 486 and a queue arbiter 488 for serializing snoop requests. Further in the embodiment depicted in FIG. 8( b ), all port snoop filters 480 a , . . . , 480 n and the shared snoop filter 484 monitor all memory read access requests 490 from the local processor which miss in the L1 level cache. The snoop filters 480 a , . . . , 480 n and 484 filter the incoming snoop requests and forward the appropriate unfiltered subset to the input queue of the next shared snoop filter 492 a , . . . , 492 n . Here, the unfiltered snoop requests are serialized by the queue arbiter 494 , and are forwarded to the processor via the processor snoop interface 496 . If one of the snoop queue devices 492 a , . . . , 492 n or 486 is full, a snoop queue full indication 498 is activated to stop all (or some of) the remote memory writers from issuing further snoop requests until the number of snoops in the snoop queue falls below a the predetermined level.
Referring now to FIG. 9 , there is depicted a further embodiment of the snoop filter block 310 . The block contains N port snoop filters 500 a , . . . , 500 n , corresponding to port snoop filters 400 , 460 a , . . . , 460 n , and 480 a , . . . , 480 n (of FIGS. 8( a ) and 8 ( b )). Each port snoop filter 500 a , . . . , 500 n includes a snoop cache device 502 a , . . . , 502 n , and a snoop check logic 504 a , . . . , 504 n . The snoop cache devices 502 a , . . . , 502 n implement a snoop filtering algorithm which keeps track of recent snoop requests from one source, where the source of snoop requests can be another processor, a DMA engine, or some other unit. For each new snoop request from a single source, the snoop request's address is checked against the snoop cache in the snoop check logic block 504 . If the result of this comparison matches, i.e., the snoop request is found in the snoop cache, the snooped data is guaranteed not to be in the local L1 level cache of the processor. Thus, no snoop request is forwarded to the snoop queue 506 and the snoop queue arbiter 508 . If no match is found in the snoop cache 502 a , . . . , 502 n for the current snoop request, the address of the snoop requests is added to the snoop cache using the signals 514 a , . . . , 514 n . Concurrently, the snoop request is forwarded to the snoop queue 506 .
All snoop cache devices 502 a , . . . , 502 n also receive read addresses and requests 512 from the local processor, and compare the memory read access addresses to the entries in the snoop cache 502 a , . . . , 502 n . If a request matches one of the entries in the snoop cache, this entry is removed from the snoop cache, as now the cache line is going to be located in the processor's first level cache. In the preferred embodiment, multiple snoop caches operating in parallel are used, each keeping track of snoop requests from a single remote memory writer. After filtering, a fraction of unfiltered snoop requests can be forwarded to the next port snoop filter, or they can be queued for one or more shared snoop filters, or they are placed in the snoop queue of the processor interface, depending on the embodiment.
It is understood that a single snoop cache device 502 includes an internal organization of M cache lines (entries), each entry having two fields: an address tag field, and a valid line vector. The address tag field of the snoop cache is typically not the same as the address tag of the L1 cache for the local processor, but it is shorter by the number of bits represented in the valid line vector. Particularly, the valid line vector encodes a group of several consecutive cache lines, all sharing the same upper bits represented by the corresponding address tag field. Thus, the n least significant bits from an address are used for encoding 2 n consecutive L1 cache lines. In the extreme case when n is zero, the whole entry in the snoop cache represents only one L1 cache line. In this case, the valid line vector has only one bit corresponding to a “valid” bit.
The size of the address tag field in the snoop cache is determined by the size of the L1 cache line and the number of bits used for encoding the valid line vector. In an example embodiment, for an address length of 32 bits (31:0), an L1 cache line being 32 bytes long, and a valid line vector of 32 bits, address bits (31:10) are used as the address tag field, (bit 31 being the most significant), address bits (9:5) are encoded in the valid line vector, and address bits (4:0) are ignored because they encode the cache line byte offset. As an illustration, three snoop caches for three different memory writers (N=3) are listed below, each snoop cache having M=4 entries, with address tag field to the left, and with 5 bits from the address used to encode the valid line vector to track 32 consecutive cache lines:
Snoop Requests Source 1
Entry 1: 01c019e 00000000000000000001000000000000
Entry 2: 01c01a0 00000000000000000000000100000000
Entry 3: 01c01a2 00000000000000000000000000010000
Entry 4: 01407ff 00000000000000000000000110000000
Snoop Requests Source 2
Entry 1: 01c01e3 00010000000000000000000000000000
Entry 2: 01c01e5 00000001000000000000000000000000
Entry 3: 01c01e7 00000000000100000000000000000000
Entry 4: 0140bff 00000000000000000000000110000000
Snoop Requests Source 3
Entry 1: 01c0227 00000000000000000001000000000000
Entry 2: 01c0229 00000000000000000000000100000000
Entry 3: 01c022b 00000000000000000000000000010000
Entry 4: 0140fff 00000000000000000000000110000000
In this example, entry 1 of the source 1 snoop cache has recorded that address 01c019ec hexadecimal has been invalidated recently and cannot possibly be in the L1 cache. Therefore, the next snoop request to the same cache line will be filtered out (discarded). Similarly, entry 4 of the source 1 snoop cache will cause snoop requests for cache line addresses 01407ff7 and 01407ff8 to be filtered out.
Referring now to FIG. 10 , the control flow for the snoop filter implementing a snoop cache device for a single snoop source is shown. At the start of operation, all M lines in the snoop cache are reset as indicated at step 600 . When a new snoop request from a snoop source i is received, the address of the snoop request is parsed into the “address tag” field 526 and into bits used for accessing the valid line vector 524 . The valid line vector of the snoop request has only one bit corresponding to each L1 cache with address bits matching the address tag field. This is performed in the step 602 . In the step 604 , the “tag” field of the snoop request is checked against all tag fields in the snoop cache associated with the snoop source i. If the snoop request address tag is the same as one of the address tags stored in the snoop cache, the address tag field has hit in the snoop cache. After this, the valid line vector of the snoop cache entry for which a hit was detected is compared to the valid line vector of the snoop request. If the bit of the valid line vector in the snoop cache line corresponding to the bit set in the valid line vector of the snoop request is set, the valid line vector has hit as well. In one preferred embodiment, the valid line vector check is implemented by performing a logical operation upon the bit operands. Thus, for example, the valid line vector check may be performed by AND-ing the valid line vector of the snoop request with the valid line vector of the snoop cache line, and checking if the result is zero. It is understood that other implementations may additionally be used without departing from the scope of this invention. It is further understood that checking for a valid line vector hit can be implemented in parallel with checking for an address tag hit.
At step 606 , a determination is made as to whether both the “tag’ field matches and the corresponding bit in the valid line vector is set. If both the “tag’ field matches and the corresponding bit in the valid line vector is set, the snoop request is guaranteed not to be in the cache as indicated at step 606 . Thus, this snoop request is not forwarded to the cache; it is filtered out as indicated at step 608 .
Otherwise, if the address “tag” field hits in the snoop cache but the bit in the valid line vector is not set or, alternately, if the tag does not hit in the snoop cache, this indicates that the line may be in the cache. Consequently, the snoop request is forwarded to the cache by placing it into a snoop queue as indicated at step 612 . This snoop request is also added as a new entry to the snoop cache as shown at step 610 .
Referring now to FIG. 11 , there is shown the details of step 610 ( FIG. 10 ) describing the process of adding new information in the snoop cache. This is accomplished by several tasks, as will now be described. At step 614 , a determination is first made as to whether the address tag is already stored in the snoop cache (i.e., the address tag was a hit). For this step, the information calculated in step 602 ( FIG. 10 ) can be used. If the address tag check gave a hit, then the process proceeds to step 624 , where the bit in the valid line vector of the selected snoop cache entry corresponding to the snoop request is set. If the address tag check gave a miss in step 614 , a new snoop cache entry has to be assigned for the new address tag, and the process proceeds to 616 where a determination is made as to whether there are empty entries available in the snoop cache. If it is determined that empty entries are available, then the first available empty entry is selected as indicated at step 620 . Otherwise, if it is determined that there are no empty entries in the snoop cache, one of the active entries in the snoop cache is selected for the replacement as indicated at step 618 . The replacement policy can be round-robin, least-recently used, random, or any other replacement policy known to skilled artisans without departing from the scope of this invention. Continuing to step 622 , the new address tag is then written in the selected snoop cache line and the corresponding valid line vector is cleared. Then, as indicated at step 624 , the bit in the valid line vector of the selected snoop cache entry corresponding to the bit set in the valid line vector of the snoop request is set.
In yet another embodiment, the new information is not added into the snoop cache based on the hit or miss of a snoop request in the snoop cache only, but instead, the addition of new values—being whole snoop cache lines or only setting a single bit in a valid line vector—is based on the decision of the decision logic block 450 ( FIG. 7 ). In this embodiment, the new information is added into the snoop cache only if the decision logic block does not filter out the snoop request. If any other filter in the snoop port filter block 400 ( FIG. 7 ) filters out the snoop request (i.e., determines that the data are not in the local L1 cache), no new information is added to the snoop cache, but the operation steps are the same as for snoop cache hit case. The advantage of this embodiment is that the snoop cache performs better because less redundant information is stored.
Referring now to FIG. 12 , there is depicted the control flow for removing an entry from a snoop cache. On each local processor memory read request which misses in the local L1 level cache, the address of the memory request is checked against all entries in all snoop caches associated with all snoop request sources. In step 630 , the address of the memory read request is parsed into an address tag field and into bits used for encoding the valid line vector. This is performed in the step 630 . In the step 632 , a determination is made as to whether there are one or more tag hits. This is accomplished by checking the “tag” field of the memory request against all tag fields in all snoop caches associated with all snoop sources. If the tag check misses, this address is not being filtered out and nothing has to be done. Thus, the control flow loops back to step 630 to wait for the next cache miss from the processor.
Returning to step 632 , if it is determined that the comparison of the address tag with all snoop caches results in one or more hits, the information has to be removed from all snoop caches for which it was hit. Thus, at step 634 , the appropriate low order bits of the memory read address are decoded into a valid line vector, and is matched against the valid line vector of the snoop cache entry that was hit as indicated in step 635 . Proceeding now to step 636 , it is determined whether the unique bit set in the read address vector is also set in the valid line vector of the snoop cache. If there is no such valid line vector hit (regardless of the address tag field hit), this memory address is not filtered out and nothing has to be changed in the particular snoop cache. Thus, the control flow proceeds to step 640 to check if all address tag hits have been processed, and if not, the process returns to step 635 .
If, however, it is determined at step 636 that the read address vector hits in the valid line vector, then the read address is being filtered out. The corresponding valid line vector bit has to be cleared since the memory read address is going to be loaded into the first level cache. This clearing of the corresponding bit in the valid line vector is performed at step 638 . If after removing the corresponding bit from the valid line vector the number of bits set of the valid line vector becomes zero, the address tag field is further removed from the snoop cache causing the entry to be empty. As next indicated at step 640 , the same process of checking for the valid line vector bit, its clearing, and clearing of the address tag—if necessary—is repeated for all snoop caches which hit the memory read request which was miss in the local L1 cache. This condition that all hit address tag lines have been processed is checked at step 640 . Once all of the cache lines have been checked, the process returns to step 630 .
In yet another embodiment, the local memory request is compared to all address tags in all snoop caches simultaneously. Concurrently, the valid line vector encoding of the local memory request may be compared with all valid line vectors in all snoop caches in which there were hits simultaneously. Then, these two results—address tag hit and valid line vector hit—can be combined to determine all snoop cache lines from which the corresponding valid line vector bit has to be removed, and all these bits can be removed from the hitting cache lines from all snoop caches simultaneously.
Referring now to FIG. 13 , there is depicted the block diagram of the snoop filter device implementing stream registers. In one preferred embodiment, the snoop filter unit comprises the following elements: two sets of stream registers and masks 700 , a snoop check logic block 702 , a cache wrap detection logic block 706 , a stream register selection logic block 704 , filter queues 703 , and a processor arbitrate and multiplex logic 710 . As will be described in greater detail herein, unlike the snoop cache filters that keep track of what is not in the cache, the stream registers and masks sets 700 keep track of recent data which were loaded into the cache of the processor. More precisely, the stream registers keep track of at least the lines that are in the cache, but may assume that some lines are cached which are not actually in the cache. However, forwarding some unnecessary snoop requests to the cache does not affect correctness.
The heart of the stream register filter is the stream registers 700 themselves. One of these registers is updated every time the cache loads a new line, which is presented to the stream registers with appropriate control signals 716 . Logic block 704 in FIG. 13 is responsible for choosing a particular register to update based upon the current stream register state and the address of the new line being loaded into the cache in signals 716 .
In operation, snoop requests received from one of the N remote processors arrive as signals 714 shown in the right-hand side of FIG. 14 . The snoop check logic 702 comprises a set of port filters that compare the addresses of the arriving snoop requests 714 with the state of the stream registers 700 to determine if the snoop requests could possibly be in the cache. If so, the requests are forwarded to queues 703 where they wait to be forwarded to the cache as actual cache snoops. The queuing structure of FIG. 13 , where each of the N remote processors has a dedicated snoop request queue 703 , is designed to allow for the maximum snoop request rate since a large number of the snoop requests will be filtered out and will never need to be enqueued. Alternative queuing structures are possible without departing from the general scope of the invention.
The arbitrate and multiplex logic block 710 simply shares the snoop interface of the cache between the N snoop request queues 703 in a fair manner, guaranteeing forward progress for all requests.
A description of how a single stream register is updated is now provided. A stream register actually comprises a pair of registers, the “base” and the “mask”, and a valid bit. The base register keeps track of address bits that are common to all of the cache lines represented by the stream register, while the corresponding mask register keeps track of which bits these are. The valid bit simply indicates that the stream register is in use and should be consulted by the snoop check logic 702 when deciding whether to filter a remote snoop request 714 . In order to understand the examples in the following description, consider an address space of 2 32 bytes with a cache line size of 32 bytes. In this case, a cache line load address is 27 bits in length, and the base and mask registers of the stream registers are also 27 bits in length.
Initially, the valid bit is set to zero, indicating that the stream register is not in use, and the contents of the base and mask register is irrelevant. When the first cache line load address is added to this stream register, the valid bit is set to one, the base register is set to the line address, and all the bits of the mask register are set to one, indicating that all of the bits in the base register are significant. That is, an address that matches the address stored in the base register exactly is considered to be in the cache, while an address differing in any bit or bits is not. For example, given a first cache line load address is 0x1708fb1 (the 0x prefix indicates hexadecimal). Then the contents of the stream register after the load is:
Base=0x1708fb1 Mask=0x7ffffff Valid=1
Subsequently, when a second cache line load address is added to this stream register, the second address is compared to the base register to determine which bits are different. The mask register is then updated so that the differing bit positions become zeros in the mask. These zeros thus indicate that the corresponding bits of the base register are “don't care”, or can be assumed to take any value (zero or one). Therefore, these bits are no longer significant for comparisons to the stream register. For example, say the second cache line load address is 0x1708fb2. Then the contents of the stream register after this second load is:
Base=0x1708fb1 Mask=0x7fffffc Valid=1
In other words, the second address and the base register differed in the two least significant bits, causing those bits to be cleared in the mask register. At this point, the stream register indicates that the addresses 0x1708fb0, 0x1708fb1, 0x17081b2, and 0x1708fb3 can all be in the cache because it can no longer distinguish the two least significant bits. However, it is important to note that the two addresses which have actually been loaded are considered to be in the cache. This mechanism thus guarantees that all addresses presented to the stream register will be included within it. In the limit, the mask register becomes all zeros and every possible address is included in the register and considered to be in the cache. Clearly, the mechanism described can be used to continue adding addresses to the stream register.
Every cache line load address is added to exactly one of the multiple stream registers. Therefore, the collection of stream registers represents the complete cache state. The decision of which register to update is made by the update choice logic block 704 in FIG. 13 . One possible selection criteria is to choose the stream register with minimal Hamming distance from the line load address (i.e. the stream register which will result in the minimum number of mask register bits changing to zero). Yet another selection criteria is to choose the stream register where the most upper bits of the base register match those of the line load address. Other selection criteria are possible and can be implemented without departing from the scope of the invention.
In selecting a stream address register to update, the line load address is compared to all base registers combined with their corresponding mask registers in parallel. The line load address is then added to the selected stream register as described herein.
The snoop check logic block 702 determines whether a snoop address 714 could possibly be in the cache by comparing it to all of the stream registers as follows: the snoop address 714 is converted to a line address by removing the low-order bits corresponding to the offset within a cache line. This line address is compared with a single stream register by performing a bitwise logical exclusive-OR between the base register and the snoop line address, followed by a bitwise logical AND of that result and the mask register. If the final result of these two logical operations has any bits that are not zero, then the snoop address is a “miss” in the stream register and is known not to be in the cache, as far as that stream register is concerned. The same comparison is performed on all of the stream registers in parallel, and if the snoop line address misses in all of the stream registers, then the snoop address is known not to be in the cache and can be filtered out (i.e. not forwarded to the cache). Conversely, if the snoop address hits in any one of the stream registers, then it must be forwarded to the cache.
The snoop check logic 702 is duplicated for each of the N remote snoop request ports, but they all share the same set of stream registers 700 .
Over time, as cache line load addresses are added to the stream registers, they become less and less accurate in terms of their knowledge of what is actually in the cache. As illustrated in the example above, every mask bit that becomes zero increases the number of cache lines that the corresponding stream registers specifies as being in the cache by a factor of two. In general, the problem of forwarding useless snoop requests to the processor (i.e., failing to filter them) becomes worse as the number of mask bits that are zero increases. Therefore, the stream register snoop filter are provided with a mechanism for recycling the registers back to the initial condition. This mechanism is based upon the observation that, in general, lines loaded into the cache replace lines that are already there. Whenever a line is replaced, it can be removed from the stream registers, since they only track which lines are in the cache. Rather than remove individual lines, the stream register snoop filter effectively batches the removals and clears the registers whenever the cache has been completely replaced. However, the new cache lines that were doing this replacement were also added into the stream registers, so the contents of those registers cannot simply be discarded.
To solve this dilemma, the stream register snoop filter performs the following: starting with an initial cache state, stream register updates occur as described previously herein. The cache wrap detection logic block 706 is provided with functionality for monitoring cache update represented by cache update signals 717 and determining when all of the cache lies present in the initial state have been overwritten with new lines, i.e. the cache has “wrapped”. At that point, contents of all of the stream registers (call them the “active” set) are copied to a second “history” set of stream registers and the stream registers in the active set are all returned to the invalid state to begin accumulating cache line load addresses anew. In addition, the state of the cache at the time of the wrap becomes the new initial state for the purpose of detecting the next cache wrap. The stream registers in the history set are never updated. However, they are treated the same as the active set by the snoop check logic 702 when deciding whether a snoop address could be in the cache. With this mechanism, the stream registers are periodically recycled as the cache is overwritten.
There are a number of ways that cache wrapping can be detected depending upon the cache update policy and the cache update signals 717 . For example, if the cache specifies the line that is overwritten, then a simple scoreboard can be used to determine the first time that any particular line is overwritten and a counter can be used to determine when every line has been overwritten at least once. Any mechanism for detecting cache wrapping can be used without departing from the scope of the invention.
FIG. 14 shows an alternative embodiment of the stream register snoop filter, where the filter is entirely shared by the N remote processors. That is, the individual snoop request ports 714 do not have their own snoop check logic 702 as shown in the embodiment described with respect to FIG. 13 . In this embodiment, snoop requests are enqueued in queue structures 708 before being input to a shared snoop check logic block 701 . The queued requests are forwarded in a fair manner to the snoop check logic block 701 via an arbitrate and multiplex logic 705 . The functionality of the snoop check logic block 701 is otherwise identical to the previous stream register snoop filter check logic as described herein with respect to FIG. 13 . Clearly, alternative queuing structures 708 are possible and do not depart from the general scope of the invention.
In a preferred embodiment, two sets of stream registers are used, but more than two sets can be used without departing from the scope of the invention. For example, in an embodiment implementing four sets of stream registers, two sets of active registers, A and B, and two sets of corresponding history registers, are implemented. In this embodiment, the A set of stream registers can contain information related to one subset of the cache, and the B set of stream registers can contain information related to a different subset of the cache. The partition of the cache into parts assigned to each set of stream registers, A and B, can be performed by dividing the cache into two equal parts, but other partitions may be used. Furthermore, the number of stream register sets can be more than two. For example, there can be one set of stream registers assigned to each cache set of a set-associative cache.
In yet another embodiment, there can be more than one history set of stream registers, allowing the active set to be recycled more frequently. However, care must be taken to manage the history registers relative to cache wrap detections so that a register is never cleared when a cache line covered by that register could still be in the cache. One way to ensure that a register is never cleared is to add history registers to the active set of stream registers and then copy all of those history registers (and the active registers) to a second set of history registers when the cache wraps. This is essentially adding a second “dimension” of history to the preferred embodiment of the stream register snoop filter as described herein.
Referring now to FIG. 15 , there is depicted a detailed process flow diagram of the control flow for the snoop filter using paired base register and mask register sets. At the start of operation, all stream registers and masks and snoop queues are reset as indicated at step 730 , and the system waits for the next snoop request from any snoop source as indicated at step 732 . When a new snoop request is received, the address of the snoop request is checked against all address stream register and masks (both sets of the stream registers) as depicted in step 734 . The address of the snoop requests is checked against all stream registers combined with accompanied masks (i.e., all address stream register and masks (both sets of the stream registers)). If the comparison of the current snoop request matches a stream register combined with the paired mask register as determined at step 736 , the snooped cache line might be in the cache and the snoop request is forwarded to the cache by placing the snoop request into snoop queue in step 740 . The process returns to step 732 to wait for the next snoop request. If, however, the snoop request does not match any stream register combined with the paired mask register in the both sets of stream registers, the snooped cache line is guaranteed not in the cache. Thus, this snoop request is filtered out in the step 738 and the process returns to step 732 .
Referring now to FIG. 16 , there is depicted the control flow for updating two stream register sets and the cache wrap detection logic block for the replaced cache lines. At the start of operation, all stream registers and masks are reset and the cache wrap detection logic is cleared as indicated at step 750 , and first set of registers is activated. For each processor memory request (including either a load or store operation) that misses in L1 cache, the address of the memory request is added to a first set of stream registers, referred to as an active address stream register set. All address stream registers from the first set of registers are checked to select the best match—as specified by the implemented register selection criteria; alternately, the first empty stream register may be selected. The address of the memory request is stored into the selected stream address register in the active register set as indicated at step 752 , and the paired mask is updated to reflect which bits of the address are relevant, and which are not. Then, at step 754 , the cache wrap detection logic is updated to reflect the new data loaded in the cache. The cache wrap detection block keeps track of whether all lines in the cache have been replaced since first use of the active registers was initiated. Thus, at step 756 , a determination is made as to whether a cache wrap condition exists. If a cache wrap condition is not detected in step 756 , the control flow loops back to the step 752 where the system waits for the next processor memory request. Otherwise, if a cache wrap condition is detected, the control continues to the step 758 where the cache wrap detection logic block is cleared and a second stream registers and masks set are cleared in the step 758 . Proceeding next to step 760 , the system waits for the next processor memory request. For the new memory request, all address stream registers from the second set of registers are checked to select the best match, e.g., as specified by the implemented register selection criteria, for example, or, the first empty stream register is selected. The address of the memory request is stored into the selected stream address register in the second register set as indicated at step 760 , and the paired mask is updated to reflect which bits of the address are relevant. Proceeding to step 762 , the cache wrap detection logic is updated to reflect the new data loaded in the cache. As the cache wrap detection logic keeps track of all lines in the cache that have been replaced since first use of the second set of registers was initiated, a determination is then made at step 764 to determine if a cache wrap condition exists. If no cache wrap event is detected in the step 764 , the system waits for the next processor memory request by returning to step 760 . If, however, the cache wrap event is detected, the first set of registers and masks will be used again. Thus, all registers and paired masks from the first set of registers are reset, the cache wrap detection logic is cleared in the step 766 . The first set of registers are going to be used again as active for approximating the content of the cache, and the control flow is looped back to the step 752 .
As described herein with respect to use of the stream register snoop filter, the power of each stream register filter to block snoop requests decreases as the number of mask bits set to zero increases. For example, if all mask bits are zero, then all snoop requests must be sent through. However, supposing these mask bits were set to zero one bit at a time (i.e., each load differs from the stream register by only one bit), then, in such a case, a snoop request for an address having exactly two bits different from the stream register would be let through, even though this address cannot be in the cache. Accordingly, additional filtering capability is provided by implementing signature filters that enable detection of more complicated, or subtle, differences such as the number of different bits. The general idea is that a snoop is forwarded from a stream register only if both the mask filter and the signature filter indicate that the address might be in the cache.
Referring to FIG. 17 , there is a signature function 900 that takes as inputs, an address 901 and a stream register 902 and computes the signature 903 of the address, relative to the stream register. There are many possible signature functions, such as:
1. The number of bits in the address that are different than the stream register address. Denote this number by s. Truncation can be used to save space, e.g., set the signature to min(M,s) for some constant M. 2. If the address is N bits long, the signature is a vector of length B=(N+1) bits with zeros in every bit except for a one in bit i if s=i. To save space, this could be truncated to a vector of length B+1 (B+1<N) where there is a one in bit i if min(s,B)=i. 3. Divide the address into k (k>1) groups of bits. The length of group i is L(i) bits and let M(i)=L(i)+1. Let s(i) be the number of address bits in group i that are different than the stream register bits in group i. Then the signature is given by (s(1), s(2) . . . , s(k)), which is simply the number of different bits in each group. These groups may consist of either disjoint sets of bits, or partially overlapping sets of bits (i.e., some bit of an address is in more than one group). The length of the signature is B(1)+ . . . +B(k) bits where B(i) is the number of bits required to represent all possible values of s(i). 4. A combination of (2) and (3) above, in which the signature consists of k bit vectors corresponding to each of the groups. Bit i in group j is set to one if s(j)=i. If group i is of length L(i) bits then it requires M(i)=(L(i)+1) bits to encode all possible values of s(i). The signature is M(1)+ . . . +M(k) bits long. Truncation can be used to save space, e.g., bit i in group j is set to one if min(M,s(j))=i for some constant M. 5. As in (3) above, but there are M(1)* . . . *M(k) different unique combinations of s(1), . . . , s(k). Assign an integer q to each combination, and set the signature to a vector of all zeros except for a one in bit q. Truncation, as in (4) above, can reduce space. 6. Divide the address into k (k>1) groups of bits and let p(i) be the parity of the address bits in group i. Then the signature is given by (p(1), p(2) . . . , p(k)). 7. As in (6) above, but encode each of the 2 k combinations of parity to an integer q, and return a bit vector of length 2 k zeros, except for a one in bit q.
It is understood that many other signatures are possible.
If the address 901 is a load to the cache, the signature 903 is fed to a signature register updater 904 . The updater also takes the previous value of a signature register 905 as input and replaces it by a new value 906 . The appropriate way to update the signature register depends on the type of signature. Let S_old denote the old value of the signature register, S_new denote the new value of the signature register, and V denote the value of the signature 903 . Corresponding to the signature functions above, the signature updater 904 computes:
1. S_new=max(S_old,V). This keeps track of the maximum number of bits that differ from the stream register. 2. S_new=S_old bit-wise-or V. This keeps a scoreboard of the number of different bits. 3. S_new=max(S_old,V). This keeps track of the maximum number of bits in each group that differ from the stream register. 4. S_new=S_old bit-wise-or V. This keeps a scoreboard of the number of different bits in each group. 5. S_new=S_old bit-wise-or V. This keeps a scoreboard of the number of different bits in each group that occur simultaneously. 6. S_new=S_old bit-wise-or V. This keeps a scoreboard of the parity in each group. 7. S_new=S_old bit-wise-or V. This keeps a scoreboard of the parity in each group that occur simultaneously.
When a snoop request comes in, its signature is computed and compared to the signature register. It a match does not occur there, the address cannot be in the cache, so the request is filtered even if the normal stream register and mask filter indicates that it might be in the cache. A snoop is forwarded only if the signature register and mask register both indicate that the address might be in the cache.
The signature filtering mechanism is shown in FIG. 18 . A load address 1001 to the cache is sent to the mask update logic 1002 which operates as described earlier, taking the previous mask register 1003 , a stream register 1004 and updating the mask register 1003 . This address 1001 is also fed to a signature function 1005 that also takes the stream register 1004 as input and produces a signature 1006 . The signature 1006 and previous signature register 1008 are fed to the signature update logic 1007 that creates a new value for the signature register 1008 .
When a snoop address 1009 a request comes in, it is received and processed by the mask filter 1010 producing a mask snoop request 1011 . In addition, this same snoop address (shown as 1009 b ) and the stream register 1004 are fed to the signature function 1012 producing a signature 1013 . Note that the signature functions 1005 and 1012 must be identical logic, meaning that if they have the same inputs they will produce the same outputs. The signature of the snoop request 1013 and the signature register are fed to the signature filter 1014 .
This filter must determine if a request having this signature might be in the cache and its exact operation depends on the type of signature. In the case of the “scoreboard” types of signature updaters, the snoop signature is bit-wise and-ed with the signature register. If the result of this is non-zero, then a signature snoop request 1015 is made (i.e., that signal is set to 1 if a request is to be made and 0 otherwise). In the case of “maximum number of bits changed” types of signature updaters, a check is made to see if the snoop signature is less than or equal to the signature register (one comparison for each group). If all such comparisons are true, the address might be in the cache and the signature snoop request 1015 is made. The mask snoop request 1011 and the signature snoop request 1015 are AND-ed together in logic element 1016 to generate a snoop request signal 1017 . If this signal is 1, a snoop request will be generated unless it is ruled out by the snoop vector lists, or an applied range filter (see FIG. 7 ). However, specifically, such a snoop request cannot be ruled out by the result of a signature-mask filter from another stream register.
The signature register is set appropriately at the same time that the stream register is first set, or reset. For scoreboard types and max-types of signatures, the signature register is set to all zeros (indicating no bits different from the stream register).
The stream register filter relies upon knowing when the entire contents of a cache have been replaced, relative to a particular starting state—a cache wrap condition as referred to herein. A set-associative cache is considered to have wrapped when all of the sets within the cache have been replaced. Normally, some sets will be replaced earlier than others and will continue to be updated before all sets have been replaced and the cache has wrapped. Therefore, the starting point for cache wrap detection is the state of the cache sets at the time of the previous cache wrap.
In one embodiment, the cache is set-associative and uses a round-robin replacement algorithm, however other replacement implementations are possible. For instance, cache wrap detection may be achieved when the cache implements an arbitrary replacement policy, including least-recently-used and random. As referred to in the description to follow, a set-associative (SA) cache comprises some number of sets, where each set can store multiple lines (each with the same set index). The lines within a set are called “ways”. Hence, a 2-way set associative cache has two (2) lines per set. All of the ways within a set are searched simultaneously during a lookup, and only one of them is replaced during an update. Furthermore, a set can be partitioned such that a subset of the ways is assigned to each partition. For example, a 4-way SA cache may be partitioned into two 2-way SA caches. The virtual memory page table (and the translation lookaside buffer (TLB)) can provide a partition identifier that specifies which cache partition a particular memory reference is targeted at (both for lookup and update). The register that stores the way to be updated for a cache wrap needs to be big enough to store a way number. For example, 2 bits for a 4-way SA cache, or 5 bits for a 32-way SA cache. There is one such register per set because each set can wrap at a different time.
In one embodiment of the invention, the cache is partitionable into three partitions, with each partition including a contiguous subset of the cache ways, and that subset is the same within each cache set. Memory references are designated by the processor's memory management unit to be cached in one of the three partitions. Updates to a partition occur independently of the other partitions, so one partition can wrap long before the entire cache wraps. However, detecting the wrapping of a partition is identical to detecting the wrapping of the entire cache when the partition being updated is known. Thus, as referred to hereinafter, cache wrapping includes either partition wrapping or entire cache wrapping.
In order for external logic to detect cache updates, a cache must provide an indication that an update is occurring and which line is being overwritten. The logic of the preferred embodiment assumes that this information is provided by means of a set specification, a way specification and an update indicator.
FIGS. 19( a ) and 19 ( b ) depict the cache wrap detection logic of the preferred embodiment for an N-way set-associative cache. In this embodiment, it is assumed that updates to a set are always performed in round-robin order. That is, the “victim” way chosen to be overwritten is always the one following the previously-overwritten one.
FIG. 19( a ) particularly depicts one embodiment of logic implemented for detecting the wrap of a single partition of a single set (set “i” in the embodiment depicted) within the logic block 920 . When this logic has detected a wrap in set i, it asserts the set_wrap(i) signal 910 . FIG. 19( b ) shows how the individual set_wrap(i) 910 signals from all N sets of the cache are combined with a logic OR function to produce the cache_wrap 912 signal, which asserts when the entire cache (i.e. all sets) have wrapped. It is understood that the logic and circuitry depicted in FIGS. 19( a ) and 19 ( b ) is only one example implementation and skilled artisans will recognize that many variations and modifications may be made thereof without departing from the scope of the invention.
On the left-hand side of FIG. 19( a ), there is depicted a partition detection logic block 922 that determines when a cache update falls within the partition that is being monitored for wrapping. This logic assumes that the partition extends from a way specified by “lower” 916 to the way specified by “upper” 918 . Therefore, the remainder of the logic that detects set wraps partition only changes state when there is an update, and that update falls within the partition of interest. Note that the partition detection logic 922 is common to all N copies of the set wrap detection logic.
Within the set wrap detection logic, the common partition update indicator is further qualified to act only when the update is to the particular set i associated with that logic. This is done by matching the set specifier 924 to the index of the set wrap detection logic 926 .
The remainder of the logic circuits function as follows: Assume that initially, the flip-flop driving set_wrap(i) 930 is clear, indicating that the set has not wrapped, and the register 928 includes the way that must be updated to complete a set wrap. In this state, the register retains its value. When a cache update occurs, where the way 914 matches the contents of the register 928 , as determined by a comparator device 919 , the flip-flop driving set_wrap(i) 930 is loaded with logic 1, causing set_wrap(i) 910 to assert. Thereafter, cache updates cause the updated way 914 to be stored in the register 928 , so the register 928 effectively tracks those updates. When all cache sets have wrapped, the combined cache_wrap 912 signal is asserted as shown in FIG. 19( b ), causing the flip-flop 930 to clear (assuming Reset takes precedence over Load). This returns the circuit to the initial state, with the register 928 storing the way that must be updated to indicate the next set wrap.
It is thus understood that there is one register per set that stores the number of a way and when that way is overwritten, then the set has wrapped. However, the sets wrap at different times (depending on the access pattern), and the entire cache is not considered to have wrapped until all sets have wrapped. At that point, the state of the victim way pointers (i.e. pointer to the last way that was overwritten; one per set) becomes the new initial condition for detecting the next cache wrap. The first embodiment accommodates this requirement by having the register described above keep track of ways that are overwritten between the time that it has wrapped and the time that the entire cache has wrapped. Then when the whole cache wraps, it stops tracking the overwritten ways and becomes the basis for comparison for determining when the set wraps again.
In a second embodiment of the cache wrap detection logic, a counter is implemented, so when the whole cache wraps, all set counters are reset to the number of ways in the partition. As ways are overwritten, the counters count down; and when a counter reaches zero, then the corresponding set has wrapped. When all counters reach zero, then the cache has wrapped and the process starts again.
According to this second embodiment, the set wrapped detection logic provided within the box 920 depicted in FIG. 19( a ) is thus based on a loadable counter, rather than a register and comparator. This logic is shown in FIG. 20 . In this logic, a down-counter device 932 is loaded with the number of ways in the partition 936 while set_wrap(i) 910 is asserted (assuming Load takes precedence over Down). When all sets have wrapped and cache_wrap 912 is asserted, the flip-flop 930 driving set_wrap(i) is cleared and the counter 932 is no longer loaded. Thereafter, each update to the partition 914 and set 934 tracked by the logic cause the counter 932 to count down by one. Once it reaches zero, the flip-flop 930 is loaded with logic 1, causing set_wrap(i) 910 to be asserted, and returning the logic to the initial state.
A third embodiment of the cache wrap detection logic, shown in FIG. 21 , will work with a cache that implements any replacement policy, including least recently used and random. In this case, a scoreboard 940 is used to keep track of the precise cache way 914 that is overwritten. Specifically, it is used to detect the first write to any way. In addition, a counter 942 keeps track of the number of times that a scoreboard bit was first set (i.e. goes from 0 to 1). It does this by only counting scoreboard writes where the overwritten bit (old bit) is zero. The counter 942 is pre-loaded to the partition size 936 (i.e. number of ways in the partition), so once this counter reaches zero, the entire cache partition has wrapped. This is indicated by the cache_wrap 912 signal being asserted, causing the counter 942 to be reloaded (assuming Load takes precedence over Down) and the scoreboard 940 to be cleared (i.e. reset).
While the preferred embodiment of the present invention is practiced in conjunction with a write-through cache, wherein snooping only occurs on write requests, and the results of a snoop action are the invalidation of a local data copy, the invention is not so limited. For instance, the invention can also be practiced in conjunction with write-back cache organizations. In accordance with a write-back cache, a coherence protocol will include additional transactions, e.g., including but not limited to, those in accordance with the well-known MESI protocol, or other coherence protocols. In accordance with a coherence protocol for writeback caches, read transaction on remote processors cause snoop actions to determine if remote caches have the most recent data copy in relation to the main memory. If this is the case, a data transfer is performed using one of several ways, including but not limited to, causing the processor having the most recent data to write the data to main memory, directly transferring the data from the owner of the most recent copy to the requester, or any other method for transferring data in accordance with a snoop intervention of a specific protocol. In accordance with this invention, a snoop filtering action can be used to determine an accelerated snoop response.
While the preferred embodiments have been described in terms of fixed interconnection topologies, and fixed snoop filtering operations, in one aspect of the present invention the snoop filtering subsystem has programmable aspects at one, or more, levels of the snoop filter hierarchy. In accordance with one embodiment of a programmable feature of the present invention, the interconnect topology is selected. In accordance with one variety of programmable topology, the one-to-one and one-to-many relationship between different filters in a topology is selectable. In accordance with another aspect of a programmable embodiment, the order in which a first snoop filter, and then a second snoop filter is accessed, or alternatively, a first or second snoop filter are accessed in parallel, is configurable under program control.
In accordance with yet another aspect of yet another embodiment of a programmable feature of the present invention, the operation of a filter subunit is programmable. This can be in the form of configurable aspects of a snoop filter, e.g., by configuring programmable aspects such as associativity of the cache being snooped, the coherence architecture being implemented, and so forth. In another aspect of a programmable filter subunit, the filter subunit is implemented in programmable microcode, whereby a programmable engine executes a sequence of instructions to implement the aspects of one or more preferred embodiments described herein. In one aspect, this is a general microcode engine. In another aspect, this is an optimized programmable microcode engine, the programmable microcode engine having specialized supporting logic to detect snoop filter-specific conditions, and, optionally, specialized operations, such as “branch on cache wrap condition”, specialized notification events, e.g., in the form of microcode engine-specific exceptions being delivered to the microcode engine, such as “interrupt on cache wrap condition”, and so forth.
In yet another embodiment of a programmable feature of the present invention, parts or all of the aspects of snoop filtering are implemented incorporating a programmable switch matrix, or a programmable gate array fabric. In one of these aspects, the routing between snoop subunits is performed by configuring the programmable switch matrix. In another aspect of this programmable embodiment, the actions of the snoop filter unit are implemented by configuring a programmable gate array logic block. In another aspect of the present invention, the entire snoop filter block is implemented by configuring at least one field-programmable gate array cell.
In accordance with another embodiment of a programmable feature of the present embodiments, one of more snoop filter subsystems can be disabled, certain snoop filtering steps can be bypassed, or snoop filtering can be disabled altogether. In one embodiment, this is achieved by writing the configuration of the snoop filter in a configuration register. In another embodiment, this configuration can be selected by input signals.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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A method and apparatus for supporting cache coherency in a multiprocessor computing environment having multiple processing units, each processing unit having one or more local cache memories associated and operatively connected therewith. The method comprises providing a snoop filter device associated with each processing unit, each snoop filter device having a plurality of dedicated input ports for receiving snoop requests from dedicated memory writing sources in the multiprocessor computing environment. Each snoop filter device includes a plurality of parallel operating port snoop filters in correspondence with the plurality of dedicated input ports, each port snoop filter implementing one or more parallel operating sub-filter elements that are adapted to concurrently filter snoop requests received from respective dedicated memory writing sources and forward a subset of those requests to its associated processing unit.
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BACKGROUND OF THE INVENTION
The present invention generally relates to image scanning apparatuses, and more specifically to an optical image scanning apparatus used for printers, facsimile machines, copy machines or digital scanners.
In many conventional copy machines, the size of an original sheet set in a copying position is detected before a copying operation is started. The detection of the size of the original sheet is generally performed by means of an optical system. One method of the detection of the size uses a scanner which is provided for reading an image on the original. This method does not require an additional optical system for detecting the size. However, this method takes time to scan the entire original sheet before an actual copying operation is started, and thus it takes a relatively long time to make a copy. Accordingly, users are dissatisfied with a copy machine in which this method is used.
Another method of detecting the size of an original sheet is to use an additional detecting device. Japanese Laid Open Patent Application No. 4-178601 discloses an original sheet size detection system in which a grating array (hologram) is used in an optical detection system. FIG. 1 is an illustration of an example of an original sheet size detection system incorporated in a copy machine which system uses a hologram. FIG. 1 is a view of the inside of a scan table (contact glass) from directly above the contact glass.
In FIG. 1, three photosensor devices 2 are shown provided in predetermined positions, under a scan table which is made of transparent material such as glass. Each of the photosensor devices 2 comprises a hologram, a light source and a photosensor (not shown). A light beam emitted by each of the photosensor devices 2 is split into three beams a, b, c. Positions of the split light beams a, b, c at the scan table surface are shown in FIG. 1. The beams a, b, c are reflected by original sheet or other material, and the reflected beams return to the respective photosensors 2. The beams a, b, c are detected by the photosensors in the photosensor devices 2.
In the above-mentioned optical original sheet size detection system, since a light beam is split into three beams, three light sources are needed to emit light beams to direct the beams in nine directions, while nine light sources are needed in a conventional system. However, the above-mentioned system still requires at least three photosensors. Additionally, the sizes of the original sheet which can be detected are limited to predetermined sizes, for example a standard A-size sheet or B-size sheet, because the positions of beams projected on the scan table are fixed. Therefore, the above-mentioned optical original sheet size detection system cannot detect a sheet size other than one of the predetermined size.
An optical sensing device is disclosed in Japanese Laid-Open Patent Application No. 53-117333. FIG. 2 is an illustrative perspective view of the optical information reading device disclosed in Japanese Laid-Open Patent application No. 53-117333. This device is used as a bar code reader.
In FIG. 2, a laser beam emitted by a semiconductor laser 3 passes through a mirror having a hole, and is incident upon a hologram scanner (hologram disk) 6 rotated by a motor 5. The laser beam is deflected and concentrated, by hologram 6a formed on the rotating hologram scanner 6, onto the plane of a bar code 7 so that the laser beam scans the bar code as indicated by dotted line S o . The laser beam reflected by the bar code is incident upon the hologram 6a at a position different from the position on which the laser beam was initially incident, and passes through the hologram scanner 6. The laser beam is then reflected by the mirror 4 and incident upon a photodetector 8. Bar code information is obtained by analyzing the intensity variations of the laser beam detected by the photodetector 8.
The above-mentioned scanning method disclosed in Japanese Laid-Open Patent application No. 53-117333 provides a simple optical detection system to recognize size and displacement of an original sheet by means of a simple construction. However, there has been suggested no image scanning apparatus using such a method in the art.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an improved and useful image scanning apparatus in which the above-mentioned disadvantages are eliminated.
A more specific object of the present invention is to provide an image scanning apparatus which can obtain, using a simple optical detection system, original sheet information including size and displacement information of an original sheet before an image scanning operation starts.
In order to achieve the above-mentioned object, according to the present invention, there is provided an image scanning apparatus scanning an image formed on an original sheet placed on a scan table, original sheet information including size and displacement information of the original sheet placed on the scan table being obtained before scanning of the image is performed, the image scanning apparatus comprising:
a beam emitting unit for emitting a coherent first beam;
a deflecting unit for deflecting the first beam so that the first beam traces a predetermined scan line on a plane including a surface of the original sheet; and
a beam sensing unit for sensing the intensity of a second beam generated by reflection of the first beam at the surface of the original, the second beam being input to the sensing unit via the deflecting unit,
wherein the original sheet information is obtained in accordance with the detection of a sharp change in the intensity of the second beam received by the sensing unit with reference to a scanning position of the first beam.
Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an example of an original sheet size detection system of a copy machine which system uses a hologram;
FIG. 2 is an illustrative perspective view of a conventional optical information reading device;
FIG. 3 is an illustration of a first embodiment of an image scanning apparatus according to the present invention;
FIG. 4 is a graph showing a relationship between intensity of a reflected beam measured by a photodetector and a scanning position of the beam;
FIG. 5 is an illustration for explaining a relationship between sizes of original sheets and a scan line S of a beam circularly deflected by a rotating hologram;
FIG. 6 is an illustration for explaining a positional relationship between the laser beam and the scan line.
FIG. 7 is a graph showing a relationship between intensity of a reflected beam measured by a photodetector and a scanning position of the beam;
FIG. 8 is an illustration showing a hologram forming two scan lines;
FIG. 9 is an illustration of a second embodiment of an image scanning apparatus according to the present invention; and
FIG. 10 is an illustration showing a scan line used in the image scanning apparatus shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description will now be given, with reference to FIGS. 3 through 5, of a first embodiment of an image scanning apparatus according to the present invention. FIG. 3 is an illustration of the first embodiment incorporated into a copy machine. In FIG. 3, parts that are the same as the parts shown in FIG. 1 are given the same reference numerals, and descriptions thereof will be omitted.
In FIG. 3, a contact glass 10 is provided on a top surface of the copy machine. An original sheet 11 is placed on the contact glass 10. Under the contact glass 10, there is provided an open space 12. A hologram scanner 6, as an optical deflector, is provided at the bottom part of the space 12. A hologram 6a is formed on the hologram scanner 6. The hologram 6 is rotated by a ring-type motor 5. A mirror 4 having a hole and a semiconductor laser 3 are provided under the hologram scanner 6. A photodetector 8 is positioned in a direction to which a laser beam reflected by a reflection surface 4a of the mirror 4 is transmitted. It should be noted that the mirror 4 having a hole therein provides a recurrent optical system which contributes to noise reduction in the optical system of the present embodiment, and thus the present embodiment has a good S/N ratio.
In the above-mentioned structure of the present embodiment, although the hologram 6 is used as an optical deflector, a galvano-mirror or a rotating mirror may be used. Additionally, mirrors may be used, instead of the hologram, to equalize path lengths and incident angles of beams to be reflected at the surface of the original sheet 11, however, complexity of the optical system is then increased. The reason for using the hologram 6a is that holograms have a simple construction with a high deflection efficiency. Especially, if a blazed grating type or a binary hologram is used as a transmission type hologram, the optical system can have a high deflection efficiency with a simple construction.
It should be noted that if a reflection type hologram is used, a beam has to be emitted from above the space 12; the hologram may be an obstacle to movement of other components such as image scanners. Thus, the reflection type hologram is not used in the present embodiment.
In the present embodiment, a laser beam having coherence and high directivity emitted by the semiconductor laser 3 scans a surface of the original 11 in the manner described with reference to FIG. 2. A reflected beam is measured by the photodetector 8. FIG. 4 is a graph showing a relationship between intensity of the reflected beam measured by the photodetector 8 and scanning position of the beam. In the graph of FIG. 4, the region indicted by an arrow A corresponds to the portion, namely surface of the original sheet 11, at which the beam is reflected. The region indicted by an arrow B represents the area (background) outside the original sheet 11. As shown in the graph, the presence of an original sheet can be recognized by detecting a sharp change in intensity of the reflected beam.
FIG. 5 is an illustration for explaining a relationship between sizes of original sheets and a scan line S of the beam circularly deflected by the rotating hologram 6a. In FIG. 5, the sizes of original sheets A3, A4, A5, B4 and B5 are shown. In the condition shown in FIG. 5, the portion corresponding to the region A shown in FIG. 4 in the A5 case is the portion of the scan line S between the two detection points A5. Similarly, the portion of the scan line S between detection points B5 corresponds to a B5 size sheet. Other size sheets have their own detection points as shown in the figure. Accordingly, by detecting the detection points at which intensity of the reflected beam sharply changes, the size of the original sheet placed on the contact glass 10 can be obtained. Sizes other than the above-mentioned sizes can also be detected by the same means.
Information of size and displacement of the original sheet placed on the contact glass 10 can be obtained by detecting a sharp change near the detection points with reference to the scanning position information. Processing to obtain the information of size and displacement can be easily performed by a processing unit (not shown in the figures) usually provided in the image scanning apparatus.
According to the above-mentioned construction of the first embodiment, the size of the original sheet and displacement (or inclination) of the original sheet placed on the contact glass can be detected using a single light source and a single photodetector with a thin and compact construction.
The scan line S traced by the laser beam deflected by the hologram 6a may take any form appropriate to detect the size of the original sheet. However, it is preferable that the length of beam paths between the hologram 6a and any detection points on the scan line are uniform, and that incident angles on the original sheet 11 at any detection points on the scan line are uniform. In order to achieve this, the laser beam is deflected by the hologram 6a so that the scan line S becomes circular as shown in FIGS. 5 and 6.
FIG. 6 is an illustration for explaining a positional relationship between the laser beam and the scan line. In the figure, the laser beam incident upon the hologram scanner 6 is deflected by the hologram 6a so that the laser beam traces a circle on the surface of the original sheet 11 (or background). By adopting this construction, the intensity of the scattered reflection beam received by the photodetector 8 becomes uniform, and thus the fluctuation of the intensity of the reflected beam measured by the photodetector 8 can be eliminated as shown in FIG. 7. The graph of FIG. 7 shows that the measured intensity of the beam is constant in the area A and the area B as compared to the graph shown in FIG. 4. Therefore, simple signal processing of the signal generated by the photodetector 8 can be used, and the occurrence rate of erroneous detections can be reduced.
It should be noted that the present embodiment uses, as mentioned above, a blazed grating or binary type hologram which traces a single scan line since normal holograms form two scan lines.
However, it may be useful to use a hologram 14 which forms two concentric scan lines as shown in FIG. 8. The hologram 14 has two gratings comprising a first grating and a second grating, the spatial frequency of the first grating is higher than that of the second grating. A deflected laser beam 15a diffracted by the first grating traces a circular scan line Sa, and a deflected laser beam 15b diffracted by the second grating traces a circular scan line Sb.
By using two deflected beams tracing different scan lines, respectively, at the same time, more information about the original sheet can be obtained than when a single scan line construction is used, and thus an accurate detection of the original sheet can be performed in a short time. Crossed scan lines which may be traced by means of a mirror system may be useful to obtain further accurate information.
Additionally, as shown in FIG. 3, a reference sample 16 for an original sheet may be provided at a position other than the detection area for the original sheet. The reference sample 16 may be a plate-like member having a beam reflection characteristic similar to that of the original sheet to be placed on the contact glass 10, and can be attached, for example, on a frame (not shown in the drawing figure) of the contact glass 10. A reference intensity of the reflected beam corresponding to the original sheet area can be obtained by scanning the reference sample 16. By comparing the intensity obtained by scanning an original sheet with the reference intensity, the intensity of the original sheet can be determined, and thus the intensity of a copy can be adjusted to have a high contrast.
A description will now be given, with reference to FIG. 9, of a second embodiment of an image scanning apparatus according to the present invention. FIG. 9 is an illustration showing the second embodiment of an image scanning apparatus according to the present invention. In FIG. 9, parts that are the same as the parts shown in FIG. 3 are given the same reference numerals, and descriptions thereof will be omitted.
The second embodiment is provided with a polygon mirror 17, instead of the hologram of the first embodiment, so as to deflect the laser beam emitted by the semiconductor laser 3 in a direction parallel to the surface of the original sheet 11. Additionally, the second embodiment is provided with a mirror system 18 comprising a plurality of mirrors 18a reflecting the laser beam deflected by the polygon mirror 17.
In the above-mentioned construction of the second embodiment, the laser beam emitted by the semiconductor laser 3 passes through the mirror 4, as is the same with the first embodiment, and is deflected by the polygon mirror 17. The direction of the laser beam deflected by the polygon mirror 17 varies within a plane generally parallel to the original sheet 11. The laser beam is then incident upon the mirrors 18a of the optical system 18, and reflected by the mirrors 18a towards the original sheet 11 so that the laser beam is projected onto the original sheet 11 in a direction perpendicular to the surface of the original sheet 11.
The laser beam reflected by the mirrors 18a traces a scan line 19 as shown in FIG. 10. The laser beam incident upon the original sheet 11 is reflected and returns to the mirror 4 since the mirrors 18a and the polygon mirror 17 form a recurrent optical system. The laser beam returned to the mirror 4 is reflected by the mirror 4 and enters into the photodetector 8. The photodetector 8 measures the intensity of the laser beam so that the presence of the original sheet 11 and displacement of the original sheet 11 are detected in the manner the same as that of the first embodiment.
According to the present embodiment, since the laser beam is projected onto the original sheet 11 in a direction perpendicular to the surface of the original sheet 11, a sufficient reflection can be obtained. Thereby, even if the distance between the polygon mirror 17 and the detection point on the scan line is large, a sufficient intensity of reflected beam can be obtained, and accordingly an image scanning apparatus which can detect a large size original sheet can be realized. Additionally, because the laser beam is always incident upon the original sheet in a direction perpendicular to the surface of the original sheet regardless of the distance between the polygon mirror 17 and the surface of the original sheet 11, the space 12 provided for the laser beam path can be minimized. Thus an image reading device using the construction of the present embodiment can be made thin.
It should be noted that, instead of the polygon mirror 17, a disk type hologram scanner or a cylindrical hologram scanner may be used.
The present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope of the present invention.
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An image scanning apparatus can obtain, using a simple optical detection system, original sheet information including size and displacement information of an original sheet before an image scanning operation starts. The image scanning apparatus comprises a single beam emitting unit for emitting a coherent first beam. A deflecting unit deflects the first beam so that the first beam traces a predetermined scan line on a plane including a surface of the original sheet. A second beam is generated by reflection of the first beam at the surface of the original, and the second beam is input to the sensing unit via the deflecting unit. The original sheet information is obtained in accordance with the detection of a sharp change in the intensity of the second beam received by the sensing unit with reference to the scanning position of the first beam.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a divisional application of application Ser. No. 09/561,922, filed May 1, 2000 now U.S. Pat. No. 6,457,292.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed toward a method for making the composite structural member employing a flange member.
The invention is further directed toward an apparatus for use in making the composite structural member.
2. Description of the Related Art
Composite structural members, such as I-beams, are known. These composite structural members usually have separate flanges joined to a central web in making beams, particularly I-beams. The materials usually employed, in both the flanges and webs, are wood; wood-based, engineered products such as plywood; and metal such as steel. Composite structural members employing metal flanges with a wooden web are efficient and cost-effective. The wooden web provides a desirable insulation factor, compared to a metal web and allows openings to be easily made through it for services. The metal flanges provide high strength and stability for the member. In addition the metal flanges can be provided with integral fasteners formed by punching teeth out of the flanges. The teeth can be easily pressed into the web to securely join the flanges to the web.
One form of a composite structural member employing a wood-based web and metal flanges is shown in U.S. Pat. No. 4,281,497. Each metal flange member is formed with side walls extending from a base. Fasteners are usually formed integrally in the side walls of the flange. An edge of the web is located against the base and the side walls of the flange, with the fasteners formed therein, are bent about the base against the web to form a pocket to receive an edge portion of the web. At the same time the fasteners in the side walls are pressed into the web to fasten the flange to the web. In this construction, the fasteners are formed in the flange, in a separate operation, before the flange and web are assembled. This additional step makes the assembling of the composite member relatively expensive.
It is preferred to have the side walls of the flange member doubled so as to have the pocket formed by side walls and base of the flange, which pocket receives an edge portion of the web, more rigid and thus more likely to tightly confine the web making the bearing capacity of the web stronger and thus making the composite member stronger. An example of such a construction is shown in U.S. Pat. No. 4,937,998. However, using metal flange members, with doubled side walls, with a wooden web, and with integral fasteners in the doubled side walls, is expensive. Openings must be provided in the inner wall panel of the doubled side wall to allow passage of the integral fasteners formed in the outer panel of the doubled side wall. The integral fasteners, and the openings for the fasteners, are formed in the flange in a separate operation, before assembly of the flange and web, again making the assembly relatively expensive.
Both types of composite members described above have the fasteners, joining the flange to the web, integrally formed in the flange in a single layer of sheet metal. The sheet metal layer must therefore be relatively thick to provide fasteners strong enough to penetrate the web. Using relatively thick sheet metal flanges, which may be thicker than the thickness required to provide the necessary strength for the composite member, increases the cost of the members.
SUMMARY OF THE INVENTION
It is the purpose of the present invention to provide a method of assembling a flange to a web in the making of a composite structural member, which method involves the step of forming integral fasteners in the side walls of the flange while assembling the flange to the web.
It is a further purpose of the present invention to provide a machine for assembling a flange to a web in the construction of a composite structural member. The machine forms fasteners in the side walls of a flange while moving the flange and web together as a unit, the fasteners then being used to connect the flange to the web.
The invention is particularly directed toward a method of making a composite structural member comprising providing an elongated metal flange having a pocket, the pocket formed by two side walls extending from a base wall; and an elongated web, made of fastener penetrable material, having opposed narrow edges. A portion of the web is mounted within the pocket of the flange with one edge abutting the base wall to form an assembled unit. The assembled unit is then fed in a longitudinal direction. Fasteners are then formed from the side walls of the flange while the side walls diverge from the web. The side walls are then moved against the web to press the fasteners into the web to securely join the flange to the web.
In a preferred embodiment, the side walls of the flange are doubled, each side wall has inner and outer wall panels, the wall panels joined along a fold line spaced from the base wall. The fasteners are integrally formed in the side walls adjacent the fold line, punched out along a line that intersects the fold line, and then bent laterally from the side wall.
The invention is further particularly directed toward a machine for use in making a composite structural member from an elongate web made from fastener penetrable material, the web having opposed narrow edges, and an elongate metal flange having side walls and a base wall joining the side walls to form a pocket for receiving a portion of the web. The machine has an elongated support table for supporting an assembled unit, comprising the flange with the web therein, for movement in the longitudinal direction of the unit. The machine has drive means on the table for moving the unit in the longitudinal direction. Forming means are on the table to form fasteners in the side walls of the flange while the side walls diverge from the web. Pressing means are on the table, downstream from the forming means, for moving the side walls of the flange against the web to cause the fasteners, integrally formed in the side walls, to enter the web and join the flange to the web as the unit is moved forwardly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a web and one type of flange used in the making of a composite structural member;
FIG. 2 is a perspective view of the web and flange assembled to provide the composite structural member;
FIG. 3 is a cross-section view showing the side walls of the flange spread apart from the web;
FIG. 4 is a cross-section view showing the fasteners formed in the spread-apart side walls;
FIG. 5 is a cross-section view showing the web and flange assembled to form the composite structural member;
FIG. 6 is a perspective view of a preferred flange used in the making of the composite structural member;
FIG. 7 is an end view showing the side walls of the preferred flange spread-apart with fasteners formed therein;
FIG. 8 is a partial perspective view of a section of side wall showing the formation of the fasteners:
FIG. 9 is a cross-section view taken along line 9 — 9 in FIG. 8 .
FIG. 10 is a detail plan view of another fastening tooth;
FIG. 11 is an end view of another embodiment of a flange;
FIG. 12 is a partial perspective view of a panel used to make the flange shown in FIG. 1 ;
FIG. 13 is a partial perspective view of a panel used to make the preferred flange shown in FIG. 6 ;
FIG. 14 is an end view of another partially formed flange;
FIG. 15 is a side view of an apparatus used to make the composite structural member;
FIG. 16 is a cross section view taken along line 16 — 16 in FIG. 15 ;
FIG. 17 is a detail plan view of a portion of the apparatus showing the forming station;
FIG. 18 is a detail plan view of another portion of the apparatus showing the press station;
FIG. 19 is a detail plan view of another embodiment of the forming element; and
FIG. 20 is a detail plan view showing the spreading station.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The flange 1 used in the present invention has a base wall 3 with a pair of side walls 5 , 5 extending laterally from the base wall 3 as shown in FIG. 1 . The side walls 5 each have inner and outer edges 7 , 9 , with the inner edges 9 joined to the base wall 3 . The base 3 and side walls 5 , 5 form a pocket 11 for receiving a web 13 . The web 13 has narrow, opposed, edges 15 , 17 and wide parallel, sides 19 , 21 joined the edges 15 , 17 . Both the flange 1 and web 13 are elongated structures with the flange 1 being made from suitable metal material, such as steel sheet or aluminum by way of example. The web 13 is made from suitable, fastener-penetrable material, such as wood or a wood based, engineered product. The web can, for example, be made from plywood or OSB (Oriented Strand Board). Or the web can be made from a mixture of wood particles and suitable plastic material pressed or molded together.
The web 13 is assembled with the flange 1 by inserting an edge portion of the web into the pocket 11 of the flange 1 so that one edge 15 of the web abuts the base wall 3 , and the side walls 5 , 5 of the flange 1 are adjacent the sides 19 , 21 of the web 13 , as shown in FIG. 2 . The assembled unit 23 is then fed forward longitudinally as shown by the arrow 25 in FIG. 2 . As the unit 23 is fed forwardly, the side walls 5 , 5 of the flange 1 are spread apart from the web 13 as shown by the arrows 27 in FIG. 3 and fasteners 31 are then formed from the side walls 5 , 5 as shown in FIG. 4 . The fasteners 31 are preferably punched out of the side walls and bent inwardly toward the web 13 , the fasteners 31 being triangular shaped and pointed. The side walls 5 , 5 are spread apart a sufficient distance from the web 13 to allow room for the formation of the fasteners 31 . The fasteners 31 are normally formed near the outer edge 7 of the side walls 5 , 5 . The fasteners 31 can be formed during the forward movement of the unit 23 or the unit 23 can be moved forwardly intermittently and the fasteners 31 formed during stoppage in movement of the unit. Once the fasteners 31 have been formed, the side walls 5 , 5 are moved back against the sides 19 , 21 of the web 13 with the fasteners 31 being pressed into the web 13 to securely join the flange 1 to the web 13 to form a composite structural member 33 as shown in FIG. 5 .
The flange 1 may be provided from the factory with the side walls 5 , 5 already spread-apart, as shown in FIG. 3 , instead of with the side walls 5 , 5 parallel, or nearly so, as shown in FIG. 2 . When the flange 1 , with the spread-apart side walls 5 , 5 , is assembled with the web 13 , the unit 23 is moved forwardly to form the fasteners 31 in the already spread-apart side walls 5 , 5 of the flange 1 .
The flange may be assembled to the web at the factory where the flange is formed to shape, or at a building site. If the assembling occurs at the building site, the flanges, since they do not yet have the fasteners formed therein, can be compactly stacked and thus less expensively shipped from the factory to the building site.
In a preferred use, the flange has doubled side walls, and the fasteners are formed in the outer edge of the side walls. As shown in FIG. 6 , the preferred flange 101 has a base wall 103 and side walls 105 , 105 , as before. Each side wall has an outer edge 107 and an inner edge 109 , the inner edges 109 joined to the base wall 103 . The base wall 103 and the side walls 105 , 105 form a pocket 111 for receiving the web 13 . Each side wall 105 , 105 has an inner wall panel 113 and an outer wall panel 115 . The inner edge of the inner wall panel 113 is joined to the base wall 103 by a fold line forming inner edge 109 . The outer edge of the inner wall panel 113 is joined to the outer edge of the outer wall panel 115 by a fold line forming the outer edge 107 of the side wall 105 .
The flange 103 and the web 13 are assembled, as before, into a unit 123 which is fed forwardly longitudinally. As the assembled unit 123 is fed forwardly, the side walls 105 , 105 of the flange 103 are spread apart from the web 13 and fasteners 131 are integrally formed from each side wall as shown in FIG. 7 . The fasteners 131 are preferably formed by cutting the side wall 105 along a line 133 that angles to, and intersects, the fold line 107 as shown in FIG. 8 . The cut can be made by punching the side wall with a punch. The triangular shaped tooth 131 , formed by the cut, is then bent inwardly from the plane of the side wall 105 toward the web 13 . The tooth 131 has wall sections 135 , 137 , formed from the inner and outer wall panels 113 , 115 respectively, as shown in FIG. 9 , and joined by a section 139 of the fold line 107 . The tooth 131 is very strong, being double-walled. Once the teeth 131 have been formed, the side walls 105 , 105 are moved back against the sides of the web 113 , the teeth 131 simultaneously pressed into the web 13 to securely join the flange 101 to the web 13 .
The fasteners 131 on one side wall preferably alternate, in a longitudinal direction, with the fasteners on the other side wall. The fasteners 131 have been shown as being triangular in shape, but they could have other shapes as well. For example, the fasteners 131 ′, as shown in FIG. 10 , could have a rectangular shaped main body 141 with a pointed free end portion 143 extending from one short side of the main body 141 . The inner end of the main body portion is preferably rounded toward the outer edge, as shown at 145 in FIG. 10 , to minimize tearing of the wall panels in this area. Similar rounding could be employed at the base of the triangular shaped tooth 131 as shown in FIG. 8 .
The flange 101 shown in FIG. 6 is particularly suited for making flanges that can be used to make I-beam composite members. The I-beam flanges have wing panels 147 extending laterally from the bottom edge of the outer wall panels 115 of the side walls 105 , the wing panels 147 aligned with each other and with the base wall 103 . The wing panels 147 are joined to the outer wall panels 115 along a fold line 149 . A narrow stiffening panel 151 can extend laterally from the free end of each wing panel 147 , the stiffening panel 149 parallel to the side wall panels 115 and joined to the wing panels 147 along a fold line 153 .
While one form of flange 101 , with single wing panels 147 and doubled side walls 105 , has been described, other forms of flanges can be employed. For example, the flange 101 ′ can have doubled side walls 205 , 205 and doubled wing panels 247 , 247 as shown in FIG. 11 .
The flanges can be easily, partly formed off-site, without the fasteners formed therein, and then shipped to the site for making composite structural members. The flange 1 , for example, can be formed by bending an elongate panel 201 , as shown in FIG. 12 , along fold lines 203 , 205 to form base wall 3 and side walls 5 , 5 . The fold lines 203 , 205 define the bottom edge 9 if the side walls 5 , 5 . Lines 207 of incisions 209 can be provided in the panel 201 adjacent each fold line 203 , 205 location, before folding, so as to facilitate folding. The incisions 209 can be right at the fold or just on either side of it. The flanges can be folded to have the side walls 5 , 5 generally parallel, as shown in FIG. 1 , or to have the side walls 5 , 5 diverging slightly, as shown in FIG. 3 . The folded flanges 1 , in either form, can be easily nested and efficiently shipped to the work site.
The flange 101 can be formed from a single panel 211 , as shown in FIG. 13 , bent along fold lines 109 to form the base wall 103 and side walls 105 , 105 . Each side wall 105 has inner and outer panels 113 , 115 , the panels joined by fold lines 107 . The wing panels 147 are joined to the bottom of the outer panels 115 by fold lines 149 . Lines of incisions, not shown, can be used to facilitate folding along the fold lines.
The flanges 101 , with the wing panels 147 , could be partly folded off-site to produce the article 301 shown in FIG. 14 . In this article, the doubled side walls 105 , 105 have not been folded up from the base wall 103 and the article 301 is flattened to make shipping easier. At the work site, the side walls 105 , 105 are partly folded up toward the web, the fasteners formed, and the composite structural member completed by completing folding of the side walls against the sides of the web.
An apparatus is provided for making the composite structural member described. The apparatus 401 , as shown in FIGS. 15 and 16 , has an elongated, work table 403 maintained in a horizontal position by legs 404 . Feeding means 405 are provided on the work table 403 for feeding the assembled unit 123 of the flange 101 , with diverging side walls, and the web 113 , in a longitudinal direction on the work support. The feeding means 405 can comprise sets 407 of side drive rollers 409 , the sets spaced along the length of the feed path. There is a drive roller 409 in each set on each side of the web 113 , the drive rollers contacting the web to feed it forwardly. The axis of these side rollers 409 is parallel to the sides of the web 113 , the rollers 409 located above the flange 101 to be able to contact the web. The side drive rollers 409 are driven by suitable motor means 410 . The feeding means 405 can also include top, drive rollers 411 biased against the top edge of the web 113 , and driven by suitable motor means 412 , to feed it forwardly. The assembled unit 123 rides on support rollers 413 , mounted for free rotation in openings in the table 403 . If desired, some of the guide rollers 413 could also be driven by suitable motor means, not shown. Guide roller sets 415 , similar to the drive roller sets 407 , but with guide rollers 409 ′, 411 ′ instead of drive rollers, could also be provided on the table 403 along the feed path for guiding the assembled unit 123 during its movement along the table in a longitudinal direction on the support rollers.
The apparatus includes a first forming station 421 , as shown in FIGS. 15 and 17 , where the fastening means on each side wall of the flange are formed. Fastener forming means 423 are provided at the forming station 421 , one on each side of the path of travel of the assembled unit to form fasteners from the side walls of the flange. The forming means 423 can include a punch 425 that is located above the table, by a support 426 at a height to partially punch out a fastener 131 out of the side wall. The punch 425 preferably is adjustable in height on the on the table and preferably is located to punch out the fastener adjacent the outer edge of the side wall of the flange. The punch 425 is operated by a hydraulic cylinder 427 or other suitable operating means and has a cutting edge 429 for cutting the side wall along the desired line to define the fastener. Continued forward movement of the punch after cutting bends the fastener out of the plane of the side wall. The forming station 421 includes an anvil plate 431 on each side of the unit, the plate 431 on each side supported by a support arm 433 on the table 403 . The anvil plate 431 is located between the side wall 105 and the web 113 , just in front of the punch 425 , and supports the side wall 105 during punching of the fastener 131 . A portion of the anvil plate 431 can extend forwardly of the punch 425 , beneath the punch, if desired, to provide additional support for the sidewall.
Once the fasteners 131 have been formed on each side wall at the forming station 421 , continued movement of the assembled unit 123 brings it to a press station 441 as shown in FIGS. 15 and 18 . The press station 441 can comprise sets 443 of press rolls 445 on each side of the unit which are sized, shaped and positioned to gradually move the spread-apart side walls 105 , 105 of the flange 101 against the web 113 while pressing the fasteners 131 into the web 113 to securely fasten the flange 101 to the web 113 . The press rolls 445 are supported by supports 447 on the table 403 .
While the assembled unit 123 is fed to the forming station 421 , the side walls 105 , 105 , diverging from the web 113 , provide a space 451 between the side walls and the web for the anvil 431 on each side. The punch 425 is periodically operated to punch a fastener out of the side wall just after it leaves the anvil so the side wall is partly supported while the fastener is being formed. The assembled unit can be moving while the punch is actuated. Alternatively, the unit can be periodically stopped to allow the punch to operate while the unit is stationary.
In one embodiment, the forming station 421 can have a gang of punches 451 mounted on a support plate 453 which support plate is movable by suitable moving means, not shown, to have the gang of punches simultaneously punch a set of fasteners out of the side walls. In this embodiment, the assembled unit is stopped and moved intermittently. The press rollers 445 on each side of the unit at the press station 441 could also be replaced by an elongated press pad, not shown, moved inwardly to press the side walls, and the fasteners, against the web. The press pad would operate at the same time that the gang of punches 451 are operated while movement of the unit is stopped.
The machine preferably includes a diverging station 461 in front of the forming station 421 . The diverging station 461 spreads the side walls 105 , 105 of the flange 101 in the assembled unit 123 apart from the web 113 , if the flange is provided with parallel side walls from the factory. The diverging station 461 has tapered guide plates 463 located between the web and the side walls, one face 465 of the plate 463 on each side flat against the side of the web, the other face 467 angled outwardly to move the side walls away from the web and to thus provide the space 451 for the anvils 431 at the forming station 421 . The guide plates 463 are carried by support means 471 fastened to the table 403 .
Suitable, programmable, control means can be provided to operate the machine to form the fasteners at the desired locations in the flange. While the apparatus has been shown fastening flange 101 to web 113 it can also be used to fasten flange 1 to web 13 .
The method of making the composite structural member is relatively inexpensive since the folding of the material, to form the flanges, can be done offsite at high speed and thus very efficiently. The forming of the fasteners, which is slower, takes place on-site during the assembly of the composite structural unit. It will be seen that the fasteners are formed during assembly of the flange to the web so that a separate fastening forming step, with attendant handling of the flange, is eliminated, thus leading to further efficiencies and less expense.
The flanges with doubled side walls provide very strong fastening members since the fastening members formed from the side walls are also doubled walled and joined together. The double walled side walls also make the flange stronger; allows the use of thinner sheet material; and retains the shape of the pocket better thus forming a stronger connection between the web and the flange and making for a stronger composite structural unit.
It is to be understood that while only one flange has been described as being attached to the web to form the structural unit, a second flange is usually attached to the other edge portion of the web, in a similar manner, but in a second operation, to form a balanced structural member such as an I-beam.
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A method for making a composite structural member. The composite structural member has a flange having a base wall and two side walls extending from the base wall, the base wall and side walls forming a pocket to receive a portion of a web. Each side wall of the flange is doubled with an inner wall panel and an outer wall panel joined along a fold line spaced from, and parallel to, the base wall. Fasteners are formed from each side wall adjacent the fold line, each fastener having inner and outer wall panel sections joined by a section of the fold line and extending transversely from its side wall toward the other side wall. The flange is used with the web, a portion of the web mounted in the pocket with the side walls of the flange adjacent the sides of the web and the fasteners pressed into the sides of the web to secure the flange to the web. The method comprises the steps of: mounting the web within the pocket of the flange to form an elongated assembled unit; moving the unit longitudinally; forming the fasteners in the side walls while the side walls diverge from the web and the unit moves; and then moving the side walls against the web to press the fasteners into the web while the unit moves to secure the flange to the web.
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TECHNICAL FIELD
Embodiments of the present disclosure relate generally to projectiles and, more particularly, to projectiles, such as practice stores, configured to seek a target identified by laser designation.
BACKGROUND
Aircraft are configured to carry a variety of stores that may be deployed during flight. These stores may include various types of projectiles that are intended to impact a predefined target. In order to train crew members in the deployment of the stores and/or to assess the performance of the aircraft, the stores or the like, practice stores may be carried by and deployed form an aircraft during a training flight. The practice stores are generally designed to mimic the performance of a corresponding store, such as in terms of its flight characteristics and/or targeting accuracy.
Since aircraft may carry and deploy a variety of different types of stores, there are also a variety of different types of practice stores, each of which mimics the performance of a respective store. In order to simulate the performance of various different stores, a number of different types of practice stores must be maintained in inventory since each practice store simulates a respective store. However, practice stores have not been designed for all types of stores, such as Global Positioning System (GPS) glide bombs, such as the Joint Direct Attack Munition (JDAM) or laser JDAM. Of the practice stores that are available, however, some practice stores may be configured to detect a target that has been designated or illuminated by a laser. In this regard, a laser designator may illuminate the target with a laser beam. The practice stores, such as Paveway II Enhanced Laser Training Rounds (E-LGTRs), may correspondingly include a laser receiver for detecting the laser designation of the target and determining the location of the target. The practice store may then be directed toward the target.
A practice store is generally destroyed or at least damaged upon impact with the target. As such, it is typically desirable to minimize the cost of a practice store while still configuring the store to appropriately mimic a conventional store since the practice store is not re-usable. However, the inclusion of a laser receiver having relatively high quality optical components within a practice store in order to detect a target that has been laser designated disadvantageously increases the cost of a practice store with the laser receiver generally being destroyed or damaged upon impact with the target.
Additionally, the costs associated with a training exercise involving the deployment of practice stores include the operational and maintenance costs of the aircraft. As a result of the size of the practice stores in some instances, an aircraft may carry only a single practice store or a relatively small number of practice stores and must therefore repeatedly land in order to take on additional practice stores during a training exercise that involves the deployment of multiple practice stores, thereby increasing the overall costs of the training exercise. Additionally, practice stores may be relatively heavy, thereby increasing the fuel and other operational costs for the training exercise.
BRIEF SUMMARY
A projectile, such as a practice store, and associated method are provided according to one embodiment of the present disclosure for seeking a target that has been laser designated even though the projectile does not include a laser receiver which otherwise would add materially to the cost of the projectile. For example, the projectile of one embodiment may simulate the flight of a respective type of projectile in a more cost effective manner. A multiple launch assembly is also provided according to another embodiment of the present disclosure to allow a launch platform, such as an aircraft, to carry a plurality of projectiles in such a manner as to have a form factor of a certified store and to launch a plurality of projectile during a single flight, thereby increasing the cost effectiveness of a training exercise.
In one embodiment, a projectile is provided that includes an aerodynamic body having positionable aerodynamic surfaces. The projectile also includes a Global Positioning System (GPS) receiver carried by the aerodynamic body and configured to receive GPS signals indicative of a location of the aerodynamic body. The projectile also includes a radio receiver carried by the aerodynamic body and configured to receive radio signals from an offboard laser receiver that provide information relating to a location of a target based upon laser designation of the target. Further, the projectile includes a processor carried by the aerodynamic body and configured to direct flight of the aerodynamic body toward the target based upon the location of the aerodynamic body as determined from the GPS signals and the location of the target based upon the information provided by the offboard laser receiver.
The radio receiver of one embodiment is also configured to receive radio signals from the offboard laser receiver that provide information relating to a time at which the location of the target was determined and a velocity, if any, of the target. The radio receiver of one embodiment is configured to repeatedly receive radio signals from the offboard laser receiver that provide information relating to the location of the target at different instances of time. In one embodiment, the practice store may also include an inertial measurement unit (IMU) configured to determine velocity and orientation of the aerodynamic body. In this embodiment, the processor is responsive to the IMU and is configured to direct flight of the aerodynamic body toward the target based also upon the velocity and orientation of the aerodynamic body as determined by the IMU.
In one embodiment, the processor is configured to direct flight of the aerodynamic body toward the target by controllably repositioning one or more of the positionable aerodynamic surfaces. Also, the positionable aerodynamic surfaces may be configurable prior to flight to simulate a respective one of a plurality of candidate stores. The processor of one embodiment is configured to operate in accordance with a respective one of a plurality of control laws with each control law configured to simulate flight of a different store.
In another embodiment, a method of directing a projectile toward a target is provided that includes receiving Global Positioning System (GPS) signals indicative of a location of the projectile while in flight and receiving radio signals from an offboard laser receiver that provide information relating to a location of the target based upon laser designation of the target. The method also directs flight of the projectile toward the target based upon the location of the projectile as determined from the GPS signals and the location of the target based upon the information provided by the offboard laser receiver.
In regards to receiving radio signals, the method may also receive radio signals from the offboard laser receiver that provide information relating to a time at which the location of the target was determined and a velocity, if any, of the target. The method may repeatedly receive radio signals from the offboard laser receiver that provide information relating to the location of the target at different instances of time. The method of one embodiment may also determine velocity and orientation of the aerodynamic body. As such, directing flight of the practice store may include directing flight of the aerodynamic body toward the target based also upon the velocity and orientation of the aerodynamic body.
The projectile of one embodiment includes a plurality of positionable aerodynamic surfaces. As such, directing flight of the projectile toward the target may include controllably repositioning one or more of the positionable aerodynamic surfaces. Additionally or alternatively, the method may include configuring the positionable aerodynamic surfaces prior to flight to simulate a respective one of a plurality of candidate stores. The method of one embodiment may also direct flight of the projectile in accordance with a respective one of a plurality of control laws with each control law configured to simulate flight of a different store. In a further embodiment, a multiple launch assembly is provided that includes a plurality of projectiles and a plurality of racks configured to carry one or more projectiles. Each projectile may include a Global Positioning System (GPS) receiver configured to receive GPS signals indicative of a location of the projectile, a radio receiver configured to receive radio signals from an offboard laser receiver that provides information relating to a location of the target based upon laser designation of the target and a processor configured to direct flight of the projectile toward the target based upon the location of the projectile as determined from the GPS signals and the location of the target based upon the information provided by the offboard laser receiver. The racks are configured to individually launch respective ones of the projectiles. The plurality of racks and the projectiles carried thereby are configured to have a form factor of a certified store, such as an external fuel tank. In this regard, the certified store may have a predefined form factor with the plurality of racks and the projectiles carried thereby having a form factor that is the same as the predefined form factor of the certified store, thereby reducing testing time and costs. The plurality of racks may be positioned in a linear arrangement. The plurality of racks of one embodiment are indexable following launch of a projectile. The plurality of racks may include an ejection mechanism for launching a projectile.
In accordance with embodiments of the present disclosure, projectiles, such as practice rounds, are provided that can be responsive to the laser designation of a target without requiring an onboard laser receiver and the associated optical elements. As such, the cost of the practice round may be reduced relative to a comparable practice round that includes a laser receiver without compromising the performance of the practice round. Additionally, the features, functions and advantages that have been discussed may be achieved independently in various embodiments of the present disclosure and may be combined in yet other embodiments, further details of which may be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Having thus described embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a schematic representation of a system for guiding a projectile to a target at a predetermined location;
FIG. 2 is a schematic representation of a system for guiding a projectile, such as a practice store, toward a target that could be in motion in accordance with a method of one embodiment of the present disclosure;
FIG. 3 is a block diagram of a projectile in accordance with one embodiment to the present disclosure;
FIG. 4 is a flowchart of the operations performed in accordance with one embodiment of the present disclosure; and
FIG. 5 is a graphical representation of a plurality of projectiles configured to have the same form factor as a certified store, such as an external fuel tank, in accordance with one example embodiment of the present disclosure.
DETAILED DESCRIPTION
The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, these embodiments may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
A projectile 10 , e.g., a store, a practice store such as a training round or the like, in accordance with embodiments of the present disclosure may be carried by and deployed or launched from an aircraft or other airborne launch platform 12 . Once launched, the projectile is configured to be guided towards a target 14 in an effort to impact the target. The projectile may be directed to various types of targets, such as fixed targets positioned at predefined locations, moving targets, such as vehicles, e.g., a truck, tank or ship, or the like. In the embodiment of FIGS. 1 and 2 , for example, the target may be a fixed target positioned at a predefined location on a target range. However, the target may, instead, be a moving target, such as an aerial target that is in flight and correspondingly has a location that changes over time. Alternatively, the moving target may be ground-based, such as a truck, tank, ship or other vehicle.
Prior to launch, the projectile 10 may be carried by and connected to the launch platform 12 , such as via a communications link and/or an electrical interface. As such, the launch platform may provide the projectile with power and may perform various system checks upon the practice store prior to launch. As described below, the projectile may also include an inertial measurement unit (IMU) that includes one or more IMU sensors for determining the velocity and orientation of the projectile. As such, the launch platform may also initialize the IMU sensors of the projectile prior to the launch. Further the projectile may be configured to conduct a built-in test (BIT) to ensure proper operation including valid telemetry with an off-board laser receiver 16 as described below.
In the embodiment of FIG. 1 in which the target 14 is positioned at a predefined location, such as a predefined location on a target range, the location, e.g., coordinates of the target, may be provided to the launch platform 12 and, in turn, to the projectile 10 . In addition to receiving the location of the target 14 , the projectile 10 may be configured to receive signals indicative of its location. In this regard, the projectile may receive GPS signals from a GPS system including a constellation of GPS satellites 18 , one of which is shown in FIG. 1 . In addition to receiving signals indicative of its location, the projectile may be notified of the time at which its location was determined. This time value may be the actual time at which the location was determined or a reference time, such as may be received in conjunction with the GPS signals, that allows for synchronization as described below. As also shown in FIG. 1 , the launch platform 12 may also receive signals, such as GPS signals, indicative of the location of the launch platform. Based upon the GPS signals as well as the signals from the IMU sensors, the projectile may determine its current location. Thereafter, based upon the location of the projectile and the location of the target 14 , the projectile may also determine the configuration of the positionable aerodynamic surfaces, such as wings 38 a and/or tailfins 38 b , that is required for the projectile to fly to the target. Thus, the projectile may be configured to command the positionable aerodynamic surfaces to the desired configuration such that the projectile flies to the target.
Based upon the configuration of the positionable aerodynamic surfaces, the projectile 10 of the embodiment of FIG. 1 may emulate any of various glide weapons including, for example, a JDAM. In order to emulate a glide weapon with laser guidance, such as a Paveway II or a laser JDAM, the projectile may also be configured to communicate with an off-board laser receiver 16 , such as via a wireless communications link, e.g., via radio signals. In this embodiment shown, for example, in FIG. 2 , the projectile may again be configured to receive signals indicative of its location, such as by receiving GPS signals. In addition, the projectile of this embodiment may receive signals indicative of the location of the target 14 from the off-board laser receiver. In the method of FIG. 2 , the system may also include a laser designator 20 . The laser designator is configured to illuminate the target, such as by directing laser signals that impinge upon the target. While the laser designator is shown in the embodiment of FIG. 2 to be hand held or otherwise manually positionable, the laser designator may be differently configured in other embodiments.
The off-board laser receiver 16 of this embodiment is configured to detect the location of the target 14 . While the target is illuminated by laser signals, the laser receiver can determine the location of the target. The location of the target can then be provided to the practice store 10 , such as via a wireless communications link, e.g., via radio signals, between the off-board laser receiver and the projectile. In this regard, the laser receiver may be configured to encrypt the location of the target prior to its transmission to the projectile. As such, the projectile of this embodiment may be correspondingly configured to decrypt the signals, including the location, prior to further processing the location information. While the laser receiver is shown in the embodiment of FIG. 2 to be mounted upon a mobile ground unit, e.g., a truck with a mast, so as to be relocatable, the laser receiver may be differently configured in other embodiments. For example, the laser receiver may be carried by any platform capable of maintaining a continuous and unobstructed line of sight to the target including the launch platform 12 , a separate fixed or rotary wing aircraft or the laser designator 20 having a GPS receiver, compass and laser seeker capable of providing information regarding both direction and distance to the target. In an instance in which the laser receiver is movable, the laser receiver may also receive GPS signals indicative of the location of the laser receiver, as shown in FIG. 2 .
In an instance in which the target 14 is moving such that its location changes over time, the off-board laser receiver 16 may also be configured to determine the time at which the location of the target was determined. While the time may be the actual time at which the location of the target was determined, the time may alternatively be a reference time that permits the time at which the location of the target was determined to be synchronized with the time frame of the projectile 10 , that is with the time at which the location of the projectile was determined. In the embodiment in which both the laser receiver and the projectile receive GPS signals, for example, the reference time provided by the GPS system along with the GPS signals may be utilized as the time according to which the measurements of the positions of the target and the practice store are synchronized.
Additionally, the off-board laser receiver 16 of one embodiment may be configured to determine the velocity, e.g., both speed and direction, at which the target 14 is moving at the time at which the location of the target is determined. The laser receiver of this embodiment may be further configured to transmit the time and velocity information to the projectile 10 , such as via a wireless communications link, e.g., via radio signals. As noted above, the time and velocity information may be transmitted in various manners, but the off-board laser receiver of one embodiment is configured to encrypt the signals prior to transmission such that the projectile of this embodiment must correspondingly decrypt the signals prior to further signal processing.
Based upon the location of the projectile 10 and the location of the target 14 and, in some embodiments, the time and velocity information provided by the off-board laser receiver 16 , the projectile may be configured to determine a path to be flown so as to impact the target. As described below, the projectile may also be configured to thereafter control the positionable aerodynamic surfaces such that the projectile flies along the path toward the target.
In one embodiment, the projectile 10 may receive a single report of the location and velocity, if any, of the target 14 from the off-board laser receiver 16 and the projectile may then determine the appropriate flight path to govern subsequent flight towards the target based upon this single report. In other embodiments, however, the off-board laser receiver may repeatedly determine the location and velocity of the target and may provide a series of reports to the projectile of the location and velocity of the target at different instances in time. Additionally, the projectile may repeatedly receive signals, such as from a plurality of GPS satellites 18 of its location. As such, the projectile of this embodiment may repeatedly update its determination of the path to be flown to the target and the commanded position of the positionable aerodynamic surfaces based upon the most recent report of the location and velocity of the target from the off-board laser receiver and the most recent information regarding the position of the projectile.
While the projectile 10 may be configured to determine the path along which the projectile is to fly toward the target 14 in the manner described above, the off-board laser receiver 16 of another embodiment may be provided with a time-stamped location and velocity of the projectile, such as based upon information provided by the projectile, such that the off-board laser receiver can determine the path to be flown to the target. In this embodiment, the off-board laser receiver may be configured to transmit the path to the projectile, such as via a wireless, e.g., radio, link. The projectile may then command the positionable aerodynamic surfaces based upon the definition of path provided by the laser receiver.
By utilizing an off-board laser receiver 16 that is configured to communicate with the projectile 10 via a wireless, e.g., radio, link, the projectile need not include a laser receiver including the relatively expensive optics. Thus, the cost of the projectile may be reduced which is of particular importance in those instances in which the projectile is a practice store that is likely to be destroyed or at least damaged upon impact with the target 14 . Moreover, the cost effectiveness of the system is further improved since the laser receiver may be re-used with a plurality of different projectiles, such as practice stores.
Although the projectile 10 may be configured in different manners, the projectile of one embodiment includes an aerodynamic body that carries each of the components shown in FIG. 3 by way of example. In this embodiment, the projectile includes GPS sensor(s) 30 for receiving GPS signals providing information regarding the location of the projectile. See operation 40 of FIG. 4 . Additionally, the projectile of this embodiment includes IMU sensor(s) 32 for determining the velocity and orientation of the projectile, thereby at least partially overcoming the lag in the target position data. See operation 42 of FIG. 4 . Further, the projectile of this embodiment includes a radio or other wireless communication receiver 34 for receiving radio signals from the off-board laser receiver 16 . The radio signals may provide information regarding the location of the target 14 and, in one embodiment, associated time and velocity information. See operation 44 of FIG. 4 .
The projectile 10 of the illustrated embodiment also includes a processor 36 . In this regard, the processor may include specifically configured processing circuitry, which may be comprised by a computer or the like. In addition to the processor, the computer of one embodiment may include a non-volatile, tangible memory storing data and computer program instructions configured to be executed by the processor so as to specifically configure the processor in accordance with embodiments of the present disclosure. The processor of one embodiment is configured to determine the path to be taken by the projectile so as to impact the target 14 . See operation 46 of FIG. 4 . Based upon the position of the projectile, as determined from the GPS signals, and the position and velocity of the target as provided by the off-board laser receiver 16 , the processor may determine the path to be flown to the target after taking into account the respective times at which the location of the projectile and target were determined. The projectile of this embodiment also includes one or more positionable aerodynamic surfaces 38 , such as one or more wings 38 a and/or tailfins 38 b , extending outwardly from the aerodynamic body. As such, the processor is also configured to determine the desired positions of the positionable aerodynamic surfaces to cause flight to the target and to then command the positionable aerodynamic surfaces, such as via respective actuators, to the desired positions, thereby controllably positioning the actuator surfaces such that the projectile will fly toward the target in a controlled fashion. See operations 48 and 50 of FIG. 4 .
The projectile 10 may be carried by and launched from a launch platform 12 in various manners. In order to increase the cost effectiveness with which the projectiles are deployed, however, the launch platform may carry a plurality of projectiles and may be configured to individually launch each of the projectiles, such as each of a plurality of practice stores, during a single training mission. As such, the launch platform of this embodiment may be considered a multiple launch assembly. While the plurality of projectiles may be carried by the launch platform in various manners, the plurality of projectiles are carried by a launch platform of one embodiment such that the plurality of projectiles as a group in combination with the launch assembly have a form factor as defined by the outer mold line that is substantially similar and, in one embodiment, identical to that of a certified store, such as an external fuel tank, e.g., an AV-8B 300 gallon drop tank, as shown in FIG. 5 in which the outline of an external fuel tank is shown with dashed lines for purposes of comparison. In this regard, the plurality of projectiles may be carried by the same portion of the launch platform that otherwise carries the certified store and in such a manner such that the plurality of projectiles as a group in combination with the launch assembly define a form factor that is similarly or identically shaped to that of the certified store. By configuring the plurality of projectiles as a group in combination with the launch assembly to have a similar or identical form factor to that of a certified store, the behavior of the launch platform while carrying the plurality of projectiles may be more predictable and, in an embodiment in which an aircraft serves as the launch platform, the certification of the aircraft may be facilitated, such as by reducing the testing time and costs.
In the illustrated embodiment, the plurality of projectiles 10 are carried by a plurality of racks, such as in a plurality of vertical racks or rotary launchers 60 . In this regard, each rotary launcher carries a plurality of projectiles. Each rotary launcher may operate under control of the launch platform 12 and independently of the other rotary launchers. As such, an individual projectile may be launched from each different rotary launcher. Following launch of a projectile, the rotary launcher may then rotatably index such that another projectile may be in position to be launched. This process of launching a projectile and then indexing the rotary launcher may be repeated until each of the projectiles has been launched. The rotary launchers may include various types of ejection mechanisms for launching the practice stores, such as pneumatic ejection mechanisms, pyrotechnic ejection mechanisms, spring-based ejection mechanisms and the like. Each rotary launcher may include a single ejection mechanism such that the projectiles are rotated relative to and individually brought into operable engagement with the ejection mechanism. Alternatively, each rotary launcher may include a plurality of ejection mechanisms, one of which is associated and in operable engagement with a respective projectile.
In order to further improve the cost effectiveness of the projectiles 10 , a practice store may be configured to have a plurality of positionable aerodynamic surfaces 38 , such as wings 38 a and/or tailfins 38 b , that may be positioned in any one of a number of different positions so as to configure the practice store to mimic the behavior of different types of stores. Thus, a practice store may effectively mimic the behavior of a respective types of store by initially positioning the positionable aerodynamic surfaces in a manner that allows the flight characteristics of the practice store to be the same or substantially similar to that of the respective type of store. Although the positionable aerodynamic surfaces may be repositioned in various manners, the wings may be deployed in one embodiment to various degrees to match the different amounts of lift available to various stores, such as various bomb units (GBUs), e.g., GBU-12, GBU-38 and GBU-54 stores. Additionally or alternatively, the tailfins may be crowed, that is, deflected, to produce drag without a directional change, so as to achieve different lift-to-drag ratios and equivalent flight paths for different types of stores, such as the Paveway II and JDAM stores.
In addition to or instead of repositioning the positionable aerodynamic surfaces 28 , the flight control software that is executed by the processor 36 of the projectile 10 may also be reconfigured in some embodiments in order to allow the projectile, such as a practice store, to fly in the same or substantially similar manner to a respective type of store. In this regard, the flight control software of one embodiment may implement a plurality of alternative\outer loop control laws intended to replicate the flight path of various stores including, for example, GBU-12, GBU-38 and GBU-54 stores, by selecting the applicable deformation of the positionable aerodynamic surfaces to mimic the flight path of the respective type of store. As such, a respective outer loop control law may be selected so as to represent the respective type of store. The outer loop control law may then take into account the current location of the projectile and the current location of the target 14 in the determination of the flight path (generally having 6 degrees of freedom (DOF)) to be flown to the target. The respective outer loop control law passes the flight path to an inner loop control law, which is the same regardless of the type of store. The inner loop control law receives the flight path (generally having 6 DOF) and translates the flight path into deflections or other deformation of the positionable aerodynamic surfaces that are required to fly in accordance with the flight path. By selecting and implementing an outer loop control law for a respective type of store, the flight control software of this embodiment may be configured to fly the practice store in the same manner as the respective type of store.
As such, the projectile 10 may be reconfigurable so as to match the flight path of various glide weapons by extending the wings 38 a to various degrees for lift, crowing the tailfins 38 b to a desired position to obtain the intended drag and/or modifying the flight control laws implemented by the processor 36 such that the projectile, such as a practice store, flies in a similar manner as a respective type of store that is being simulated. By being capable of simulating different types of stores, the practice store of one embodiment may further improve the cost effectiveness of the training system of embodiments of the present disclosure.
Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments described and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A projectile and associated method are provided for seeking a target that has been laser designated even though the projectile does not include a laser receiver. A projectile includes an aerodynamic body and a GPS receiver configured to receive GPS signals indicative of a location of the aerodynamic body. The projectile also includes a radio receiver configured to receive radio signals from an offboard laser receiver that provide information relating to a location of the target based upon laser designation of the target. Further, the projectile includes a processor configured to direct flight of the aerodynamic body toward the target based upon the location of the aerodynamic body as determined from the GPS signals and the location of the target based upon the information provided by the offboard laser receiver.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a method for the modular production of coverings for paper machines, paperboard machines or tissue machines and to a covering for a paper machine, paperboard machine or tissue machine.
[0003] 2. Description of the Related Art
[0004] Paper machines, paperboard machines or tissue machines have coverings in the forming section, press section and drying section.
[0005] The different categories of coverings, namely forming meshes, press felts and dryer fabrics, must meet many different requirements, for example with regard to dewatering behavior, moisture adsorption capacity and the like.
[0006] Furthermore, coverings of the same category must meet different requirements depending on the operating conditions. For example, the requirements for the structure of the side of a forming mesh facing the fibrous web in the production process for graphic paper differ fundamentally from those for the production of tissue.
[0007] Due to the different categories of coverings described above, each of which has to meet many different requirements, the historical development has seen the manufacturers of coverings produce, for practically every category and operating condition, a covering type which differs almost fundamentally from the covering types of other categories and operating conditions.
[0008] For example, covering manufacturers often produce forming meshes with different weave patterns for specific customers.
SUMMARY OF THE INVENTION
[0009] The current invention provides a method for providing coverings, as well as coverings which are easier and cheaper to produce than those coverings known from the prior art.
[0010] The invention is based on the idea of reducing the production costs of coverings for paper machines, paperboard machines or tissue machines by simplifying the production method for the entire product range of paper machine coverings.
[0011] The method according to the invention provides for producing different categories of coverings modularly from a construction kit of prefabricated web-shaped material layers. According to the invention, several web-shaped material layers are selected from the construction kit of prefabricated web-shaped material layers depending on the category and operating condition of the covering to be produced. The web-shaped material layers selected from the construction kit are stacked atop one another and joined to one another at least in sections, two-dimensionally, and in a manner that prevents them from being detached.
[0012] In other words, a method is proposed which provides a construction kit of prefabricated material layers. By defining a construction kit of prefabricated web-shaped material layers for the entire product range of paper machine coverings and by selecting prefabricated web-shaped material layers from the construction kit, depending on the category and the operating conditions of the covering, the number of different material layers and, for example, weave structures is greatly reduced.
[0013] Whereas in the past a different weave structure was required for each operating condition for example, it is possible in accordance with the invention to produce coverings for the different categories and operating conditions by combining several of the prefabricated web-shaped material layers.
[0014] According to one embodiment, provision is made for the order in which the selected web-shaped material layers are stacked to depend on the category and the operating conditions of the covering. The flexibility in using the prefabricated material layers is thus increased, as different properties of the covering can be achieved depending on the order in which the selected web-shaped material layers are stacked.
[0015] In this connection it should be noted that the prefabricated web-shaped material layers are constructed such that they fulfill, on their own or in combinations, specific functions such as damping properties, dimensional stability, wear stability, surface properties, liquid adsorption capacity and the like.
[0016] According to another embodiment, provision is made for the construction kit of prefabricated material layers to include at least one material layer influencing the surface of a fibrous web and at least one wear-stable material layer. In this case the material layer influencing the surface of the fibrous web is understood to be the material layer which terminates the covering in the direction of the fibrous web. Furthermore, the wear-stable material layer is understood to be the material layer which terminates the covering in the direction of the paper machine.
[0017] According to another embodiment, provision is made for the construction kit of prefabricated material layers to include at least one dimensionally stable material layer. The dimensionally stable material layer can be configured either as a material layer which is constructed separately from the two previously mentioned material layers or as an integral component of the one or other previously mentioned material layers.
[0018] Various possibilities for the construction of the above-mentioned material layers are conceivable.
[0019] Another embodiment of the invention provides for the material layer influencing the surface of the material web to be a textile or a non-textile areal structure.
[0020] Another embodiment of the invention provides furthermore for the wear-stable material layer to be a textile or a non-textile areal structure.
[0021] Another embodiment of the invention provides for the construction kit of prefabricated material layers to include at least one material layer influencing the liquid adsorption capacity. The material layer influencing the liquid adsorption capacity can be constructed either separately from the previously mentioned material layers or as an integral component of one of the previously mentioned material layers.
[0022] The material layer influencing the liquid adsorption capacity can be constructed either as a material layer with a high liquid adsorption capacity or as a material layer with a low liquid adsorption capacity.
[0023] A material layer with a high liquid adsorption capacity should have a liquid adsorption capacity which is greater than 50% of the total capacity of the material layer, in particular preferably greater than 70% of the total capacity of the material layer and most preferably greater than 80% of the total capacity of the material layer.
[0024] A material layer with a low liquid adsorption capacity should have a liquid adsorption capacity which is less than 50% of the total capacity of the material layer, in particular preferably less than 30% of the total capacity of the material layer and most preferably less than 20% of the total capacity of the material layer.
[0025] According to another embodiment of the invention, provision is made for the construction kit of prefabricated web-shaped material layers to include at least one anti-rewetting material layer.
[0026] Furthermore, other embodiments provide for the dimensionally stable material layer and/or the material layer influencing the liquid adsorption capacity and/or the anti-rewetting material layer to be textile or non-textile areal structures.
[0027] A textile areal structure is understood to be a weave structure or a fleece or a thread plaiting or a warp knitting.
[0028] Furthermore, a non-textile areal structure is understood to be a structured and/or penetrated film or a structured and/or penetrated membrane and/or a foamed layer.
[0029] It is advantageous, for example, for the material layer with a large liquid adsorption capacity to be a foamed layer.
[0030] Furthermore, it is advantageous for the material layer with a small liquid adsorption capacity to be a foamed layer or a penetrated film or a membrane.
[0031] Furthermore, it is advantageous for the foamed layer to have a defined pore size. By providing a defined pore size it is possible, for example, to establish the liquid adsorption capacity and hence the dewatering behavior. Furthermore, it is also conceivable for the foamed layer belt to have several defined pore sizes.
[0032] According to an embodiment of the invention the foamed layer has a defined pore transverse profile (i.e., different pore sizes in the transverse profile of the material layer). It is thus possible to selectively establish the dewatering behavior and the pressing behavior by way of the web width of the paper machine covering, as the result of which the fibrous web transverse profile can be selectively established.
[0033] A film mentioned above can be produced by an extrusion method and/or a rolling method for example.
[0034] Various possibilities for joining together the several material layers selected from the construction kit are conceivable.
[0035] For example, it is possible for at least two of the material layers to be joined together chemically. Furthermore, it is possible for at least two of the material layers to be joined together mechanically and/or by means of a textile joining method. The different material layers of a covering according to the invention can be joined together by just one or the other ways. However, it is also possible for the material layers to be joined together not only mechanically but also by textile and chemical ways.
[0036] For example, a first material layer of a covering according to the invention can be joined mechanically to a second material layer and the second material layer can be joined chemically to a third material layer. Furthermore, the third material layer can be joined by a textile joining method to a fourth material layer of this covering, with the fourth material layer being joined mechanically and chemically to a fifth material layer.
[0037] According to another embodiment the chemical bond is effected by an interface-active bond. In this connection an interface-active bond is understood to be a bond resulting from vulcanizing or melting or welding (i.e., ultrasonic welding). In other words, the interfaces of the two material layers which are to be joined together are changed/activated in such a way that they bond together without a bonding medium.
[0038] Another embodiment of the invention provides for the chemical bond to be effected by introducing a bonding medium. In this case the bonding medium can be an adhesive for example.
[0039] Furthermore it is possible for the bonding medium itself to form a material layer between the joined material layers, in which case the bonding medium is a foamed material layer for example, which is arranged between the material layers that are joined together and bonds said material layers together.
[0040] The bonding medium constructed as a separate material layer can fulfill specific functions on its own or in combination with one or more material layers. For example, by combining the bonding medium with one or more material layers it is possible to exert an advantageous influence on the properties of the covering according to the invention.
[0041] If the material layers are joined together mechanically it is conceivable for them to be pressed together.
[0042] If the material layers are joined together by a textile joining method it is possible for them to be sewn or pinned together.
[0043] If the covering is one which is not constructed of material webs in the form of endless belts, it makes sense for the various web-shaped material layers which are stacked atop one another to be joined together, two-dimensionally, in sections that are mutually offset in machine direction so that the covering forms two end areas which complement each other in form and function and can be joined together. Through the material layers which are mutually offset in machine direction and joined together, two-dimensionally, in sections, the covering forms two end areas which complement each other in form and function and can be joined together, two-dimensionally, so that the covering is constructed in the form of an endless belt. The two-dimensional bond between the two end areas is particularly stable and durable.
[0044] If the covering is constructed of several material layers arranged side by side over its width, it also makes sense for the material layers which are stacked atop one another to be mutually offset at least in sections transverse to the machine direction so that above and/or under neighboring material layers of a certain layer of the covering there is always a material layer which overlaps with both material layers arranged side by side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of (an) embodiment(s) of the invention taken in conjunction with the accompanying drawing(s), wherein:
[0046] FIG. 1 is a detail in longitudinal section of a forming mesh according to the invention,
[0047] FIG. 2 is a detail in longitudinal section of a press felt according to the invention,
[0048] FIG. 3 is a detail in longitudinal section of a dryer fabric according to the invention,
[0049] FIG. 4 is shows the two end areas of the forming mesh of the invention according to FIG. 1 ,
[0050] FIG. 5 is a detail in cross section of a forming mesh according to the invention,
[0051] FIG. 6 is a detail in cross section of a press felt according to the invention,
[0052] FIG. 7 is a detail in cross section of a dryer fabric according to the invention.
[0053] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification(s) set out herein illustrate(s) one preferred embodiment of the invention, in one form, and such exemplification(s) (is)(are) not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0054] FIGS. 1 to 4 show coverings which are produced from a construction kit of prefabricated web-shaped material layers 2 , 3 , 4 , 11 and 15 . All the web-shaped material layers 2 , 3 , 4 , 11 and 15 of the construction kit are formed in this embodiment as non-textile areal structures.
[0055] FIG. 1 shows in longitudinal section in machine direction sections of a forming mesh 1 according to the invention. The forming mesh 1 has a paper-side web-shaped material layer 2 through which the surface of the fibrous web formed on the forming mesh is essentially influenced, and a machine-side web-shaped material layer 3 through which the wear behavior of the forming mesh 1 is essentially influenced. The machine-side material layer 3 is thus a wear-stable material layer 3 . In the embodiment in question the machine-side material layer 3 also has dimension-stabilizing properties. The machine-side material layer 3 is thus also a dimension-stable material layer 3 , as the result of which the dimension-stable and the wear-stable material layer 3 form an integral unit.
[0056] Arranged between the paper-side material layer 2 and the machine-side material layer 3 is a material layer 4 influencing the liquid absorption capacity.
[0057] The material layers 2 to 4 were taken from the construction kit of prefabricated web-shaped materials layers 2 , 3 , 4 , 11 and 15 in order to produce the forming mesh 1 of the invention (see also FIGS. 2 and 3 ).
[0058] In the embodiment in question the material layer 2 is formed as a non-textile areal structure in the form of a penetrated film with holes 5 and is produced from a material such as PE, PET, PPS or PA. The paper-side material layer 2 is undetachably joined, two-dimensionally at the interface 7 , to the material layer 4 influencing the liquid absorption capacity by chemical ways through application of a bonding medium 72 in the form of an adhesive 72 .
[0059] The material layer 4 influencing the liquid absorption capacity is formed as a foamed layer with pores 9 . In this case the pores have a defined size.
[0060] In the embodiment in question the material layer 3 is formed as a non-textile areal structure in the form of a penetrated film with holes 6 and is produced from a material such as PE, PET, PPS or PA. The machine-side material layer 3 is undetachably joined, two-dimensionally at the interface 8 , to the material layer 4 influencing the liquid absorption capacity by chemical ways through application of a bonding medium 72 in the form of an adhesive 72 .
[0061] FIG. 2 shows in longitudinal section in the machine direction sections of a press felt 10 according to the invention. The press felt 10 is formed by the paper-side web-shaped material layer 2 known from FIG. 1 , the machine-side web-shaped material layer 3 known from FIG. 1 , the material layer 4 influencing the liquid absorption capacity known from FIG. 1 , by a material layer 11 likewise influencing the liquid absorption capacity and by an anti-rewetting material layer 15 .
[0062] All the material layers 2 , 3 , 4 , 11 and 15 were taken from the construction kit of prefabricated web-shaped material layers 2 , 3 , 4 , 11 and 15 in order to produce the press felt 10 of the invention. The order in which the individual material layers are stacked atop one another is defined by the operating conditions for which the press felt 10 of the invention is designed.
[0063] The material layer 2 is joined, at the interface 13 , to the anti-rewetting material layer 15 by chemical ways through application of a bonding medium 72 in the form of an adhesive 72 .
[0064] The material layer 11 influencing the liquid absorption capacity is formed as a foamed layer with pores 12 . In this case the pores 12 have a defined size which is greater than the size of the pores 9 . The anti-rewetting material layer 15 is joined, at the interface 16 , to the material layer 11 influencing the liquid absorption capacity by chemical ways through application of a bonding medium 72 in the form of an adhesive 72 .
[0065] The two material layers 4 and 11 influencing the liquid absorption capacity are undetachably joined together, two-dimensionally at the interface 14 , by chemical ways in the form of an adhesive bond 72 .
[0066] The machine-side material layer 3 is undetachably joined, two-dimensionally at the interface 8 , to the material layer 4 influencing the liquid absorption capacity by chemical ways through application of a bonding medium 72 in the form of an adhesive 72 .
[0067] FIG. 3 shows in longitudinal section in the machine direction sections of a dryer fabric 20 according to the invention. The dryer fabric 20 is formed from the paper-side web-shaped material 2 known from FIGS. 1 and 2 and from the machine-side web-shaped material layer 3 known from FIGS. 1 and 2 .
[0068] The two material layers 2 and 3 are undetachably joined together, two-dimensionally at the interface 21 , by chemical ways in the form of an adhesive bond 72 .
[0069] FIG. 4 shows a detail in longitudinal section in the machine direction of the forming mesh 1 of the invention in the area of the two end areas 30 and 31 of the forming mesh 1 . In the situation illustrated, the two end areas 30 and 31 are not yet brought fully into contact with each other
[0070] As is evident from FIG. 4 , the web-shaped material layers 2 , 3 and 4 are mutually offset in machine direction and joined together, two-dimensionally, in sections. As the result, the two end areas complement each other in form and function and can be joined together two-dimensionally.
[0071] FIGS. 5 to 7 show coverings which are produced from a construction kit of prefabricated web-shaped material layers 41 , 42 and 61 .
[0072] FIG. 5 shows in cross section, meaning transverse to the machine direction, sections of a forming mesh 40 according to the invention. The forming mesh 40 has a paper-side web-shaped material layer 41 through which the surface of the fibrous web formed on the forming mesh is essentially influenced, and a machine-side web-shaped material layer 42 through which the wear behavior of the forming mesh 40 is essentially influenced. The machine-side material layer 42 is thus a wear-stable material layer 42 . In the embodiment in question the paper-side 41 and machine-side material layer 42 also have dimension-stabilizing properties.
[0073] The material layers 41 and 42 are formed in this embodiment as textile areal structures in the form of weave structures 41 and 42 .
[0074] The weave structure 41 is formed by the warp threads 45 and the weft threads 44 , whereby each weft thread 44 passes alternately under and over a warp thread 45 in order to form a smooth weave pattern, thus creating a smooth contact area for the paper fibers.
[0075] The weave structure 42 is formed by the warp threads 46 and the weft threads 47 , whereby each weft thread 47 in a repeat unit passes under two consecutive warp threads 46 and then over one warp thread 46 in order to form a particularly wear-stable weave pattern in which the highly tensioned warp threads are protected by the weft threads 47 against wear.
[0076] In the embodiment in question the two weave structures 41 and 42 are joined together, two-dimensionally at the interfaces 48 and 19 , by chemical ways through a bonding medium. Here the bonding medium itself forms a foamed material layer 43 , which is arranged between the two joined weave structures 41 and 42 . The foamed material layer 43 has pores 50 with a defined size. This means that the foamed material layer 43 has the function of joining together the two weave structures 41 and 42 in addition to the function of influencing the liquid absorption capacity.
[0077] FIG. 6 shows in cross section, meaning transverse to the machine direction, sections of a press felt 60 according to the invention. The press felt 60 has the machine-side weave structure 42 known from FIG. 5 and a fleece 61 with fibers 62 .
[0078] The fleece 61 and the weave structure 42 are joined together at the two interfaces 63 and 49 by the bonding medium 43 forming a material layer 43 . In the case of the press felt 60 , the bonding medium again has the function of joining together the weave structure 42 and the fleece 61 as well as the function of influencing the liquid absorption capacity of the press felt 60 .
[0079] FIG. 7 shows in cross section, meaning transverse to the machine direction, sections of a dryer fabric 70 according to the invention. The dryer fabric 70 has the paper-side weave structure 41 known from FIG. 5 and the machine-side weave structure 42 known from FIG. 5 .
[0080] The two weave structures 41 and 42 are joined together, two-dimensionally, by chemical ways through a bonding medium 71 in the form of an adhesive 71 .
[0081] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
[0000] List of Reference Numerals:
[0000]
1 Forming mesh
2 Paper-side material layer
3 Machine-side material layer
4 Material layer defining the liquid adsorption capacity
5 Holes (paper-side material layer)
6 Holes (machine-side material layer)
7 Interface
8 Interface
9 Pores (material layer defining the liquid adsorption capacity)
10 Press felt
11 Material layer defining the liquid adsorption capacity
12 Pores (material layer defining the liquid adsorption capacity)
13 Interface
14 Interface
15 Anti-rewetting material layer
16 Interface
20 Dryer fabric
21 Interface
30 End area
31 End area
40 Forming mesh
41 Weave structure (paper-side material layer)
42 Weave structure (machine-side material layer)
43 Bonding medium (material layer defining the liquid adsorption capacity)
44 Weft thread (weave structure)
45 Warp thread (weave structure)
46 Warp thread (weave structure)
47 Weft thread (weave structure)
48 Interface
49 Interface
50 Pores (bonding medium)
60 Press felt
61 Fleece
62 Fibers (fleece)
63 Interface
70 Dryer fabric
71 Bonding medium
72 Adhesive
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A covering for paper machines, paperboard machines or tissue machines, which is constructed from a construction kit includes a plurality of prefabricated web-shaped material layers. Each web-shaped material layer is configured dependent upon a category and operating conditions of the covering, and the plurality of prefabricated web-shaped material layers are stacked atop one another and are joined to one another at least in sections, two-dimensionally, and in a manner that prevents the plurality of prefabricated web-shaped material layers from being detached. The invention also relates to a method for producing the inventive covering.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly assigned, co-pending U.S. Patent Applications:
[0002] Serial Number______ by Bermel et al., (Docket 81820) filed of even date herewith entitled “Ink Jet Recording Element”;
[0003] Serial Number______ by Bermel et al., (Docket 82109) filed of even date herewith entitled “Ink Jet Recording Element”;
[0004] Serial Number______ by Bermel et al., (Docket 82110) filed of even date herewith entitled “Ink Jet Recording Element”;
[0005] Serial Number______ by Bermel et al., (Docket 82111) filed of even date herewith entitled “Ink Jet Recording Element”;
[0006] Serial Number______ by Bermel et al., (Docket 82133) filed of even date herewith entitled “Ink Jet Printing Method”;
[0007] Serial Number______ by Bermel et al., (Docket 82134) filed of even date herewith entitled “Ink Jet Printing Method”;
[0008] Serial Number______ by Bermel et al., (Docket 82138) filed of even date herewith entitled “Ink Jet Printing Method”;
[0009] Serial Number______ by Bermel et al., (Docket 82139) filed of even date herewith entitled “Ink Jet Printing Method”;
[0010] Serial Number______ by Lawrence et al., (Docket 81817) filed of even date herewith entitled “Ink Jet Printing Method”;
[0011] Serial Number______ by Lawrence et al., (Docket 81818) filed of even date herewith entitled “Ink Jet Printing Method”;
[0012] Serial Number______ by Lawrence et al., (Docket 81821) filed of even date herewith entitled “Ink Jet Printing Method”;
[0013] Serial Number______ by Lawrence et al., (Docket 81893) filed of even date herewith entitled “Ink Jet Printing Method”;
[0014] Serial Number______ by Lawrence et al., (Docket 81894) filed of even date herewith entitled “Ink Jet Printing Method”; and
[0015] Serial Number______ by Lawrence et al., (Docket 81983) filed of even date herewith entitled “Ink Jet Printing Method”.
FIELD OF THE INVENTION
[0016] This invention relates to an inkjet printing process for improving the light stability and waterfastness of a printed image containing an ink jet ink containing a water-soluble anionic dye and a cationic receiver.
BACKGROUND OF THE INVENTION
[0017] Ink jet printing is a non-impact method for producing images by the deposition of ink droplets in a pixel-by-pixel manner to an image-recording element in response to digital signals. There are various methods which may be utilized to control the deposition of ink droplets on the image-recording element to yield the desired image. In one process, known as continuous ink jet, a continuous stream of droplets is charged and deflected in an imagewise manner onto the surface of the image-recording element, while unimaged droplets are caught and returned to an ink sump. In another process, known as drop-on-demand inkjet, individual ink droplets are projected as needed onto the image-recording element to form the desired image. Common methods of controlling the projection of ink droplets in drop-on-demand printing include piezoelectric transducers and thermal bubble formation. Ink jet printers have found broad applications across markets ranging from industrial labeling to short run printing to desktop document and pictorial imaging.
[0018] The inks used in the various ink jet printers can be classified as either dye-based or pigment-based. A dye is a colorant which is molecularly dispersed or solvated by a carrier medium. The carrier medium can be a liquid or a solid at room temperature. A commonly used carrier medium is water or a mixture of water and organic co-solvents. Each individual dye molecule is surrounded by molecules of the carrier medium. In dye-based inks, no particles are observable under the microscope. Although there have been many recent advances in the art of dye-based inkjet inks, such inks still suffer from deficiencies such as low optical densities on plain paper and poor light-fastness.
[0019] When water is used as the carrier medium, such inks also generally suffer from poor water-fastness.
[0020] An ink jet recording element typically comprises a support having on at least one surface thereof an ink-receiving or image-forming layer. The ink-receiving layer may be a polymer layer which swells to absorb the ink or a porous layer which imbibes the ink via capillary action.
[0021] Ink jet prints, prepared by printing onto ink jet recording elements, are subject to environmental degradation. They are especially vulnerable to water smearing, dye bleeding, coalescence and light fade. For example, since ink jet dyes are water-soluble, they can migrate from their location in the image layer when water comes in contact with the receiver after imaging. Highly swellable hydrophilic layers can take an undesirably long time to dry, slowing printing speed, and will dissolve when left in contact with water, destroying printed images. Porous layers speed the absorption of the ink vehicle, but often suffer from insufficient gloss and severe light fade.
[0022] U.S. Pat. No. 5,942,335 discloses an ink jet recording sheet comprising a support carrying an ink-receiving layer comprising a hydrophilic polymer and a polyvinylpyridine. However, there is a problem with this recording sheet in that images formed in the image-receiving layer have poor waterfastness.
[0023] U.S. Pat. No. 6,045,917 relates to the use of poly(N-vinyl benzyl-N, N, N-trimethyl ammonium chloride-co-ethyleneglycol dimethacrylate) particles in an inkjet image-recording layer. However, there is a problem with these particles in that images formed in the image-receiving layer have poor light stability, as will be shown hereafter.
[0024] It is an object of this invention to provide an ink jet printing method using anionic dyes suitable for use in aqueous inks for ink jet printing that will provide images with better light stability and waterfastness using certain receiver elements.
SUMMARY OF THE INVENTION
[0025] This and other objects are achieved in accordance with this invention which relates to an inkjet printing method, comprising the steps of:
[0026] A) providing an ink jet printer that is responsive to digital data signals;
[0027] B) loading the printer with ink-receptive elements comprising a support having thereon an image-receiving layer comprising a cationic, water-dispersible, partially quaternized pyridine-containing polymer,
[0028] C) loading the printer with an ink jet ink composition comprising water, a humectant, and a water soluble anionic dye; and
[0029] D) printing on the image receiving layer using the ink jet ink in response to the digital data signals.
[0030] It has been found that use of the above dyes and image-receiving layer provides excellent light stability and waterfastness.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Any anionic, water-soluble dye may be used in composition employed in the method of the invention such as a dye having an anionic group, e.g., a sulfo group or a carboxylic group. The anionic, water-soluble dye may be any acid dye, direct dye or reactive dye listed in the COLOR INDEX but is not limited thereto. Metallized and non-metallized azo dyes may also be used as disclosed in U.S. Pat. No. 5,482,545, the disclosure of which is incorporated herein by reference. Other dyes which may be used are found in EP 802246-A1 and JP 09/202043, the disclosures of which are incorporated herein by reference. In a preferred embodiment, the anionic, water-soluble dye which may be used in the composition employed in the method of the invention is a metallized azo dye, a non-metallized azo dye, a xanthene dye, a metallophthalocyanine dye or a sulfur dye. Mixtures of these dyes may also be used. An example of an anionic dye which may be used in the invention is as follows:
[0032] The dyes described above may be employed in any amount effective for the intended purpose. In general, good results have been obtained when the dye is present in an amount of from about 0.2 to about 5% by weight of the ink jet ink composition, preferably from about 0.3 to about 3% by weight. Dye mixtures may also be used.
[0033] In a preferred embodiment of the invention, the cationic, water-dispersible, dispersible, partially quaternized pyridine-containing polymer has the formula:
[0034] wherein:
[0035] each A independently represents a carbonyl group or a direct link, i.e., a bond;
[0036] each A independently represents O, NH or a direct link, i.e., a bond;
[0037] each R 1 independently represents H or CH 3 ;
[0038] each R 2 independently represents an alkyl, cyclic alkyl or alkoxy group having from 1 to about 10 carbon atoms or a direct link, i.e., a bond;
[0039] R 3 represents a substituted or unsubstituted pyridine ring;
[0040] R 4 represents a substituted or unsubstituted pyridinium ring;
[0041] R 5 represents a linear, branched or cyclic alkyl, alkoxy or aryl group having from 1 to about 24 carbon atoms;
[0042] X represents an anion or a mixture of anions, such as halide (e.g., chloride or bromide), alkylsulfate (e.g. methylsulfate), alkylsulfonate (e.g. methylsulfonate), or arylsulfonate (e.g. benzenesulfonate or toluenesulfonate);
[0043] Z represents at least one ethylenically unsaturated monomer;
[0044] a represents a mole % of from about 0 to about 98;
[0045] b represents a mole % of from about 5 to about 98; and
[0046] c represents a mole % of from about 75 to about 2.
[0047] In a preferred embodiment of the invention, each R 1 represents H, each A, B and R 2 represents direct links, R 3 is pyridine and R 4 is pyridinium. In another preferred embodiment, R 5 is hydroxyethyl, a linear alkyl group having from about 12 to about 18 carbon atoms or benzyl.
[0048] As noted above, Z in the formula represents at least one ethylenically unsaturated, nonionic monomer. Examples of these include a styrene or an alpha-alkylstyrene, where the alkyl group has 1 to 4 carbon atoms and the aromatic group may be substituted or part of a larger ring system. Other examples of Z include acrylate esters derived from aliphatic alcohols or phenols; methacrylate esters; acrylamides; methacrylamides; N-vinylpyrrolidone or suitably substituted vinylpyrrolidones; vinyl esters derived from straight chain and branched acids, e.g., vinyl acetate; vinyl ethers, e.g., vinyl methyl ether; vinyl nitrites; vinyl ketones; halogen-containing monomers such as vinyl chloride; and olefins, such as butadiene. The ethylenically unsaturated, nonionic monomer may contain more than one polymerizable group. In a preferred embodiment, Z represents styrene.
[0049] Specific examples of the cationic, water-dispersible, partially quaternized pyridine-containing polymer useful in the invention include the following:
Polymer m (mol %) n (mol %) p (mol %) P-1 45 42 13 P-2 50 44 6 P-3 50 38 12 P-4 45 50 5 P-5 45 45 10
[0050] The cationic, water-dispersible, partially quaternized pyridine-containing polymer employed in the invention may be used in an amount of from 0.2 to about 32 g/m 2 , preferably from about 0.4 to about 16 g/m 2 .
[0051] The polymers employed in this invention can be prepared using conventional polymerization techniques including, but not limited to bulk, solution, emulsion, or suspension polymerization. They also can be partially crosslinked.
[0052] A binder may also be employed in the image-receiving layer in the invention. In a preferred embodiment, the binder is a hydrophilic polymer. Examples of hydrophilic polymers useful in the invention include poly(vinyl alcohol), polyvinylpyrrolidone, poly(ethyl oxazoline), poly-N-vinylacetamide, non-deionized or deionized Type IV bone gelatin, acid processed ossein gelatin, pig skin gelatin, acetylated gelatin, phthalated gelatin, oxidized gelatin, chitosan, poly(alkylene oxide), sulfonated polyester, partially hydrolyzed poly(vinyl acetate-co-vinyl alcohol), poly(acrylic acid), poly(1-vinylpyrrolidone), poly(sodium styrene sulfonate), poly(2-acrylamido-2-methane sulfonic acid), polyacrylamide or mixtures thereof. In a preferred embodiment of the invention, the binder is gelatin or poly(vinyl alcohol).
[0053] If a hydrophilic polymer is used in the image-receiving layer, it may be present in an amount of from about 0.02 to about 30 g/m 2 , preferably from about 0.04 to about 16 g/m 2 of the image-receiving layer.
[0054] The weight ratio of cationic, water dispersible partially quaternized pyridine-containing polymer to binder is from about 1:99 to about 8:2, preferably from about 1:9 to about 4:6.
[0055] Latex polymer particles and/or inorganic oxide particles may also be used as the binder in the image-receiving layer to increase the porosity of the layer and improve the dry time. Preferably the latex polymer particles and/or inorganic oxide particles are cationic or neutral. Examples of inorganic oxide particles include barium sulfate, calcium carbonate, clay, silica or alumina, or mixtures thereof. In that case, the weight % of particulates in the image receiving layer is from about 80 to about 95%, preferably from about 85 to about 90%.
[0056] The pH of the aqueous ink compositions employed in the invention may be adjusted by the addition of organic or inorganic acids or bases. Useful inks may have a preferred pH of from about 2 to 10, depending upon the type of dye being used. Typical inorganic acids include hydrochloric, phosphoric and sulfuric acids. Typical organic acids include methanesulfonic, acetic and lactic acids. Typical inorganic bases include alkali metal hydroxides and carbonates. Typical organic bases include ammonia, triethanolamine and tetramethylethlenediamine.
[0057] A humectant is employed in the inkjet composition employed in the invention to help prevent the ink from drying out or crusting in the orifices of the printhead. Examples of humectants which can be used include polyhydric alcohols, such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, tetraethylene glycol, polyethylene glycol, glycerol, 2-methyl-2,4-pentanediol 1,2,6-hexanetriol and thioglycol; lower alkyl mono- or di-ethers derived from alkylene glycols, such as ethylene glycol mono-methyl or mono-ethyl ether, diethylene glycol mono-methyl or mono-ethyl ether, propylene glycol mono-methyl or mono-ethyl ether, triethylene glycol mono-methyl or mono-ethyl ether, diethylene glycol di-methyl or di-ethyl ether, and diethylene glycol monobutylether; nitrogen-containing cyclic compounds, such as pyrrolidone, N-methyl -2-pyrrolidone, and 1,3-dimethyl-2-imidazolidinone; and sulfur-containing compounds such as dimethyl sulfoxide and tetramethylene sulfone. A preferred humectant for the composition employed in the invention is diethylene glycol, glycerol, or diethylene glycol monobutylether.
[0058] Water-miscible organic solvents may also be added to the aqueous ink employed in the invention to help the ink penetrate the receiving substrate, especially when the substrate is a highly sized paper. Examples of such solvents include alcohols, such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, t-butyl alcohol, iso-butyl alcohol, furfuryl alcohol, and tetrahydrofurfuryl alcohol; ketones or ketoalcohols such as acetone, methyl ethyl ketone and diacetone alcohol; ethers, such as tetrahydrofuran and dioxane; and esters, such as, ethyl lactate, ethylene carbonate and propylene carbonate.
[0059] Surfactants may be added to adjust the surface tension of the ink to an appropriate level. The surfactants may be anionic, cationic, amphoteric or nonionic.
[0060] A biocide may be added to the composition employed in the invention to suppress the growth of microorganisms such as molds, fungi, etc. in aqueous inks. A preferred biocide for the ink composition employed in the present invention is Proxel® GXL (Zeneca Specialties Co.) at a final concentration of 0.0001-0.5 wt. %.
[0061] A typical ink composition employed in the invention may comprise, for example, the following substituents by weight: colorant (0.05-5%), water (20-95%), a humectant (5-70%), water miscible co-solvents (2-20%), surfactant (0.1-10%), biocide (0.05-5%) and pH control agents (0.1-10%).
[0062] Additional additives which may optionally be present in the ink jet ink composition employed in the invention include thickeners, conductivity enhancing agents, anti-kogation agents, drying agents, and defoamers.
[0063] The ink jet inks employed in this invention may be employed in ink jet printing wherein liquid ink drops are applied in a controlled fashion to an ink receptive layer substrate, by ejecting ink droplets from a plurality of nozzles or orifices of the print head of an ink jet printer.
[0064] The image-recording layer used in the process of the present invention can also contain various known additives, including matting agents such as titanium dioxide, zinc oxide, silica and polymeric beads such as crosslinked poly(methyl methacrylate) or polystyrene beads for the purposes of contributing to the non-blocking characteristics and to control the smudge resistance thereof; surfactants such as non-ionic, hydrocarbon or fluorocarbon surfactants or cationic surfactants, such as quaternary ammonium salts; fluorescent dyes; pH controllers; anti-foaming agents; lubricants; preservatives; viscosity modifiers; dye-fixing agents; waterproofing agents; dispersing agents; UV- absorbing agents; mildew-proofing agents; mordants; antistatic agents, anti-oxidants, optical brighteners, and the like. A hardener may also be added to the ink-receiving layer if desired.
[0065] The support for the ink jet recording element used in the invention can be any of those usually used for inkjet receivers, such as paper, resin-coated paper, polyesters, or microporous materials such as polyethylene polymer-containing material sold by PPG Industries, Inc., Pittsburgh, Pa. under the trade name of Teslin ®, Tyvek ® synthetic paper (DuPont Corp.), and OPPalyte® films (Mobil Chemical Co.) and other composite films listed in U.S. Pat. No. 5,244,861. Opaque supports include plain paper, coated paper, synthetic paper, photographic paper support, melt-extrusion-coated paper, and laminated paper, such as biaxally oriented support laminates. Biaxally oriented support laminates are described in U.S. Pat. Nos. 5,853,965; 5,866,282; 5,874,205; 5,888,643; 5,888,681; 5,888,683; and 5,888,714, the disclosures of which are hereby incorporated by reference. These biaxally oriented supports include a paper base and a biaxially oriented polyolefin sheet, typically polypropylene, laminated to one or both sides of the paper base. Transparent supports include glass, cellulose derivatives, e.g., a cellulose ester, cellulose triacetate, cellulose diacetate, cellulose acetate propionate, cellulose acetate butyrate; polyesters, such as poly(ethylene terephthalate), poly(ethylene naphthalate), poly(1,4-cyclohexanedimethylene terephthalate), poly(butylene terephthalate), and copolymers thereof; polyimides; polyamides; polycarbonates; polystyrene; polyolefins, such as polyethylene or polypropylene; polysulfones; polyacrylates; polyetherimides; and mixtures thereof. The papers listed above include a broad range of papers, from high end papers, such as photographic paper to low end papers, such as newsprint.
[0066] The support used in the invention may have a thickness of from about 50 to about 500 μm, preferably from about 75 to 300 μm. Antioxidants, antistatic agents, plasticizers and other known additives may be incorporated into the support, if desired. In a preferred embodiment, paper is employed.
[0067] In order to improve the adhesion of the image-recording layer to the support, the surface of the support may be subjected to a corona-discharge-treatment prior to applying the image-recording layer.
[0068] In addition, a subbing layer, such as a layer formed from a halogenated phenol or a partially hydrolyzed vinyl chloride-vinyl acetate copolymer can be applied to the surface of the support to increase adhesion of the image recording layer. If a subbing layer is used, it should have a thickness (i.e., a dry coat thickness) of less than about 2 μm.
[0069] The image-recording layer may be present in any amount which is effective for the intended purpose. In general, good results are obtained when it is present in an amount of from about 2 to about 44 g/m 2 , preferably from about 6 to about 32 g/m 2 , which corresponds to a dry thickness of about 2 to about 40 μm, preferably about 6 to about 30 μm.
[0070] The following examples illustrates the utility of the present invention.
EXAMPLES
[0071] The following polymers were used as controls in the image-receiving layer:
[0072] CP-1: poly(styrene-co-4-vinylpyridine) (about 50:50 mole %) (U.S. Pat. No. 5,942,335)
[0073] CP-2: poly(N-vinylbenzyl-N,N,N-trimethylammonium chloride-co-divinylbenzene) (about 90/10 mole %) (U.S. Pat. No. 6,045,917)
[0074] Synthetic Preparation
[0075] Preparation of poly(styrene-co-4-vinylpyridine-co-1-(2-hydroxyethyl)4-vinylpyridinium chloride) (P-1)
[0076] A 1-L 3-necked round-bottomed flask fitted with a mechanical stirrer, reflux condenser, and N 2 inlet was charged with 395 g of tetrahydrofuran, 74.6 g of styrene, and 74.4 g of 4-vinylpyridine. The solution was sparged with N 2 for approx. 15 min, 1.53 g of 2,2′azobisisobutryonitrile was added, and the solution was stirred and sparged an additional 15 min. The reaction mixture was heated at 60° C. with stirring under a slight positive pressure of N 2 for 18 hr, cooled, concentrated to approximately ½ the initial volume, and precipitated into a large excess of ether. The precipitate was dried in a vacuum oven at 35-40° C. overnight. The polymer was dissolved in methanol and reprecipitated into ether, filtered, and dried in vacuo.
[0077] To a 250-mL 3-necked round-bottomed flask fitted with a mechanical stirrer, reflux condenser, and N 2 inlet was added a solution of 20.0 g of the copolymer above in 80 g of dimethylformamide. After the solution had been sparged with N 2 for 20 min, 3.84 g of 2-chloroethanol was added and the solution stirred and heated at 100° C. for 24 hr under a slight positive pressure of N 2 . The clear, brown solution was precipitated into 1500 mL of ether and the precipitate dried at 35° C. in a vacuum oven overnight. Tg 135-136° C.
Example 1
[0078] Light Stability
[0079] Preparation of a water soluble, anionic dye ink composition, I-1
[0080] Ink I-1 containing Dye 1 identified above was prepared by mixing the dye concentrate (3.1%) with de-ionized water containing humectants of diethylene glycol (Aldrich Chemical Co.) and glycerol (Acros Co.), each at 6%, a biocide, Proxel GXL ® biocide (Zeneca Specialties) at 0.003wt %, and a surfactant, Surfynol 465 ® (Air Products Co.) at 0.05wt. %.
[0081] The dye concentration was based on solution absorption spectra and chosen such that the final ink when diluted 1:1000, would yield a transmission optical density of approximately 1.0.
[0082] Preparation of Control Ink Recording Elements C-1 and C-2
[0083] The composite side of a polyethylene resin-coated photographic grade paper based support was corona discharge treated prior to coating. Ink receptive layers were composed of a mixture of 0.86 g/m 2 of polymer CP-1 or CP-2, 7.75 g/m 2 of pig skin gelatin and 0.09 g/m 2 of S-100 12 μm polystyrene beads (ACE Chemical Co.), and coated from distilled water on the above mentioned paper support.
[0084] Preparation of Invention Ink Recording Elements E-1 through E-5
[0085] Recording elements E-1 through E-5 of the invention were coated the same as described above, using P-1 through P-5 instead of CP-1 or CP-2.
[0086] Printing
[0087] Elements E-1 through E-5 and control elements C-1 and C-2 were printed using an Epson 200 ® printer using I-1 ink described above. After printing, all images were allowed to dry at room temperature overnight, and the densities were measured at all steps using an X-Rite 820® densitometer. The images were then subjected to a high intensity daylight fading test for 2 weeks, 50Klux, 5400° K., approximately 25% RH. The Status A blue reflection density nearest to 1.0 was compared before and after fade and a percent density retained was calculated for the yellow dye with each receiver element. The results can be found in Table 1 below.
TABLE 1 Recording Blue Density Blue Density % Retained Element Polymer Before Fade After Fade After Fade E-1 P-1 1.09 0.84 77 E-2 P-2 1.01 0.84 84 E-3 P-3 1.02 0.73 71 E-4 P-4 0.97 0.97 90 E-5 P-5 0.99 0.72 73 C-1 CP-1 1.0 0.88 88 C-2 CP-2 1.04 0.72 69
[0088] The above results show that the recording elements E-1 through E-5 of the invention, as compared to the control recording elements C-2, gave higher % retained density after high intensity daylight fading. Although control receiving element C-1 gave higher % retained densities than several of the recording elements of the invention, C-1 exhibits poor dye fixation as will be shown in Example 2 below.
Example 2
[0089] Waterfastness
[0090] Preparation of a water soluble, anionic dye ink composition, I-2
[0091] Ink I-2 was prepared as described in Example 1 except Dye 2 (0.58%) was added in place of Dye 1.
[0092] Printing
[0093] Elements E-1 and E-5 and control elements C-1 through C-2 were printed as described in Example 1 except I-2 was used instead of I-1. After printing, all images were allowed to dry at room temperature overnight.
[0094] The images were then subjected to a waterfastness test (WF) which involves soaking each imaged receiver in room temperature, distilled water for 5 minutes and then allowing the image to dry at room temperature overnight. The image quality of each print was then visually ranked and assigned a value between 0 and 5. The visual ranking is an indirect measure of how well the dye is fixed (dye fixation) to the receiver layer. Zero represents no image degradation (better dye fixation) and 5 represents severe image degradation (poor dye fixation) and the results are summarized in Table 2 below.
TABLE 2 Recording Element Polymer WF Rank E-1 P-1 2 E-2 P-2 3 E-3 P-3 2 E-4 P-4 3 E-5 P-5 2 C-1 CP-1 4 C-2 CP-2 1
[0095] The above results show that the recording elements E-1 through E-5 of the invention, as compared to the control recording element C-1, gave better dye fixation after the waterfastness test. Although control receiver element C-2 gave better dye fixation than the recording elements of the invention, the light stability was worse as illustrated in Example 1 above.
Example 3
[0096] Light Stability Using Particulates
[0097] Preparation of Control Ink Recording Element C-3
[0098] Control recording element C-3 was prepared the same as C-2 in Example 1 except the ink receptive layer was composed of two layers. The bottom layer was composed of a mixture of 37.9 g/m 2 of fumed alumina (Cabot Corp.), 4.3 g/m 2 of GH-23 ® poly(vinyl alcohol) (Nippon Gohsei); 0.9 g/m 2 of dihydroxydioxane (Clariant) hardener, and 0.04 g.m 2 of Olin 10G ® (Olin Co.) surfactant coated from distilled water.
[0099] On top of the above layer was then coated a mixture of 2.68 g/m 2 of fumed alumina, 0.06 g/m 2 of GH-23 poly(vinyl alcohol), and 0.48 g/m 2 of CP-2 coated from distilled water.
[0100] Preparation of Invention Ink Recording Element E-6
[0101] Recording element E-6 of the invention was coated the same as described for control receiver element C-3, except P-2 was used in place of CP-2.
[0102] Printing
[0103] The recording element E-6 of the invention and control recording element C-3 were printed and evaluated as described in Example 1 above and the results are summarized in Table 3 below.
TABLE 3 Recording Blue Density Blue Density % Retained Element Polymer Before Fade After Fade After Fade E-6 P-2 1.08 0.57 53 C-3 CP-2 0.98 0.31 31
[0104] The above results show that the recording element E-6 of the invention, as compared to the control recording element C-3, gave higher % retained density after high intensity daylight fading.
[0105] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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An inkjet printing method, comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with ink-receptive elements comprising a support having thereon an image-receiving layer comprising a cationic, water-dispersible, partially quaternized pyridine-containing polymer;
C) loading the printer with an inkjet ink composition comprising water, a humectant, and a water soluble anionic dye; and
D) printing on said image-receiving layer using said ink jet ink in response to said digital data signals.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to surgical implants that are designed to replace meniscal tissue and cartilage in a mammalian joint, such as a knee joint and methods to implant the same. While a knee is the primary joint of concern, the invention applies to other body joints as the hip, shoulder, elbow, temporomandibular, sternoclavicular, zygapophyseal, and wrist.
[0002] Compared to the hip the knee has a much greater dependence on passive soft tissues (menisci, ligaments, and the joint capsule) for stability and function. Although the mechanics of the two joints are different, known hip and knee implants are very similar in design, both consisting of a semi-rigid on rigid (polyethylene on CoCr) bearing surface. In many prosthetic knee implants, function and mobility are impaired because rigid structures are used to replace the natural soft tissues.
[0003] Normal anatomical knees have two pliable, mobile menisci that function to absorb shock, distribute stress, increase joint congruity, increase contact area, guide arthrokinematics, help lubrication by maintaining a fluid-film bearing surface, and provide proprioceptive input, i.e., nerve impulse via its attachment to the joint capsule. Even under physiologic loading a natural knee with natural menisci will primarily distribute stresses through a fluid film, only 10% of a load is transmitted via a solid on solid contact. Due to the fluid film bearing surface contact wear is greatly reduced. In simple terms the menisci function to reduce joint stresses, decrease wear, and help guide normal kinematics. Without menisci, peak contact stresses in the knee increase by 235% or more and degenerative changes start to progress rapidly. At 0°, 30°, and 60° of flexion, natural knees with intact menisci have approximately 6 to 8 times the contact area of typical prosthetic knee implants many of which have a similar geometry to that of a natural knee without menisci.
[0004] Typical existing knee replacements lack the functional features normally provided by the menisci and the common polyethylene on metal such as cobalt chrome (CoCr) bearing interface lacks the wear-reducing fluid film bearing surface. By adding a well-designed meniscal substitute, many shortcomings of existing knee replacements can be addressed. In theory, prosthetic menisci could have the same impact on a prosthetic knee as natural menisci do for natural knees.
[0005] The prosthetic knee meniscus of the present invention has at least one and preferably two compliant prosthetic menisci (medial and lateral in the knee) that are attached to the joint capsule and meniscal horns in a similar fashion to the way a natural meniscus is attached to a natural knee. Like a natural meniscus, the meniscal knee implant of the present invention will be able to pivot and glide on a prosthetic tibial plateau. Arthrokinematic constraint comes from the meniscal attachments and will gently guide movements, providing a highly mobile but stable joint. Also through its attachments, the Anatomical Meniscal-Bearing Knee will provide proprioceptive input, giving the central nervous system feedback for refined motor control.
[0006] A preferred material for the meniscal implant of the present invention is polyurethane. Polyurethane can be made flexible so it can conform to the femoral and tibial components, thus giving the knee a large contact area throughout the entire range of motion. Such a polyurethane is described in U.S. Pat. No. 5,879,387. Alternatively, a hydrogel such as a poly(vinyl) alcohol can be used as a prosthetic meniscal implant. Such a hydrogel can be cross-linked to increase its strength and wear properties. Like cartilage, it imbibes aqueous fluids and generates a fluid-film bearing surface.
[0007] The flexible, pliable, gel-like nature of a synthetic hydrogel (when saturated with water) arises mainly from crosslinking attachments between non-parallel fibers in the gel. Depending on the specific polymeric structure that has been chosen, these crosslinking attachments between the long “backbone” chains in a polymer can be formed by covalent bonding, by hydrogen bonding or similar ionic attraction, or by entangling chains that have relatively long and/or “grabby” side-chains.
[0008] Regardless of which type of bonding or entangling method is used to bind the backbone chains together to form a hydrogel, the “coupling” points between molecular chains can usually be flexed, rotated, and stretched.
[0009] In addition, it should be recognized that the back-bone chains in hydrogel polymers are not straight; instead, because of various aspects of interatomic bonds, they are somewhat kinked, and can be stretched, in an elastic and springy manner, without breaking the bonds.
[0010] In a typical hydrogel, the fibers usually take up less than about 10% of the volume; indeed, many hydrogels contain less than 2% fiber volume, while interstitial spaces (i.e., the unoccupied spaces nestled among the three-dimensional network of fibers, which become filled with water when the gel is hydrated) usually make up at least 90 to 95% of the total volume. Accordingly, since the “coupling” point between any two polymeric backbone chains can be rotated and flexed, and since any polymeric backbone molecule can be stretched without breaking it, a supple and resilient gel-like mechanical structure results when a synthetic hydrogel polymer is hydrated.
[0011] Various methods are known for creating conventional polymeric hydrogels. A number of such methods involve mixing together and reacting precursor materials (monomers, etc.) while they are suspended in water or other solvent. This step (i.e., reacting two or more monomers while they are suspended in a solvent) gives a desired density and three-dimensional structure to the resulting polymerized strands or fibers. The resulting material is then frozen, to preserve the desired three-dimensional structure of the fibers. The ice (or other frozen solvent) is then vaporized and removed, without going through a liquid stage, by a sublimizing process (also called lyophilizing), using high vacuum and low temperature. After the solvent has been removed, any final steps (such as a final crosslinking reaction and/or rinsing or washing steps, to remove any unreacted monomers, crosslinking agents, quenching agents, etc.) are carried out. The polymer is then gradually warmed up to room temperature, and it is subsequently saturated with water, to form a completed hydrogel.
[0012] In the past, effort mainly has been placed on the development of meniscal replacement. In the attempt to repair or replace torn menisci, allographs, xenographs, and autographs have been implanted for over 20 years. Current focus has been on the development of collagen-matrix meniscal implants. However, these implants do not reproduce the mechanical properties of a normal meniscus.
[0013] As used herein, all references to “implants” or “implantation” (and all terms such as surgery, surgical, operation, etc.) refer to surgical or arthroscopic implantation of a reinforced hydrogel device, as disclosed herein, into a mammalian body or limb, such as in a human patient. Arthroscopic methods are regarded herein as a subset of surgical methods, and any reference to surgery, surgical, etc., includes arthroscopic methods and devices. The term “minimally invasive” is also used occasionally herein, even though it is imprecise; one should assume that any surgical operation will be done in a manner that is minimally invasive, in view of the needs of the patient and the goals of the surgeon.
[0014] Meniscal Tissues in Knees—Each knee joint of a human contains a “medial” meniscus, and a “lateral” meniscus. The lateral meniscus is located on the outer side of the leg, directly above the location where the upper end of the fibula bone is coupled to the tibia (“shinbone”). The medial meniscus is located on the inner side of the leg.
[0015] Each meniscus (also referred to, especially in older texts, as a “semilunar fibrocartilage”) has a wedged shape, somewhat comparable to a segment from an orange or other citric fruit, but with a substantially larger curvature and “arc.” The thickest region is around the periphery (which can also be called the circumference, the rim, and similar terms). When implanted into a knee, this peripheral rim normally will be anchored to the surrounding wall of a fibrous “capsule” which encloses the knee joint and holds in the synovial fluid, which lubricates the cartilage surfaces in the knee. The two ends of each semi-circular wedge are coupled, via thickened collagen structures called horns to the “spine” protrusions in the center of the tibial plateau.
[0016] The inner edge of a meniscus is the thinnest portion of the wedge; this edge can also be called the apex, the margin, and similar terms. It is not anchored; instead, as the person walks or runs, each meniscus in a knee is somewhat free to move, as it is squeezed between the tibial plateau (beneath it) and a femoral runner or condyle (above it). The bottom surface of each meniscus is relatively flat, so it can ride in a relatively stable manner on top of the tibial plateau. The top surface is concave, so it can provide better, more closely conforming support to the rounded edge of the femoral runner. Because of its shape, location, and ability to flex and move somewhat as it is pushed, each meniscus helps support and stabilize the outer edge of a femoral runner, as the femoral runner presses, slides, and “articulates” against the portion of the tibial plateau beneath it.
[0017] However, because all four of the menisci inside a person's knees are in high-stress locations, and are subjected to frequently-repeated combinations of compression and tension (and sometimes abrasion as well, especially in people suffering from arthritis or other forms of cartilage damage), meniscal damage often occurs in the knees of humans, and occasionally other large animals.
[0018] It should be noted that, in humans, meniscal-type tissues also exist in temporomandibular, sternoclavicular, zygapophyseal, and wrist joints.
[0019] Various efforts have been made, using prior technology, to repair or replace damaged meniscal tissue. However, because of the complex structures and anchoring involved, and because of the need to create and sustain extremely smooth and constantly wet surfaces on the inner portions of each meniscal wedge, prior methods of replacing or repairing damaged meniscal are not entirely adequate.
[0020] Many meniscal implants for the knee address the need for attachment to the surrounding soft tissue but they do not address the need to resurface the femoral and/or the tibial articulating surfaces. An example of this type of implant is described by Kenny U.S. Pat. No. 4,344,193 and Stone U.S. Pat. No. 5,007,934.
[0021] A free-floating cobalt chrome meniscal replacement has been designed to cover the tibial bearing surface. Because this implant is rigid and because it is disconnected from the soft tissues it lacks the ability to shock absorb and/or provide proprioceptive input. In fact, because it is approximately 10-20 times more rigid than bone it may actually cause concentrated loading, increased contacts stresses, and therefore accelerate degenerative joint changes.
[0022] Various unicondylar knee implants for joint replacement contain a meniscus-like component. The tibial-bearing component of the known Oxford Knee (British Patent Application No. 49794/74) contains a free-floating piece of polyethylene that can glide or spin on a polished, flat, tibial CoCr surface in the transverse plane. The tibial-bearing component in turn articulates with the CoCr femoral implant. Because the polyethylene meniscus is semi-rigid it has a limited capacity to absorb shock or conform to the femoral component. Because of its materials, the Oxford knee also lacks a wear-reducing fluid film bearing surface.
SUMMARY OF THE INVENTION
[0023] The anatomical meniscal-bearing knee implant of the present invention has one or more compliant prosthetic menisci that are attached to the joint capsule and meniscal horns in a similar fashion to the way a natural meniscus is attached to a natural knee. Like a natural meniscus, the meniscal implant will be able to pivot and glide on the prosthetic tibial plateau. Arthrokinematic constraint will come from the meniscal implant's attachments, which will gently guide movements, providing a highly mobile but stable joint. Also through its attachments, the Anatomical Meniscal-Bearing Knee will provide proprioceptive input, giving the central nervous system feedback for refined motor control. Like a natural knee with intact menisci, the outer border of the menisci implants will be mechanically linked to the tibial plateau via the coronary ligament, such as for example by the implant being attached such as by its being sutured directly to the joint capsule/coronary ligament or indirectly by attaching it to the remaining meniscal rim which is in turn attached to the coronary ligament. Tendon slips from the quadriceps, attached to both medial and lateral meniscus, will pull the meniscal replacements forward during active extension and likewise, the semimembranosus (medial meniscus) and/or popliteus tendons (lateral meniscus) will pull the meniscal replacements posteriorly during active flexion.
[0024] The proposed anatomical meniscal-bearing arthroplasty has one or multiple prosthetic menisci that are attached to either the diarthrodial joint capsule and/or the remnant of the natural menisci. The knee will be used to describe the preferred embodiment of this concept. However, the proposed meniscal bearing can be used to repair cartilage in other body joints.
[0025] The prosthetic is preferably implanted in the knee via a minimally invasive procedure, leaving the quadriceps muscle group intact. A small arthrotomy will be performed, allowing the access to the knee joint. Then the central portion of the meniscus will be resected, leaving the horns, a peripheral meniscal rim, and the coronary ligament intact. One or more well-defined cavities will then be formed in the articular surfaces of the tibia and/or femur. One or more resurfacing implants would then either be press-fit, cemented or sutured into the prepared pocket. The meniscal prosthetic is then sewed into the meniscal rim.
[0026] The non-meniscal articular resurfacing portion of the implants which contact the meniscus consists of cobalt chrome alloys, stainless steel, ceramics, polyethylene, and/or polyurethane and will closely approximate the normal articular geometry.
[0027] The bulk of the meniscal prosthetic implant will preferably consist of a compliant polyvinyl alcohol polymer and/or polyurethane. A meshed fabric may be molded into the peripheral rim of the prosthetic body, allowing biological glues and/or sutures to connect the implant to the surrounding soft tissue. If the entire original meniscus needs to be removed, a flexible tube can be placed in the space bordered by the tibial plateau, coronary ligament, and anatomical meniscus in order to measure the natural soft tissue laxity. Different diameters of tubing represent different amounts of laxity/mobility in the natural meniscus/coronary ligament construct. This tubing can then be reused as a spacer to balance the soft tissue connections, simulating the restraint of the natural meniscus.
[0028] One preferred material for the meniscal implant is polyurethane. Polyurethane can be made flexible so it can conform to the femoral and tibial components, thus giving the knee a large contact area throughout the entire range of motion. Likewise, a polyvinyl alcohol polymer which imbibes aqueous fluids can be used. Like cartilage, it imbibes aqueous fluids and generates a fluid-film-bearing surface.
[0029] The shape of the meniscal implants will closely conform to the tibial plateaus and femoral condyles, generating large areas of contact. They can either be congruent or, to distribute stresses more evenly they can be slightly incongruent as described by Goodfellow et al., The Design of Synovial Joints, Scientific Foundations of Orthopaedics and Traumatology, pp. 78-88. The meniscal portions of the implant will be flexible so they can conform to the tibial and femoral bearing surfaces throughout the entire range of motion.
[0030] The anatomical meniscal-bearing concept could also be used in a unicondylar knee replacement. Because the meniscal portion of the implant is able to spin and glide on the tibial plateau, and because the meniscal replacement is flexible, the implant will be less sensitive to malaligement. With existing unicondylar knee replacements if the implant is malaligned the entire joint will likely experience abnormal stresses.
[0031] Another possible use for this implant would be in the meniscal replacement surgery. The meniscal portion of the implant can be used by itself, being sewed to the joint capsule and meniscal horns of the knee. Also, variation in the meniscal implant can be made for replacement of menisci from other joints, i.e., sternoclavicular, temperomandibular, and zygapophyseal.
[0032] The invention also relates to a surgical procedure which is minimally invasive when compared to standard techniques currently used for resurfacing the knee joint or other body joints. In this method, the incision length is limited between 2 and 2½ times the patellar width. During forming the incision, the surgeon should avoid turning the patella (everting) over from its natural position. Steps should also be taken to leave the quadriceps muscle in its natural position by making sure it is not severed or twisted. Attachments to the peripheral tibial plateau, horns and surrounding ligaments and musculature is maintained through the meniscal rim. For example, the anterior cruciate ligament, if attached to the meniscal rim, should be maintained. Likewise, the transverse ligament should be left attached to the meniscal horns. The inner portion of the meniscus is then removed. Preferably, the incision/resection is made within or at the border of the zone of the meniscus known as the red or vascularized region. Tibial sizing guides are used to measure the size of the meniscal resection (length of resection arc and thickness at the red-zone border).
[0033] If femoral resurfacing is needed, the femoral resection may be done using a femoral alignment guide which has a rod extending externally of the incision, which rod points to the femoral head. The rod indicates implant flexion and implant rotation within the frontal plane. Once properly aligned, a femoral sizing template is used to measure and guide a posterior femoral cut. Obviously, there will be several different size templates corresponding to the several femoral implant sizes. The template may include a saw blade slot for preparing the posterior surface of the femur.
[0034] A tibial-sizing tray is utilized to prepare the tibial bone cuts within the inner portion of the meniscus. Preferably, the meniscus will be removed in an oval or “D”-shape with the oval aligned with the two anatomic meniscal horns. Obviously, again, there are various size templates corresponding to different size tibias. Once aligned, the tray template is pinned in position and a burr or end mill is used to mill a pocket into the tibial plateau. A second template or deeper layer of the first template-shaped like an “I” beam (if a second template is used, it is placed over the pins after the initial template is removed) and a deeper recess is formed within the initial recess or cavity. In other words, the “I”-shaped pocket is deeper than the original “D”-shaped or oval pocket to accommodate an “I”-shaped keel on the implant. Preferably as the “D”-shaped pockets grow in size, the “I”-shaped keel receiving recess also increases, however, it may remain the same size if desired. The “D”-shaped pocket formed should encompass the entire tibial plateau within the rim with the “I”-shaped recess in the center.
[0035] On the femoral side, a femoral burr template is pinned in position and a recess of general uniform depth is formed, as by milling with a burr, along the condyle of the distal femur. A femoral implant, preferably made of a cobalt chrome alloy such as Vitallium® alloy or a ceramic material is implanted in the recess formed on the femoral condyle. Preferably, this implant has a thickness corresponding to the depth of the recess formed so that the outer surface of the implant is located at the correct anatomical position.
[0036] A tibial resurfacing implant is provided and has a “D”-shaped corresponding the various size templates provided. For each implant profile, several implant thicknesses are provided. The thickness is chosen such that the implant will be aligned in the varus/valgus direction. Once the implant thickness is determined, the actual implant will either be press fit or cemented into place. The tibial plateau implant has a contact surface preferably made of polyethylene and will have a porous titanium surface against the bone. The bone contacting porous surface attached to the polyethylene preferably is made of titanium or cobalt chrome or any other biocompatible porous material. Alternatively, the tibial implant can be made of polyurethane, cobalt chrome, ceramics, or a polyvinyl alcohol hydrogel. Alternatively, the implant may be in the shape of a circular disc with a periphery located immediately inside the remaining rim of the tibia.
[0037] Once the tibial plateau is resurfaced, a meniscal implant is attached to the remaining meniscal rim such by suturing. A sizing template is used to determine the required implant size in all three anatomical planes. The meniscus, which is attached to the remaining rim of the tibial plateau is preferably made of a polyvinyl alcohol hydrogel or a polyurethane but can be made of any biocompatible soft, compliant material that is able to withstand the functional loading and tribiological conditions. The implant is sutured into the remaining meniscal rim. The sutures can be made part of the implant such as by molding. See, for example, the implant of Kenny U.S. Pat. No. 4,344,193. The sutures may be made integral with a mesh that is also molded into the implant. The mesh can abut the meniscal rim and allow for the potential of soft tissue ingrowth. Bioactive factors such as tissue cultures, resorbables, bone morphogenic proteins can be added to the mesh to encourage the tissue ingrowth. See Stone U.S. Pat. No. 5,007,934.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1 is an isometric view of a knee joint capsule showing the exposed tibial meniscal portions;
[0039] [0039]FIG. 2 shows the capsule of FIG. 1 after removal of the central portion of the lateral meniscus but leaving a meniscal rim;
[0040] [0040]FIG. 3 shows the location of a femoral sizing template and alignment guide mounted within the joint capsule;
[0041] [0041]FIG. 4 shows a tibial tray sizing template located within the remaining meniscal rim on the tibial plateau;
[0042] [0042]FIG. 5 shows the template of FIG. 4 pinned in a position aligned with the meniscal horns;
[0043] [0043]FIG. 6 shows a burr used to mill a pocket in the tibial plateau conforming to the tibial sizing template;
[0044] [0044]FIG. 7 shows an “I” beam template placed within the pocket milled in FIG. 6 on the resected tibial plateau;
[0045] [0045]FIG. 8 shows the “I” beam template of FIG. 7 pinned in position;
[0046] [0046]FIG. 9 shows a burr shaping the “I”-shaped pocket;
[0047] [0047]FIG. 10 shows the “I”-shaped pocket of FIG. 9 within the oval or “D”-shaped pocket formed in FIG. 6 along with a femoral burr template for forming a recess in the lateral femoral condyle;
[0048] [0048]FIG. 11 shows the recess formed in FIG. 10;
[0049] [0049]FIG. 12 shows both the femoral resurfacing implant on the femur and the tibial resurfacing implant attached to the tibial plateau;
[0050] [0050]FIG. 13 shows the tibial resurfacing implant of FIG. 12 covered by a compliant meniscal implant which is attached to the remaining natural meniscal rim; and
[0051] [0051]FIG. 14 is a bottom view of a medial and lateral tibial resurfacing implant including lateral implants of FIGS. 12 and 13.
DETAILED DESCRIPTION
[0052] Referring to FIG. 1 there is shown, for purposes of reference, an open knee joint capsule including a lateral femoral condylar surface 10 and a medial femoral condylar surface 12 . The anterior cruciate ligament 14 is shown running through the joint. The quadriceps 16 is shown coupled to the tibia 17 and the lateral collateral ligament 18 is shown connecting the tibia and the femur. The lateral meniscus 20 which includes a rim area 22 is located above the tibial plateau 24 .
[0053] Referring to FIG. 2, there is shown the joint capsule of FIG. 1 with the inner portion of the meniscus 20 removed leaving meniscal rim 22 . In the preferred method, which will be discussed below, the incision/resection of the meniscus 20 is made within or at the border of what is known as the red zone of the meniscus, i.e., the vascularized region of the meniscus. The resection of the inner part of meniscus 20 leaves meniscal horns 26 , 28 in place. Since the meniscal rim 22 remains, all the attachment points to the peripheral tibial plateau 24 are left and the surrounding ligaments and musculature is maintained through the meniscal rim.
[0054] Referring to FIG. 3, a femoral alignment guide 30 includes an alignment rod 32 which extends outwardly of the knee capsule and can be aligned with the femoral head and laid parallel to the femoral shaft in the frontal plane for referencing the location of the femoral sizing template. Specifically, implant flexion and implant rotation with regard to the frontal and sagittal planes can be set. A femoral sizing template 34 is thus aligned with alignment guide 30 on the lateral condyle 10 of the femur. In the preferred embodiment, femoral sizing template 34 includes a handle 36 and a posterior saw guide 38 . The posterior saw guide 38 is used to make the posterior femoral cut via a slotted saw guide 40 .
[0055] With regard to FIG. 4, there is shown a tibial sizing template 42 . In the preferred embodiment, template 42 has a “D”-shaped outer surface 44 and a generally oval inner surface 46 . In the preferred embodiment, template 42 includes a handle 48 so that a straight side 50 of the “D”-shaped template 42 may be aligned with the meniscal horns 26 , 28 . Preferably, a series of templates 42 of varying sizes are provided in a kit, each corresponding to a population of different size tibial plateaus. It is contemplated that a series of 5 to 7 templates 42 would be provided in a kit to be used during the surgical procedure. This is also true for template 34 in which a variety of sizes may be provided to accommodate different size femurs. In the preferred embodiment, template 42 includes a series of through bores 52 .
[0056] Referring to FIG. 5, there is shown the template 42 of FIG. 4 pinned in position utilizing three pins 54 which are sunk into the bone of the tibial plateau through holes 52 of “D”-shaped template 42 . Pins 54 locate template 42 on the tibial plateau in a location which, in the preferred embodiment, places a surface 44 of template 42 in close proximity of the remaining rim portion 22 of the natural meniscus. As can be seen in FIG. 6, there is shown a burr or end mill 60 which is used to form a recess surface in tibial plateau 24 having the shape of inner surface 46 of template 42 . Burr 60 is driven by any convenient means via a drive shaft 62 . In the preferred embodiment, burr 60 includes a stop plate 64 which contacts an upper surface 48 of template 42 . Stop plate 64 is set at a predetermined distance from the lower most cutting face of mill or burr 64 so that a depth of resection into the surface of tibial plateau 24 is set. In the preferred embodiment, this is at least 0.2 and preferably 0.24 inches.
[0057] Referring to FIGS. 7 and 8, there is shown a second template 72 having an outer surface 74 matching outer surface 44 of template 42 . As shown in FIG. 8, template 72 includes a series of preferably three through holes 76 for receiving the same series of pins 54 as used for template 42 . In the preferred embodiment, template 72 includes an “I”-shaped inner recess 80 . While recess 80 is preferably “I”-shaped, it is conceivable that other shapes may be used which would the keel of receive an implant to be discussed below and prevent the translation and rotation thereof. Resection template 72 is located in a manner similar to that of resection template 42 and recess 80 is centrally located within the generally oval recess previously cut with template 42 .
[0058] In the preferred embodiment, template 72 includes a handle 82 to facilitate its alignment on the tibial plateau. Pins 78 are placed through throughbores 76 and the original pin holes used with template 42 to maintain the resection template 72 in its aligned orientation. Alternately the pins used to hold down template 42 can be left in place and template 72 can be slid over the remaining pins.
[0059] Referring to FIG. 9, a burr or end mill 84 , which is similar or identical to end mill 60 , is utilized to form an “I”-shaped recess within the oval recess already formed. Obviously, this recess has to be deeper into the tibial bone than the original oval shaped recess formed. Thus, burr 84 includes a stop plate 86 spaced at a greater distance from upper surface 88 of template 72 than stop 64 of burr or end mill 60 . Generally, the thickness of template 42 and 72 will be identical, however, the dimensions between the bottom surface end mill or burr 84 and the guide surface 88 is dimensioned to produce an “I”-shaped recess of the desired depth. In the preferred embodiment, this depth is 0.240 inches and at least 0.2 inches below the recess surface initially formed in tibial plateau 24 with template 42 .
[0060] Referring to FIG. 10 there is shown the two level recess formed in plateau 24 . As discussed above, the recess has a first recessed area 66 and a more recessed area, in the shape of an “I”, 82 . As indicated above, the size of the resection templates 42 and 72 may change to match varying anatomy. In general, for each template 42 there will be a corresponding identically sized template 82 . Consequently, if there are five templates 42 in a kit, there will be preferably five templates 82 in a kit. Thus, the size of the pockets or recesses 66 , 82 will get larger as the template size increases. The use of the two depth recesses or pockets 66 , 82 will be discussed below.
[0061] Referring again to FIG. 10, there is shown a femoral burr template 90 attached to lateral condyle 10 via pins 92 . In the preferred embodiment, template 90 includes a pair of through bores 94 for receiving pins for attaching template 90 to the femoral condyle 10 . Obviously, more pins 92 than two may be used. An end mill or burr similar to that discussed above with regard to elements 60 , 84 is used to mill a recess within the inner surface 96 of template 90 . If a thin wall of bone is left due to the center island, that remaining portion of bone is resected free-handed with the burr.
[0062] As best seen in FIG. 11, a recess 100 is formed in the lateral condyle 10 of the femur.
[0063] Referring to FIGS. 12 - 14 , there is shown the tibial and femoral resurfacing implants 102 , 106 respectively. Tibial implant 102 includes an “I”-shaped keel 104 (shown in phantom in FIG. 12) which extends to the base of the “I”-shaped recess 82 . Implant 102 has a periphery 105 which has a portion extending into the upper level, i.e., extending at a lesser distance from the base of the tibial resurfacing implant 104 and engaging with outer recess 66 . Referring to FIG. 14, there is shown a bottom view of a preferred medial and lateral implant 102 ′ and 102 ″ each having a keel 104 . The arcuate portion of the implants is placed adjacent remaining rim 22 of a tibial plateau 107 . The tibial implant 102 is either press fit or cemented into recesses 66 , 82 . Femoral resurfacing implant 106 has an outer bearing surface 108 shaped to be congruent with the natural surface of the femoral condyle 10 . Preferably, this component will be a cobalt chrome alloy implant having a thickness such that outer surface 108 is placed at or about the level of the natural femoral condyle 10 prior to resurfacing. Again, implant 108 may be either press fit or cemented into position. Alternately, the femoral resurfacing implant 106 may be made of a ceramic and cemented in position. In the preferred embodiment, tibial implant 104 is preferably made of polyethylene having a porous surface contacting the bone. Alternately, the tibial contact can be made of polyurethane, cobalt chrome, ceramic or a polyvinyl alcohol hydrogel.
[0064] Referring to FIG. 13, there is shown a meniscal implant 110 which is positioned proximally of the resurfacing implant 104 . In the preferred embodiment, meniscal implant 110 is made of a polyvinyl alcohol hydrogel or a polyurethane but can be made of any biocompatible soft, compliant material that is able to withstand the loading in the knee joint and capable of the wear properties requires. Such a hydrogel meniscus is described in U.S. Publication No. 2002/0022884 published Feb. 21, 2002, the teachings of which are incorporated herein by reference. In the most preferred embodiment, the meniscus is made of a polyurethane which is molded to include an inner mesh or sutures. In the preferred embodiment, meniscal implant 110 is attached to the meniscal rim 22 via the sutures or mesh integrally molded into the hydrogel implant. Preferably, this is done around the entire circumference 112 of implant 110 so that it is maintained in position by the remaining natural meniscal rim 22 . The mesh of the implant, for example that shown in U.S. Pat. No. 5,007,934, the teachings of which are incorporated herein by reference, may be coated or impregnated with bioactive factors, tissue cultures, BMPs or other resorbable polymers to encourage potential soft tissue ingrowth. This ingrowth would supplement or, in some cases, replace the suture attachment to meniscal rim 22 .
[0065] While only the resurfacing of the lateral side of the tibial plateau and femur have been described, the process could as easily be used on the medial condyle 12 and medial tibial plateau.
[0066] The preferred surgical procedure utilizes a minimally invasive method which, when compared to standard techniques current used for resurfacing the knee joint of other body joints, uses a smaller incision. In this preferred method, the incision length is between 2 and 2½ times the patellar width. During forming the incision, everything or turning the patella over from its nature position should be avoided. Steps should also be taken to leave the quadriceps muscle 16 in its natural position by making sure it is not severed or twisted. Attachments to the peripheral tibial plateau such as horns 26 , 28 and surrounding ligaments and musculature should be maintained through the meniscal rim 22 . For example, the anterior cruciate ligament 14 , if attached to the meniscal rim, should be maintained. Likewise the transverse ligament should be left attached to the meniscal horns. Initially, the posterior surface of the femur is prepared. This is done using femoral alignment guide 30 which has rod 32 extending externally of the incision, which rod points to the femoral head. The rod indicates implant flexion and implant rotation within the frontal and sagittal planes. Once properly aligned, a femoral sizing template 34 is used to measure and guide a posterior femoral cut. Obviously, there will be several different size templates corresponding to the several femoral implant sizes. The template may include guide 38 having saw blade slot 40 for preparing the posterior surface of the femur in a known manner.
[0067] Tibial sizing template 42 is then utilized to prepare the inner portion of the meniscus. Preferably, the meniscus will removed in an oval shape with the oval aligned via surface 50 with the two anatomic meniscal horns 26 , 28 . Obviously, again, there are various size templates 42 corresponding to different size tibias. Once aligned, the template 42 is pinned in position via pins 54 and burr 60 is used to mill pocket 66 into tibial plateau 24 . A second “I” beam template 72 is placed over pins 54 after the initial template 42 is removed and a deeper recess is formed within the initial cavity. In other words, the “I”-shaped pocket 88 is deeper than the original “D”-shaped or oval pocket 66 to accommodate an “I”-shaped keel on the implant. Preferably, as the “D”-shaped pockets grow in size, the “I”-shaped keel receiving recess also grows. The “D”-shaped pocket 66 formed should encompass the maximum possible tibial plateau area within rim 22 with the “I”-shaped recess 82 in the center.
[0068] On the femoral side, a femoral burr template 90 is pinned in position via pins 92 and a recess of general uniform depth is formed, as by milling with a burr similar to burr 60 along with the condyle 10 of the distal femur. A femoral implant 106 , preferably made of a cobalt chrome alloy such as Vitallium® alloy or a ceramic is implanted in the recess formed on the femoral condyle. Preferably, this implant has a thickness corresponding to the depth of the recess formed so that outer surface 108 of implant 106 is located at the correct anatomical position.
[0069] A tibial resurfacing implant 104 which may be circular or preferably have a general “D”-shape corresponding the various size template provided is implanted in recesses 66 , 82 . For each implant profile, several implant thicknesses are provided. The thickness is chosen such that the implant will be aligned in the varus/valgus direction. Once the implant thickness is determined, implant 104 will either be press fit or cemented into place. The tibial plateau implant bearing surface is preferably made of polyethylene and will have a porous metal surface against the bone. Alternatively, the tibial implant can be made of polyurethane, cobalt chrome, ceramics or a poly vinyl alcohol hydrogel. If the implant is made in the shape of a “D”, the arcuate periphery of the “D” is located immediately inside the remaining rim 22 of the tibia.
[0070] Once the tibial plateau is resurfaced with implant 104 , meniscal implant 10 is attached to the remaining meniscal rim 22 such by suturing. A sizing template is used to determine the required meniscal implant size in all three anatomical planes. The sizing template is similar to the D-shaped resection template with the arcuate portion sizing the meniscal implant. The meniscus, which is attached to remaining rim 22 of tibial plateau 24 preferably made of poly vinyl alcohol hydrogel or polyurethane but can be made of any biocompatible soft, compliant material that is able to withstand the functional loading and tribiological conditions. The implant is sutured into the remaining meniscal rim. The sutures can be made part of the implant such as by molding. See, for example, the implant of Kenny U.S. Pat. No. 4,344,193. The sutures may be made integral with a mesh that is also molded into the implant. The mesh can abut the meniscal rim and allow for the potential of soft tissue ingrowth. Bioactive factors such as tissue cultures, resorbables, bone morphogenic proteins can be added to the mesh to encourage the tissue ingrowth.
[0071] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Instrumentation and a method for resurfacing a joint capsule having cartilage and meniscal surfaces such as a knee joint includes resecting a central portion of the joint cartilage on one joint member such as the tibia while leaving a meniscal rim attached to the peripheral joint capsule. A cavity is then formed in the bone underlying the central portion of the joint surface such as the lateral tibial surface. A resurfacing implant is then coupled, by cementing for example, to the cavity. A soft prosthetic meniscal implant is then coupled to the remaining meniscal ring such as by suturing.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to devices used for cleaning shaving razors, and more particularly to a portable device that produces a flow of cleaning fluid, which can be directed at hair particles and shaving cream trapped in a razor, thereby dislodging and washing such debris away from the razor.
[0002] Trapped hair particles in a razor reduce its cutting effectiveness, and are a source of skin irritation during shaving. Therefore, constant cleaning of the razor during shaving is required to maintain an acceptable performance. The most common method of cleaning is by placing the razor under running water and, often, imparting mechanical shock by “tapping” the razor against the sink surface. This method is very ineffective and time-consuming, especially with the double- and triple-blade razors, and the newer, thicker shaving creams. These creams, mixed with the hair particles, are extremely difficult to remove from the crevices between the blades. “Tapping” also creates mechanical stresses that are damaging to the razor.
[0003] Clearly, a need exists for a fast, effective and low-mechanical-stress method to clean razors. There is a number of patents describing devices that attempt to address the issue. U.S Pat. No. 4,027,387 (Kellis), U.S Pat. No. 4,480,387 (d'Alayer de Costemore d'Arc), U.S Pat. No. 4,838,949 (Dugrot) and U.S Pat. No. 4,941,492 (Morgan) all describe devices that have a chamber which receives the razor head and means that attach to a water faucet, which provides water under pressure for cleaning the razor. The usefulness of such devices is limited, as they cannot be used with all available faucet designs. Furthermore, as the water flow needs to be aimed accurately at the areas of hair particle and soap accumulation, positioning the razor head within the cavity that receives it, is critical. “Blindly” placing the razor head within the cavity will not result in an effective cleaning. Additionally, with the proliferation of razor head shapes and sizes in the market, proper fit between the chamber and the razor head is not always possible.
[0004] U.S Pat. No. 5,365,958 (Stuhlmacher) describes a device which allows the razor to be moved relative to the water jets, therefore addressing one of the disadvantages of the earlier inventions. However, this device requires permanent attachment to the water supply for operation, hampering its portability.
[0005] All the patents discussed so far need to be attached to the water supply during operation, which limits their flexibility and requires them to use water as the only cleaning fluid.
[0006] U.S Pat. No. 6,009,622 (Liedblad) describes a device having a recess for the razor, which is submerged in water together with the razor and water pressure is generated by squeezing the device. This system requires the application of manual power in real time for its operation, so results will vary from person to person. While this device eliminates the need for connection to the faucet, and is capable of using cleaning fluids other than water, it still has the disadvantage of most of the previously discussed devices in that the placement of the razor head relative to the water flow is fixed resulting, as explained earlier, in diminished cleaning effectiveness. This device will also be slippery, and therefore difficult to operate, when covered with shaving cream and water.
[0007] A simple approach to cleaning razors would be to use a syringe with a nozzle attached to one end and a piston-plunger combination that is able to move freely within it. After initially filling the syringe with water, pushing the plunger would force water to be expelled through the nozzle. The water jet thus created could be used to clean a razor. A disadvantage of this approach is that it is difficult to accurately aim the nozzle while concurrently pushing the plunger on the opposite end of the syringe.
[0008] The advantages of a moveable and aimable nozzle are clear in mouth irrigation systems. There exist in the market several such systems capable of producing a high pressure, aimable water jet that could be used to clean razors. The disadvantage of such devices is that they all require AC power, and they are fairly large in size, both of which reduce their portability and their usefulness as razor cleaning systems.
[0009] The need, therefore, exists for a portable, self-contained razor cleaning system, capable of using water and/or a variety of other cleaning fluids, that allows the user to direct a stream of said cleaning fluids to areas of shaving residue accumulation in the razor for high cleaning effectiveness.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention addresses the above and other needs, by providing a method of generating pressure independent of the user's physical ability and independent of faucet design, using relatively small amounts of water or other cleaning fluids. Furthermore, this invention describes a razor cleaning device able to produce at least one maneuverable stream of cleaning fluid that can advantageously be directed at areas of shaving residue accumulation in a razor, for cleaning the razor.
[0011] One important advantage of this invention is that it allows manipulation of the stream of cleaning fluid, in moving this stream across the razor and altering its angle of incidence, which further enhance the ability of this invention to clean the razor, as these actions create pressure waves that dislodge all shaving residue. Another advantage of this invention is the use of turbulent flow to enhance its cleaning ability.
[0012] A further advantage of this invention is that it is capable of cleaning any razor, cartridge or blade of any size, of the single- or multi-blade configuration, and whether the razor cartridge or blade is attached to the body of the razor or has been removed therefrom. The usefulness of the device is not limited to cleaning razor blades only, but this invention is also capable of cleaning the entire body of the razor, or other items, from accumulated debris over a period of use.
[0013] In the following, we shall refer to water and the cleaning fluid interchangeably, with the understanding that this invention is capable of using a variety of cleaning fluids, even including compressed gases, instead of, or in addition to, water.
[0014] In a preferred embodiment of this invention a set of batteries supply power to an electric motor driving a pump. Water is stored in a compartment within the device, and is forced by the pump through an opening in the wall of the device. This opening, by manipulation of the device, can easily and advantageously be directed at the specific locations of hair and lather accumulation in the razor. The battery-motor combination allows the device to be extremely small in size and self-sufficient in regards to energy needs. The water holding compartment and the small size of the device increase its portability. The pressure that the motor generates can advantageously and controllably produce a high velocity stream of water, with high cleaning effectiveness, such that smaller amounts of water and shorter times are necessary to thoroughly clean a razor.
[0015] In a second embodiment of this invention a set of batteries supply current to an electric motor driving a pump, which is immersed in water. The pump is forcing water through flexible tubing having one open end. This open end can easily and advantageously be directed at the specific locations of hair and lather accumulation in the razor. The battery-motor combination allows the device to be extremely small in size, and self-sufficient in regards to energy needs. The small size of the device permits its placement in an open container as small as a drinking cup. The pressure that the motor generates can advantageously and controllably produce a high velocity stream of water, with high cleaning effectiveness, such that smaller amounts of water and shorter times are necessary to thoroughly clean a razor.
[0016] In a third embodiment of the invention a spring located within the proximal end of a water chamber is driving a piston that moves within said water chamber. On the distal end of the water chamber a nozzle, or flexible tubing terminating in a nozzle, is attached. In operation the user preloads the spring by pulling onto a plunger connected to the piston. This action also may be used to fill the water chamber with water through the nozzle. Once the spring is preloaded, it can be controllably released via a mechanical trigger that acts directly onto the plunger, or via a valve advantageously located near the nozzle or at the distal end of the water chamber. This design combines the operation of preloading and filling the device with water in one step. Operating costs of this embodiment are minimal.
[0017] A variety of other embodiments are within the scope of the present invention. By way of example such an embodiment may comprise a miniature compressed gas cylinder which is attached to the main body of the device via a quick disconnect valve, and forces water contained in a chamber within the device, through a nozzle. The nozzle may be attached to the main body of the invention either directly or through flexible tubing. Means for controlling the pressure and flow of the water may advantageously be located near the nozzle and, optionally, between the compressed gas cylinder and the water chamber.
[0018] In yet another embodiment of the invention a manual pump and pressure chamber may replace the compressed gas cylinder. The user at first uses the pump to drive and pressurize air into the pressure chamber. Then operation continues as in the previous embodiment. This design eliminates the dependency on the availability of a compressed gas cylinder, and has lower operating costs.
[0019] These embodiments of the invention describe a miniature, flexible, self-contained, and very portable system, with improved cleaning and water usage efficiency over systems described in the prior art. All these embodiments can operate independently of faucet design and employ a maneuverable nozzle, which advantageously permits directing the water jet to the specific locations of the razor with hair and lather accumulation. The designs describe a single nozzle, but a multiple-nozzle design is also within the scope of this invention.
[0020] Although the invention has been presented herein in terms of specific embodiments, a person skilled in the art will realize that several other variations are possible and are within the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings, wherein:
[0022] [0022]FIG. 1 is a cross-sectional view of a self-contained, motor-driven razor cleaner;
[0023] [0023]FIG. 2 is a cross-sectional view of an immersion-type, motor-driven razor cleaner having a flexible output tube;
[0024] [0024]FIG. 3 is an isometric view of an immersion-type, motor-driven razor cleaner;
[0025] [0025]FIG. 4 is a cross-sectional view of a tabletop, AC motor-driven razor cleaner, having flexible intake and output tubes;
[0026] [0026]FIG. 4A is a cross-sectional view of a motor-driven razor cleaner, wherein the free end of the intake tube has a weight attached;
[0027] [0027]FIG. 4B depicts a clip and ring system for attaching an intake tube to a cleaning fluid container.
[0028] [0028]FIG. 5 is a cross-sectional view of a manually-operated razor cleaner;
[0029] [0029]FIG. 6 is a detail cross-sectional view of a nozzle;
[0030] [0030]FIG. 6A is a detail cross-sectional view of a nozzle, having turbulence-generating internal wall features;
[0031] [0031]FIG. 6B is a detail cross-sectional view of a nozzle, having splash guards;
[0032] [0032]FIG. 7 is an isometric view of an AC operated, tabletop, motor-driven razor cleaner, having conditioning electronics, a collapsible chamber for holding cleaning fluid, and a multi-output nozzle design;
[0033] [0033]FIG. 8 is an isometric view of a charging station, and a motor-driven razor cleaner having rechargeable batteries;
[0034] [0034]FIG. 9 is a cross-sectional view of a manually-operated razor cleaner, having a brake for controlling the flow of cleaning fluid;
[0035] [0035]FIG. 10 is a cross-sectional view of a nozzle having a flow control valve.
[0036] For the convenience of the reader, below is a list of reference numbers associated with the figures.
Ref. Number Component 10 Housing 15 Clearance Bump 20 Motor 25 Motor Shaft 30 Holding Chamber 35 Cleaning Fluid Container 36 Cleaning Fluid 40 Battery 45 Pump Cavity 50 Impeller 60 Pump Intake Port 70 Pump Output Port 75 Nozzle 76 Nozzle Input Aperture 77 Nozzle Output Aperture 78 Roughened Interior Wall of Output Aperture 79 Splash Guard 80 Pump Seal 90 Intake Channel 100 Switch 110 Switch Cover 120 Negative Wire 121 Neutral Wire 125 Positive Wire 126 Hot Wire 130 Battery Chamber Cover 140 Negative Contact 150 Vent 160 Holding Chamber Cover 170 Vent Valve 180 Battery Chamber 190 Positive Contact 200 Flexible Output Tube 210 Free End of Flexible Output Tube 220 Attached End of Flexible Output Tube 230 Flexible Intake Tube 240 Free End of Flexible Intake Tube 245 Weight 247 Clip 248 Ring 250 Attached End of Flexible Intake Tube 260 Plunger 270 Piston 280 Spring 290 Electric Cable 300 Electric Plug 310 Charging Base 320 Conditioning Electronics 350 Valve Actuator 360 Actuator Port 370 Actuator Spring 380 Valve Input Aperture 390 Valve Output Aperture 400 Brake Mechanism 410 Brake Handle 420 Brake Plate 430 Brake Spring 440 Pivot Pin 450 Brake Support Structure 460 Brake Plate Opening
DETAILED DESCRIPTION OF THE INVENTION
[0037] The following description is of the best modes presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
[0038] [0038]FIG. 1 depicts a cross section of a preferred embodiment of this invention, comprising a Housing 10, having a Holding Chamber 30, for holding cleaning fluid. The Holding Chamber 30, has a Holding Chamber Cover 160, having a Vent 150, and a Vent Valve 170, and is fluidly communicating with a Pump Intake Port 60, via an Intake Channel 90. The Pump Intake Port 60, leads to a Pump Cavity 45, which houses an Impeller 50. The Pump Cavity 45, also has a Pump Output Port 70, which forms the output of the system.
[0039] The Impeller 50, is mechanically connected to a Motor 20, via a Motor Shaft 25. A Pump Seal 80, around said Motor Shaft 25, separates the Pump Cavity 45, from said Motor 20, and prevents cleaning fluid from flowing towards the Motor 20.
[0040] Said Motor 20, is electrically connected to Batteries 40, residing in a Battery Chamber 180, within said Housing 10, via a Positive Contact 190, a Switch 100, a Positive Wire 125, a Negative Wire 120, and a Negative Contact 140, such that the Switch 100, controls the flow of electrical current through the Motor 20. Said Negative Contact 140, is attached to a Battery Chamber Cover 130, said Battery Chamber Cover 130, forcing the Batteries 40, against themselves and the Negative Contact 140, and the Positive Contact 190, thereby maintaining good electrical connection between said components.
[0041] A flexible Switch Cover 110, preferably made by an elastomeric material, is attached to the Housing 10, and environmentally protects the Switch 100.
[0042] The Switch 100, is preferably a push-on momentary switch, but other types of switches, including toggle types may be used.
[0043] Wherein, in operation, a user first fills the Holding Chamber 30, with cleaning fluid, and then closes the Holding Chamber 30, using the Holding Chamber Cover 160. Then the user operates the Switch 100, by depressing the Switch Cover 110, thus activating the Motor 20. The Motor 20, pumps cleaning fluid from the Holding Chamber 30, and expels it through the Pump Output Port 70. The user, by manipulating the entire device, may then direct the stream of cleaning fluid thus generated, at locations of shaving residue accumulation in the razor, cleaning said razor. The Holding Chamber Cover 160, prevents cleaning fluid from flowing outside the Holding Chamber 30, while the device is manipulated by the user. The Vent Valve 170, is preferably a thin elastomeric leaf, such as one made of silicone rubber, of generally rectangular shape, having three free sides and having a fourth side attached to the inside surface of the Holding Chamber Cover 160, extending over the opening of the Vent 150. The Vent Valve 170, is thus able to maintain atmospheric pressure within the Holding Chamber 30, by allowing air to enter, while keeping cleaning fluid from flowing out of the Holding Chamber 30. Other valve designs, commonly known as check valves, essentially accomplishing the same task, may be used in lieu of the aforementioned valve design.
[0044] [0044]FIG. 2 depicts a different embodiment of the invention, of the immersion type, wherein the invention comprises a Housing 10, having a Motor 20, mechanically connected to an Impeller 50, residing in a Pump Cavity 45, via a Motor Shaft 25. A Pump Seal 80, around the Motor Shaft 25, keeps fluids from entering the Motor 20.
[0045] The Pump Cavity 45, has a Pump Intake Port 60, connected to the outside via an Intake Channel 90, and a Pump Output Port 70, fluidly communicating with a Flexible Output Tube 200, having an Attached End 220, attached to the Housing 10, and a Free End 210, open to the outside.
[0046] The motor is electrically connected to Batteries 40, residing in a Battery Chamber 180, via a Positive Wire 125, a Switch 100, a Positive Contact 190, a Negative Contact 140, and a Negative Wire 120, such that the Switch 100, controls the flow of electrical current through the Motor 20. Said Negative Contact 140, is attached to a Battery Chamber Cover 130, said Battery Chamber Cover 130, forcing the Batteries 40, against themselves and the Negative Contact 140, and the Positive Contact 190, thereby maintaining good electrical connection between said components.
[0047] The Switch 100, is advantageously located in the bottom of the Housing 10, and operated by the weight of said Housing 10. The Switch 100, is preferably a push-on momentary switch, but other types of switches, including toggle types may be used.
[0048] Said Battery Chamber Cover 130, environmentally protects the Battery Chamber 180, preventing liquids from entering the Battery Chamber 180, whereas a flexible Switch Cover 110, attached to the Housing 10, environmentally protects the Switch 100.
[0049] [0049]FIG. 3 depicts an isometric view of the immersion-type device, having Clearance Bumps 15, at the bottom of the Housing 10, which Clearance Bumps 15, facilitate the flow of cleaning fluid into Intake Channel 90. Furthermore, in this variation the Switch Cover 110, protecting the Switch 100, is at the top of said Housing 10. Finally, the Flexible Output Tube 200, terminates in a Nozzle 75, attached at the Free End 210, of said Flexible Output Tube 200.
[0050] Wherein, in operation, a user fills a Cleaning Fluid Container 35, such as a small drinking cup, with Cleaning Fluid 36, and immerses the device within said Cleaning Fluid Container 35. Whereas the Switch 100, is at the bottom of the Housing 10, the device will automatically operate, else the user will depress the Switch Cover 110, activating the device. Upon such activation, the Motor 20, rotates the Impeller 50, forcing the Cleaning Fluid 36, into the device through the Intake Channel 90, and expelling it through the Free End 210, of the Flexible Output Tube 200, or through the Nozzle 75, in the form of a powerful jet. The user, by manipulating the Free End 210, of the Flexible Output Tube 200, may then direct the stream of cleaning fluid thus generated, at locations of shaving residue accumulation in the razor, cleaning said razor.
[0051] Other variations of the invention exist, such as depicted in FIG. 4. This variation is a countertop device, comprising a Housing 10, having a Motor 20, mechanically connected to an Impeller 50, residing in a Pump Cavity 45, via a Motor Shaft 25. A Pump Seal 80, around the Motor Shaft 25, keeps fluids from entering the Motor 20.
[0052] The Pump Cavity 45, has a Pump Intake Port 60, fluidly communicating with an Attached End 250, of a Flexible Intake Tube 230, via an Intake Channel 90, said Flexible Intake Tube 230, also having a Free End 240 open to the outside. Said Pump Cavity 45 furthermore has a Pump Output Port 70, fluidly communicating with a Flexible Output Tube 200, having an Attached End 220, attached to the Housing 10, and a Free End 210, open to the outside.
[0053] Said Motor 20, is electrically connected to an Electric Plug 300, via an Electric Cable 290, a Hot Wire 126, a Switch 100, and a Neutral Wire 121, whereby, when the Electric Plug 300 is plugged into a wall outlet, and the Switch 100, operated, electric current flows through the Motor 20.
[0054] A flexible Switch Cover 110, protects the Switch 100, from splashes of liquid and other debris.
[0055] In operation, a user fills a small container such as a drinking cup with cleaning fluid, and immerses the Free End 240, of said Flexible Intake Tube 230, within such cleaning fluid. Then the user plugs in the device and runs the Motor 20, by activating the Switch 100. The Motor 20, rotates the Impeller 50, which forms a self-priming pump within said Pump Cavity 45, and forces cleaning fluid into the Free End 240, of said Flexible Intake Tube 230, expelling it through the Free End 210, of said Flexible Output Tube 200, forming a powerful jet of cleaning fluid. The user, by manipulating the Free End 210, of said Flexible Output Tube 200, may then direct the stream of cleaning fluid thus generated, at locations of shaving residue accumulation in the razor, cleaning said razor.
[0056] [0056]FIG. 4A shows a variation of the device depicted in FIG. 4, wherein the Free End 240, of said Flexible Intake Tube 230, has a Weight 245, attached, wherein said Weight 245, ensures proper immersion of the Free End 240, of said Flexible Intake Tube 230, within the cleaning fluid.
[0057] [0057]FIG. 4B shows another example of securing the Flexible Intake Tube 230, to a Cleaning Fluid Container 35, and ensuring that the Free End 240, of said Flexible Intake Tube is immersed within the Cleaning Fluid 36. A Clip 247, having an attached Ring 248, is placed on the lip of said Cleaning Fluid Container 35, such that the Ring 248, hangs on the inside of said Cleaning Fluid Container 35. The Flexible Intake Tube 230, is threaded through said Ring 248, and the Free End 240, of the Flexible Intake Tube 230, is immersed in said Cleaning Fluid 36. Said Clip 247, with said attached Ring 248, could be an integral part of said Flexible Intake Tube 230, with the Clip 247, and its attached Ring 248, being slidably adjustable along said Flexible Intake Tube 230. Other methods of attachment, such as magnetic attachment of the Flexible Intake Tube 230, to the Cleaning Fluid Container 35, are also within the scope of the present specification.
[0058] [0058]FIG. 5 depicts a manually operated embodiment of the invention, wherein a Housing 10, has a Holding Chamber 30, of generally cylindrical shape, wherein a Piston 270, attached to a Plunger 260, is moving freely. A Spring 280, is biasing the Piston 270, toward the front end of said Holding Chamber 30, said front end forming a Nozzle 75, having a Nozzle Input Aperture 76, and a Nozzle Output Aperture 77, open to the outside. In operation, a user immerses the nozzle in cleaning fluid and withdraws the Piston 270, by pulling back the Plunger 260. This action compresses the Spring 280, and fills the Holding Chamber 30, with cleaning fluid. The user subsequently releases the Plunger 260, and the Spring 280, forces the Piston 270, forward, expelling fluid in a powerful stream through the Nozzle Output Aperture 77. The user, by manipulating the entire device, may then direct the stream of cleaning fluid thus generated, at locations of shaving residue accumulation in the razor, cleaning said razor.
[0059] The nozzle design and/or use is not limited to the specific embodiments described thus far. By way of example, a Nozzle 75, could be attached to the Pump Output Port 70, of the self-contained device described in conjunction with FIG. 1. FIG. 6A depicts such an embodiment. FIG. 6B depicts a similar embodiment, wherein the Nozzle 75, has Roughened Interior Walls 78, advantageously inducing a turbulent flow, which more effectively cleans razors with the inherent sudden velocity variations within the turbulent stream of cleaning fluid. FIG. 6C depicts a Nozzle 75, having a Splash Guard 79, preferably of sufficient size to contain the entire razor head. Said Splash Guard 79, controls splashes of cleaning fluid as it is deflected by the razor, and may be rigid or flexible, permanently attached to the Nozzle 75, or removable, or having features to attach directly to Housing 10.
[0060] [0060]FIG. 7 is an isometric view of a countertop embodiment of the invention, wherein the Flexible Output Tube 200, terminates in a Nozzle 75, having multiple Nozzle Output Apertures 77. Furthermore, the Flexible Intake Tube 230, is connected to the Holding Chamber Cover 160, of a Holding Chamber 30, said Holding Chamber 30, advantageously having collapsible walls. Additionally, an Electric Cable 290, has Conditioning Electronics 320, attached to its end, wherein, in operation a user fills the Holding Chamber 30, with cleaning fluid, and attaches the Flexible Intake Tube 230, to said Holding Chamber 30, by means of the Holding Chamber Cover 160. Then the user depresses the Switch Cover 110, operating the device. The Conditioning Electronics 320, reduce the electric outlet voltage to a safe level, and may also perform an AC/DC conversion. Although the Conditioning Electronics 320, are depicted attached at the free end of the Electric Cable 290, they alternatively may reside within the Housing 10.
[0061] The collapsible walls of Holding Chamber 30, collapse as the cleaning fluid is removed from the Holding Chamber 30, thus eliminating the need for a vent valve for venting said Holding Chamber 30.
[0062] Yet another embodiment of the invention comprises rechargeable batteries enclosed within the Housing 10. For example, the device depicted in FIG. 8, may contain a rechargeable battery permanently installed within the Housing 10, or removable, a power coil, and conditioning electronics for charging the battery. A user would recharge the battery by placing the device within a Charging Base 310, having a matching power coil, and an Electric Cable 290, connected to an Electric Plug 300, and plugging the Electric Plug 300, into a wall outlet. The use of such methods for charging rechargeable batteries is well known in the art.
[0063] [0063]FIG. 9 is a cross-sectional view of a variation of the manually-operated embodiment shown in FIG. 5, wherein this variation has means for controllably releasing a stream of cleaning fluid. Said means comprise a Brake Mechanism 400, having a Brake Handle 410, rigidly attached to a Brake Plate 420, said Brake Plate 420, having an Opening 460. Said Brake Mechanism 400, pivots about a Pivot Pin 440, attached to a Brake Support Structure 450. Said Brake Support Structure 450, is rigidly attached to the Housing 10. A Brake Spring 430, is biasing the Brake Handle 410, in a clockwise direction with reference to FIG. 9, and away from the Housing 10. This action of the spring rotates the Brake Plate 420, thereby rotating the Opening 460, such that the internal walls of the Opening 460, interfere with the Plunger 260. When the user withdraws the Plunger 260, compressing the spring, the shape of the Opening 460, and its position relative to the Pivot Pin 440, force the Brake Mechanism 400, to rotate slightly counterclockwise and allow movement of the Plunger 260. Upon release of the Plunger 260, the frictional forces generated by the interference between the Plunger 260, and the internal walls of the Opening 460, further tend to rotate the Brake Mechanism 400, clockwise, increasing the interference, effectively locking the Plunger 260, and preventing its motion. To release the Plunger 260, and expel cleaning liquid from the Nozzle 75, the user slightly depresses the Brake Handle 410, removing the interference. Upon release of the Brake Handle 410, the Brake Spring 430, biases the Brake Mechanism 400, clockwise again, thereby stopping the plunger once more, stopping the ejection of cleaning fluid.
[0064] Whereas a specific brake mechanism is described herein, several other brake mechanisms and other methods of controlling the flow of cleaning fluid may be implemented and are within the scope of the present invention. By way of example, FIG. 10 depicts a cross-sectional view of a flow control valve located in the Nozzle 75, separating the Nozzle Input Aperture 76 from the Nozzle Output Aperture 77. The valve comprises walls having a Valve Input Aperture 380, and a Valve Output Aperture 390. Within the valve a Valve Actuator 350, having an Actuator Port 360, is allowed to move. An Actuator Spring 370, biases the Valve Actuator 350, such that the Actuator Port 360, the Valve Input Aperture 380, and the Valve Output Aperture 390, are misaligned, thereby preventing the flow of cleaning fluid through the valve. When the pressurizing means of the razor cleaning device is activated, a user depresses the Valve Actuator 350, thereby aligning the Actuator Port 360, the Valve Input Aperture 380 and the Valve Output Aperture 390, permitting the flow of cleaning fluid from the Nozzle Input Aperture 76 to the Nozzle Output Aperture 77. Upon release of the Valve Actuator 350, the Actuator Spring 370, biases the Valve Actuator 350, in a position of misalignment, thereby stopping the flow of cleaning fluid.
[0065] The valve described herein is commonly known in the art as a gate valve. Other types of valves may be used instead, such as a ball valve, a needle valve, a valve wherein a flexible tube gets pinched thereby controlling the flow of fluid, etc.
[0066] Whereas the invention has been described herein in terms of specific embodiments, persons skilled in the art will readily recognize that many more embodiments are possible and fall within the scope of this invention. For example, all combinations of all features of each embodiment with each other embodiment will result in a multitude of new embodiments which all fall within the scope of this invention. Furthermore, a variety of other features, may be added or substitute existing features in each embodiment. By way of example, pressurizing means may include a pressurized gas cylinder able to attach to the Housing 10, by means of quick disconnect valves, or a manual pump and a pressure chamber, in fluid communication with the Holding Chamber 30. In such embodiments means for controlling the gas pressure may be included. The flow valve may be placed within the Housing 10, instead of in the Nozzle 75. The electrical switch may be substituted by an optoelectronic switch, or Hall effect switch, or a Reed switch. The switch may be placed near the Free End 210, of the Flexible Output Tube 200. Alternatively, such embodiments may have no switch at all, operating the moment that are plugged into the wall, or the batteries installed, for example. Also, the rechargeable batteries may be recharged by photoelectric cells, attached to the Housing 10, or in a separate module that the device is plugged in after each use. Therefore, the scope of this invention should be determined in reference to the claims, herein.
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A device for cleaning razors uses a variety of pressurizing means to force water or other cleaning fluid contained in an external container or in a chamber within the device, through a maneuverable nozzle. The maneuverability of the nozzle allows the user to direct the jet of water or other cleaning fluid to areas of the razor that are filled with lather and hair particles, and quickly and efficiently clean the razor. Means for controlling the water flow may be included and preferably located near the nozzle.
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BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,798,923 to Pink et al. discloses a power driven ice dispenser which discharges ice down a chute through the front of a freezer-refrigerator while the co-pending application of John J. Pink, Ser. No. 433,901, filed Jan. 16, 1974 is directed to an improved version of that dispenser. In both those instances, the lower end of the chute is closed by an outwardly swinging door hinged along its top which is opened when a depending actuating lever is pushed rearwardly, the lever also starting the dispenser at the same time. When the lever is released, the door is closed and the dispenser is shut off. Obviously some ice could be trapped in the chute after the dispenser ceases if closing of the door is not delayed a few seconds to allow the chute to clear. If ice is trapped in the chute or between it and the door, it will slowly melt, making a mess in both instances, and in the case of the latter instance, will also allow warm, moist air up into the dispenser and frost up the chute and other parts.
Various schemes have been used, in other arrangements for dispensing ice down a chute through the front of a freezer-refrigerator, to delay closing of the door in the circumstances explained above. But these tend to be elaborate and piecemeal as well as requiring considerable space. Their reliability may also be suspect. Hence, the primary object of the present invention is the provision of a compact, neat and reliable mechanism to delay closing the door at the lower end of the chute until it has been emptied of all ice from the dispenser after the latter is shut off.
SUMMARY OF THE INVENTION
In the present invention, the door is spring-loaded to its closed position and the activating lever separately spring-loaded to its forward position. When the lever is pushed rearwardly, closing a switch to start the dispenser, at the same time it opens the door against the spring loads of both the door and the lever. When the lever is released, it alone immediately returns to its forward position. The closing of the door, however, is delayed owing of the action of an inertia motor.
The motor comprises a gear train with a very high step up ratio from its input shaft, which is connected to the door, to its output shaft which drives a small fly wheel. A slip clutch, in effect, disconnects the input shaft from the fly wheel when the door is opened so that the motor does not impede door opening. But when the spring load of the door later attempts to close it, the gear train and fly wheel act to resist closing a sufficient time for the chute to clear itself of ice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial isometric view of a fixed panel which closes a portion of the front of the freezer compartment in a typical side by side refrigerator-freezer, certain portions being broken away to show the ice discharge chute, its door when closed, the activating lever, the inertia motor and other parts of the apparatus.
FIG. 2 is similar to FIG. 1, but illustrates the door in its open position.
FIG. 3 is a detail view taken along the line 3--3 of FIG. 1.
FIG. 4 is a partially exploded view of the inertia motor itself, certain portions being broken away to illustrate its details.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1, 10 depicts the fixed panel or closure, as shown in the aforementioned patent and application, across the front of the freezer compartment of a typical side by side freezer refrigerator, the door closing the portion of freezer compartment above the panel 10 being indicated at 11 and the door for the adjacent refrigerator compartment being indicated at 12. Behind the panel 10 is disposed the power driven ice dispenser 13, which is closed over by a shelf plate 14, in the freezer compartment. Fitting up into a pocket 15 in the upper portion of the panel 10 is a laterally extending, integrally molded mounting assembly 20 having adjacent recesses 21 and 22 separated by a vertical mullion 23 to the front of which is secured a plate 24 carrying a lamp 25 for purposes of illumination. The recess 21 carries the dispensing mechanism (not shown) for chilled water, while recess 22 includes a downwardly leading ice chute 26 (see FIGS. 2 and 3), molded integrally with the assembly 20, which leads from the ice dispenser 13 into the panel pocket 15.
The lower end of the chute 26 is closed by a door 27, over whose edges is fitted and retained an elastomeric gasket 28 flanged at 29 so that the door 27 will seal against the chute 26. The outer face of the door 27 is clipped at 30 to a wire-formed hinge assembly 31 having two rearward legs 31a bent toward each other at 31b. The ends 31b are pivoted beneath retainers 32 screwed to suitable bosses 32a, integral with the top wall 26a of the chute 26, to provide a hinge for the top of the door 27. The latter is biased toward its closed position by a suitable spring 33 about one of the hinge legs 31b. The door is opened by a vertical lever 34 having a depending bar and cross member 35 adapted to be engaged by a container to be filled with ice. The upper portion of the lever 34 is formed as a yoke having side legs 36 straddling the door 27 and connected across their top ends by a bar 37. The outer faces of the lower ends of the yoke legs 36 are provided with trunnions 38 (See FIG. 3) on which the lever is pivoted in the adjacent side walls of the recess 22, a suitable spring 39 biasing the lever 34 to its forward position shown in FIG. 1. Toward the upper ends of the yoke legs 36 and to the inner faces of the latter are attached a pair of cylindrical knobs 40 which engage the rear of the hinge side members 31a just below the hinge legs 31b. Hence, when the cross member 35 is pushed rearwardly by a container, the door 27 is opened as shown in FIG. 2 against the resistance of both springs 33 and 39. At the same time, the upper cross bar 37 is moved forwardly to close a switch 41 secured to the top of the recess 22 in order to actuate the ice dispenser 13.
One member of the hinge assembly 31 is laterally extended toward the adjacent side wall of the recess 22 and bent in order to form a crank arm 42. The latter slides in an elongated slot 43 inwardly from the outer end of an arm 44 fixed at its inner end to the input shaft 45 of an inertia motor M. The motor M is enclosed by a cupped housing 46 and secured by a back plate 47 to a boss 48 in the recess 22 between the outer side wall of the latter and the chute 26. Basically, the motor M is an adaptation of a gear train from a timer and comprises a series of step-up gears G1-10 all journalled between two spaced mounting plates 49 and 50 separated by stools 51. The output shaft 52 from the gear G10 passes through the plate 50 and to its outer end is fitted a small flywheel F. The motor M is manufactured by Bristol Saybrook Company of Old Saybrook, Connecticut, and the step-up ratio between its input and output shafts 45 and 52 is 1:3,600. A small slip clutch mechanism 53 is interposed between gears G2 and G3 so that the gears G3-10 and the flywheel F are not driven when the input shaft 45 is rotated in the direction indicated by the arrow A, but are driven when the shaft is rotated in the direction indicated by the arrow B. When the lever 34 is pushed to open the door 27, the crank arm 42 rotates the shaft arm 44 and input shaft 45 in the direction A so that the motor M offers little resistance to the opening of the door 27. When the lever 34 is released, its spring 39 returns it immediately to its normal position independently of the door 27. The motor M, however, since its input shaft is being rotated in direction B and thus all the gears G1-10 and the flywheel F are being driven, delays the closing of the door 27 despite its spring 33 so that all the ice in the chute 26 can escape before the door 27 finally closes.
Through the present invention has been described in terms of a particular embodiment, being the best mode known of carrying out the invention, it is not limited to that embodiment alone. Instead, the following claims are to be read as encompassing all adaptations and modifications of the invention falling within its spirit and scope.
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A power driven ice dispenser in a freezer-refrigerator or the like discharges ice down a chute through the front of the unit. The chute is closed by a spring-loaded door opened by a lever. When the lever is released, an inertia motor delays closing of the door until the chute is emptied of ice.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent Applications No. 2004-312207 and No. 2004-312208, filed on Oct. 27, 2004, the contents of which are hereby incorporated by reference into the present application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus for ejecting droplets.
[0004] 2. Description of the Related Art
[0005] The apparatus for ejecting droplets is used in various technical fields. For example, an ink jet printer uses a printing head that ejects ink droplets toward a printing sheet. There is known a machine for forming a printed circuit board by ejecting droplets made of conductive material towards an insulating board. There is also known a machine for coating an adhesive layer by ejecting droplets made of adhesive material towards an object to be adhered. A machine for fabricating a three dimensional model by ejecting molten resin droplets towards the three dimensional model under construction is also known. These machines commonly use the apparatus for ejecting droplets.
[0006] An apparatus for ejecting droplets in which an ejecting head and an electric circuit board are combined is disclosed in Japanese Laid-Open Patent Application Publication 2003-63042. The ejecting head and the electric circuit board are connected by means of a cable, and the ejecting head and the electric circuit board are fixed to each other.
[0007] In use of the apparatus for ejecting droplets, there is a possibility that liquid droplets reach a point where the cable and the electric circuit board are connected. When the contacting point between the cable and the electric circuit board becomes wet, there is a possibility that the electric circuit will be short-circuited or that smoke will be produced. Accordingly, technology has been proposed which covers the contacting point between the cable and the electric circuit board with a liquid absorbent elastic member. When the apparatus for ejecting droplets is mounted on the machine, the liquid absorbent elastic member will be interposed between the apparatus for ejecting droplets and the machine, and the liquid absorbent elastic member reliably covers the contacting point between the cable and the electric circuit board.
BRIEF SUMMARY OF THE INVENTION
[0008] When liquid droplets are discharged from the ejecting head, not only will primary droplets be ejected toward an object, but there will be times in which more microscopic liquid droplets will also be generated to form a cloud, i.e., an mist, that will float.
[0009] The mist can pass through even narrow gaps. Because of this, there are times in which the mist generated by the ejecting head in a conventional apparatus for ejecting droplets will reach the electric circuit board covered by the liquid absorbent elastic member. As a result, the mist may adhere to the electric circuit to short the electric circuit, and cause damage of the electric circuit of the apparatus for ejecting droplets.
[0010] An object of this invention is to obtain an apparatus for ejecting droplets that can prevent mist that is generated when the ejecting head discharges droplets from adhering to an electric circuit of the apparatus for ejecting droplets.
[0011] An apparatus for ejecting droplets of the invention comprises an ejecting head, an electric circuit board, a holder, a cover, and a seal member. The ejecting head discharges droplets. The electric circuit board has an electric circuit formed on a top surface of the electric circuit board. The electric circuit is connected to the ejecting head. The holder supports the ejecting head and the electric circuit board. The holder has an opening. When the cover is fixed to the holder, the cover overlaps the top surface of the electric circuit board. The seal member fills at least a part of a gap formed between a peripheral region of the top surface of the electric circuit board and an inner surface of the cover.
[0012] When the cover is fixed to the holder in the aforementioned apparatus for ejecting droplets, the top surface of the electric circuit board will be protected by the cover, and the electric circuit formed on the top surface of the electric circuit board will be sheltered from the mist. Because it is unavoidable that a gap is formed between the inner surface of the cover and the top surface of the electric circuit board, it is possible for the mist to penetrate into the gap, however, because at least a part of the gap is sealed by means of the seal member, the mist will be prevented from penetrating into the gap. The mist can be prevented from adhering to the electric circuit.
[0013] A cable is connected to the electric circuit board. The cable is folded within the holder. Because of this, a force that pushes out the electric circuit board from the holder will be applied to the electric circuit board due to the resilient force of the cable. The force applied to the electric circuit board is not uniform, but rather differs depending on a location within the electric circuit board.
[0014] In the event that a force that pushes out the electric circuit board is applied from the holder to the electric circuit board, and that force differs depending on the location within the electric circuit board, then when one attempts to uniformly compress the seal member disposed along the periphery of the electric circuit board, a large force must be applied between the cover and holder and the cover and the holder must be fixed with the large force. In this situation, there will be a problem in which the cover and/or the holder may deform. When the cover is deformed, the function of protecting the electric circuit from the mist by means of the cover and the seal member will be damaged. When the holder is deformed, problems will occur in which the position of the ejecting head that is supported by the holder will change, and the discharging direction of the droplets discharged from the ejecting head will shift, and the like.
[0015] An additional and optional object of the present invention is to achieve a structure in which a seat member that fills the gap between the cover and the electric circuit board is compressed only the amount needed for shielding by fixing the cover and the holder with a comparatively light force that does not deform the cover and the holder.
[0016] An apparatus for ejecting droplets developed for achieving this optinal object for providing the better sealing performance, further comprises a support member, a biasing member, and a local pressing member. The support member is provided within the holder to support a bottom face of the electric circuit board. The biasing member applies a force to the electric circuit board in a direction to separate the electric circuit board from the support member. The local pressing member is formed at an area corresponding to a part of the peripheral region of the electric circuit board. When the cover is fixed to the holder, the local pressing member presses the seal member more tightly at the area where the local pressing member is formed than the rest of the area where the local pressing member is not formed.
[0017] When a local pressing member is used, the seal member that fills the gap between the cover and the electric circuit board is compressed only the amount needed for shielding by fixing the cover and the holder with the comparatively light force. The electric circuit board can be protected from the mist at the same time that the discharging direction of the droplets can be maintained in the correctly aimed direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a schematic plan view of an ink jet printer according to the best mode for carrying out the invention.
[0019] FIG. 2 shows an oblique view of a state in which a cover and an electric circuit board have been removed from an ink jet head unit of the first embodiment.
[0020] FIG. 3 shows a partial cross-sectional view of the ink jet head unit of the first embodiment.
[0021] FIG. 4 shows the A-A cross-sectional view of FIG. 3 .
[0022] FIG. 5 shows an oblique view of an aspect in which a cover and an electric circuit board have been removed from an ink jet head unit of the second embodiment.
[0023] FIG. 6 shows a partial cross-sectional view of the ink jet head unit of the second embodiment.
[0024] FIG. 7 shows the A-A cross-sectional view of FIG. 6 .
[0025] FIG. 8 shows a cross-sectional view of the process of installing an electric circuit board and a cover into a holder of the second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Next, the best mode for carrying out the invention will be described with reference to the figures. In this embodiment, the present invention is applied to an ink jet head unit. The ink jet head unit is one example of an apparatus for ejecting droplets of the invention. The apparatus for ejecting droplets is not limited to the ink jet head unit. The ink jet head unit uses a printing head or an ink jet head. The printing head or the ink jet head is one example of an ejecting head of the invention. The ejecting head is not limited to the printing head or the ink jet head.
[0000] (Primary Structure of the Ink Jet Printer)
[0027] First, the primary structure of an ink jet printer 1 of this embodiment will be described with reference to FIG. 1 . FIG. 1 is a plan view showing the primary structure of the ink jet printer 1 .
[0028] Two guide shafts 6 , 7 are arranged in the interior of the ink jet printer 1 , and an ink jet head unit 99 that is also used as a carriage is installed on the guide shafts 6 , 7 . An ink jet head 30 that discharges ink droplets toward a printing sheet P to perform recording is secured on the ink jet head unit 99 . The ink jet head unit 99 is attached to an endless belt 11 that rotates by means of a motor 10 . By rotating the motor 10 , the ink jet head unit 99 will move along the guide shafts 6 , 7 . Note that a known timing guide member (not shown in the figures) is provided that extends as a strip along the guide shaft 7 , and marks for detecting the position of the ink jet head unit 99 are inscribed on the timing guide member.
[0029] The interior of the main unit of the ink jet printer 1 comprises an ink tank 5 a in which yellow ink is stored, an ink tank 5 b in which magenta ink is stored, an ink tank 5 c in which cyan ink is stored, and an ink tank 5 d in which black ink is stored. Each respective ink tank 5 a - 5 d is connected with a tube joint 20 of the ink jet head unit 99 by means of flexible tubes 14 a, 14 b, 14 c, 14 d. Each ink tank 5 a - 5 d is stationary in the interior of the ink jet printer 1 .
[0030] A flushing unit 12 is arranged on one end of the movement direction of the ink jet head unit 99 . A maintenance unit 4 is arranged on the other end of the movement direction of the ink jet head unit 99 . The ink jet head 30 will discharge undesirable ink that contains air bubbles to the flushing unit 12 in order to maintain the discharge characteristics of the ink in an optimal state. In addition, the maintenance unit 4 will draw in ink that contains air bubbles, wipe a nozzle surface of the ink jet head 30 , and maintain the discharge characteristics of the ink in an optimal state.
[0031] The printing sheet P is usually paper, but may also be a plastic sheet for use in an OHP, fabric, or the like. When the printing sheet P is a fabric, it may be sewn onto an article of clothing such as a T-shirt in advance.
[0000] (Primary Structure of the Ink Jet Head Unit)
[0032] Next, the primary structure of the ink jet head unit 99 will be described with reference to FIGS. 2 to 4 . FIG. 2 is an oblique view of a state in which an electric circuit board 84 and a cover 98 have been removed from the ink jet head unit 99 (the cover 98 is not shown in FIG. 2 , but is shown in FIGS. 3 and 4 ). FIG. 3 shows a partial cross-sectional view of the ink jet head unit 99 . FIG. 4 shows the A-A cross-sectional view of FIG. 3 .
[0033] Note that in the following description, the side that discharges ink is the lower surface and the downward direction, and the opposite side is the upper surface and the upward direction. In addition, when viewing the lower portion of the ink jet printer 1 in FIG. 1 , e.g., from the front, the left end side is the leftward direction, the right end side is the rightward direction, the lower part of the FIG. 1 is the forward direction, and the upper part of the FIG. 1 is the rearward direction.
[0034] As shown in FIG. 2 , the ink jet head unit 99 comprises a box-shaped holder 9 that is open on the upper surface thereof. As shown in FIG. 3 and FIG. 4 , the ink jet head 30 is secured to the lower surface of a bottom wall 9 e of the holder 9 .
[0035] As shown in FIG. 4 , the ink jet head 30 is a laminated structure composed of a flow path unit 31 having a plurality of ink flow paths, and a piezoelectric actuator unit 32 that selects an ink flow path from the plurality of the ink flow paths and applies a voltage thereto. A plurality of ink discharge nozzles is formed on the lower surface 31 a of the flow path unit 31 . The ink discharge nozzles for each ink color are arranged in a row. Ink flow ports 31 b ( FIG. 3 ) that are independent for each ink color are formed on the upper surface of the flow path unit 31 .
[0036] As shown in FIG. 4 , a frame-shaped reinforcement frame 33 is adhered and fixed to the upper surface of the ink jet head 30 . As shown in FIG. 3 , ink channels 33 a are formed in the reinforcement frame 33 . Each ink channel 33 a corresponds to each ink flow port 31 b. As shown in FIG. 4 , a unit composed of the ink jet head 30 and the reinforcement frame 33 is disposed along the lower surface of the bottom wall 9 e of the holder 9 , and is adhered and fixed to the holder 9 by means of an adhesive 91 that are injected into openings 90 formed through the bottom wall 9 e.
[0037] As shown in FIG. 3 , a buffer tank 40 is stored in a space within the holder 9 above the bottom wall 9 e of the holder 9 . Partitions 40 f ( FIG. 4 ) are formed inside the buffer tank 40 , and divide the buffer tank 40 into ink collection chambers 40 a that are independent for each ink color. An ink supply port 40 e ( FIG. 3 ) is formed in the lower surface of each ink collection chamber 40 a. The ink supply port 40 e for each color of ink communicates with each ink flow port 31 b via the ink channel 33 a for each color of ink.
[0038] As shown in FIG. 2 , the upper surface opening of each ink collection chamber 40 a ( FIG. 3 ) is covered with a flexible film member 41 . More specifically, the film member 41 is constructed of a resin film, and is fixed to the partitions 40 f that define each ink collection chamber 40 a ( FIG. 4 ) and the upper ends of the outer peripheral walls of the buffer tank 40 by means of adhesion, ultrasonic welding, or the like. A heretofore predefined quantity of air is stored in the upper portion of each ink collection chamber 40 a ( FIG. 3 ), and the pressure variations of the ink that accompany the scanning of the ink jet head 30 ( FIG. 3 ) are absorbed by means of the synergy between the air and the flexible film member 41 . Air that exceeds the aforementioned predefined quantity is exhausted to the exterior by means of an exhaust device 45 that is arranged on a lateral surface of the buffer tank 40 .
[0039] As shown in FIG. 4 , the exhaust device 45 comprises, for each color, a tubular case 45 b that communicates via an exhaust channel 45 a with the air in the upper portion of each ink collection chamber 40 a. Each tubular case 45 b comprises a valve 45 c that opens and closes the flow path in the interior thereof. The lower ends of the tubular cases 45 b are open in substantially the same plane as the lower surface 31 a of the ink jet head 30 , and when the ink jet head unit 99 has moved to one end of a scan, the valve 45 c will be opened by means of an operation member not shown in the figures, and air can be discharged from each ink collection chamber 40 a by connecting a drawing device (not shown) to the lower end openings of the tubular cases 45 b.
[0040] As shown in FIG. 3 , an attachment arm 9 a that extends horizontally forward is integrally formed with the holder 9 on the front end of the ink jet head unit 99 . A portion that extends horizontally over the attachment arm 9 a is formed on the front end of the buffer tank 40 , and the extended portion of the buffer tank 40 is configured as a tube joint 20 .
[0041] Each flexible tube 14 a - 14 d that extends from each ink tank 5 a - 5 d is respectively connected to the tube joint 20 by means of tube connection ports 21 a - 21 d ( FIG. 2 ).
[0042] A retaining member 29 is formed to project outward on the front end of the tube joint 20 . An electric circuit board 84 described below is electrically connected by means of a flexible flat cable 71 to a control device not shown in the figures that is arranged in a main control unit of the ink jet printer 1 . The flexible flat cable 71 is supported by passing it through a slit 29 a of the retaining member 29 ( FIG. 2 ).
[0043] As shown in FIG. 4 , an electric circuit board 84 made of a rigid material is disposed along an upper opening 9 x of the holder 9 . More specifically, the electric circuit board 84 is supported on the upper end of a wall that forms the holder 9 , and is removably fixed by means of the method described below. A horizontal space 9 g is provided between the electric circuit board 84 and the buffer tank 40 . Furthermore, a cover 98 is fixed so as to cover an upper portion of the electric circuit board 84 . The cover 98 is removably fixed to the holder 9 . In order to close the opening 9 x of the holder 9 from the outside, the cover 98 is formed into a box shape that has an opening in the lower portion, and hooks 9 r, 9 r that extend toward the inside are formed on the ends of the opening. The hooks 9 r, 9 r are engaged in recesses 9 s, 9 s that are arranged in positions that correspond to the outer side surfaces of the holder 9 . When the hooks 9 r, 9 r of the cover 98 are engaged in the recesses 9 s, 9 s of the holder 9 , the cover 98 will be fixed to the holder 9 . At this point, the seal members 87 , 88 described below will be compressed between the cover 98 and the electric circuit board 84 .
[0044] Electric components are attached to the lower spice 84 a of the left side of the electric circuit board 84 (the left side of FIG. 4 ) in a state in which they project outward. More specifically, as shown in FIG. 2 , a bypass condenser 81 , a sheet sensor 82 that detects the presence or absence of the printing sheet P, and an encoder 83 that reads the marks of the strip-shaped timing guide member on the main unit side are suspended from the electric circuit board 84 . Accommodation spaces 9 b, 9 c that respectively accommodate the bypass condenser 81 and the sheet sensor 82 are formed. When the electric circuit board 84 is attached to the holder 9 , the bypass condenser 81 is accommodated in the space 9 c and the sheet sensor 82 is accommodated in the space 9 b. The bypass condenser 81 accumulates the electric charge needed to drive an IC chip 80 ( FIG. 4 ).
[0045] As shown in FIG. 4 , the piezoelectric actuator 32 of the ink jet head 30 is electrically connected to the electric circuit board 84 by means of the flexible flat cable 70 . The IC chip 80 is mounted on the flexible flat cable 70 . The IC chip 80 converts recording data that was serially transferred from the control device on the ink jet printer main unit to parallel data that corresponds to the ink jet nozzle array not shown in the figures, and also to piezoelectric signals that are suitable for driving the piezoelectric actuator 32 .
[0046] The flexible flat cable 70 is inserted into the holder 9 through a slit 9 h that is formed through the bottom wall 9 e of the holder 9 . The flexible flat cable 70 passes through a vertical space 9 f between a heat sink 60 described below and a lateral wall 9 i of the holder 9 , and a horizontal space 9 g between the electric circuit board 84 and the buffer tank 40 , curves leftward on the right side of the right end 84 b of the electric circuit board 84 , and extends above the electric circuit board 84 . The flexible flat cable 70 is folded in two locations, and from above sequentially forms folded portions 70 a - 70 c. The tip of the flexible flat cable 70 is removably and electrically connected to a connector 85 that is fixed on the top surface 84 f of the electric circuit board 84 .
[0047] Here, the folded portion 70 a and the folded portion 70 b are adhered and fixed by means of double sided tape 70 d, and a worker can handle this portion to easily connect the flexible flat cable 70 to the connector 85 . After the flexible flat cable 70 is connected to the connector 85 , the folded portion 70 b and the folded portion 70 c are integrally adhered and fixed by means of double sided tape 70 e. Note that double sided tape is employed in the present embodiment to perform adhesion, but other fixing means such as an adhesive or the like may also be employed.
[0048] The flexible flat cable 70 passes between the cover side seal member 88 and the board side seal member 87 described below. One curved point 70 x of the flexible flat cable 70 is on the left side of the cover side seal member 88 and the board side seal member 87 , and another curved point 70 y of the flexible flat cable 70 is on the right side of the cover side seal member 88 and the board side seal member 87 . The three folded portions 70 a - 70 c pass between the cover side seat member 88 and the board side seal member 87 .
[0049] The heat sink 60 is fixed in a position adjacent to the slit 9 h of the bottom wall 9 e of the holder 9 . The heat sink 60 includes a base 60 a that is parallel with the bottom wall 9 e, and a side 60 b that stands upright therefrom. The IC chip 80 is pressed to the base 60 a by means of a rubber-like resilient member 86 . Heat generated by the IC chip 80 is transmitted to the heat sink 60 , and is dissipated from the broad area of the heat sink 60 .
[0050] An electric circuit 84 c ( FIG. 2 ) that connects the connector 85 , the bypass condenser 81 , the sheet sensor 82 , and the encoder 83 is formed on the top surface of the electric circuit board 84 . The electric circuit board 84 is also connected to the control device on the ink jet printer main unit via a flexible flat cable 71 ( FIG. 2 ).
[0051] As shown in FIG. 2 , ribs 50 , 51 that project upward are arranged on the upper end of the left side wall 42 of the buffer tank 40 . The ribs 50 , 51 are slightly spaced sideward from the upper end 42 a of the left side wall 42 of the buffer tank 40 , project into the horizontal space 9 g between the electric circuit board 84 and the film member 41 , and are integrally formed with the left side wall 42 .
[0052] As shown in FIG. 2 , support members 9 m, 9 m are arranged on an inner face of the rearward wall 9 j of the holder 9 , and serve to contact the bottom surface 84 a of one end (the rear side end, the first edge) 84 d of the electric circuit board 84 and support the one end 84 d of the electric circuit board 84 from below. Retaining projections 9 n, 9 n are formed on the left upper side of the support members 9 m, 9 m and contact the top surface of the electric circuit board 84 to prevent the one end 84 d of the electric circuit board 84 from moving upward. There is a difference between the heights of the retaining projections 9 n, 9 n and the heights of the support members 9 m, 9 m, and a gap in which the one end 84 d of the electric circuit board 84 can be inserted is secured thereby.
[0053] A support member 9 p that serves to support the bottom surface 84 a of the other end 84 e (the front side end, the second edge) of the electric circuit board 84 is arranged on the corner of the front side of the lateral wall 9 k on the right side of the holder 9 . The upper surfaces of the support members 9 m, 9 m, and the upper surface of the support member 9 p, are arranged so as to be the same height.
[0054] The board side seal member 87 that substantially extends along the outer periphery of the electric circuit board 84 is attached to the top surface 84 f of the electric circuit board 84 . The board side seal member 87 extends around the outer periphery of the electric circuit board 84 , so as to encircle the electric circuit 84 c.
[0055] As shown in FIG. 3 , the cover side seal member 88 that is the same shape as the board side seat member 87 is attached to the inner surface 9 t of the cover 98 , in a position that corresponds to the board side seal member 87 . The seal members 87 , 88 have a transverse cross section that is square in this embodiment, and have a width that is sufficient to protect the electric circuit 84 c from the ink mist. In addition, as shown in FIG. 3 , when the cover 98 is fixed to the holder 9 , the seal members 87 , 88 fill a gap 9 u formed between the inner surface 9 t of the cover 98 and the top surface 84 f of the electric circuit board 84 . The seal members 87 , 88 fill the gap 9 u formed between the inner surface 9 t of the cover 98 and the top surface 84 f of the electric circuit board 84 in the compressed state.
[0056] In this embodiment, the seal members 87 , 88 are formed with a porous resin having resiliency, and are respectively fixed to the top surface 84 f of the electric circuit board 84 and the inner surface 9 t of the cover 98 by means of double sided tape.
[0057] As shown in FIG. 4 , the electric circuit board 84 is pressed downward via the seal members 87 , 88 by means of the cover 9 that closes the opening 9 x of the holder 9 . As shown in FIG. 3 , the one end 84 d of the electric circuit board 84 (the first edge, the right side of FIG. 3 ) is inserted between the support members 9 m, 9 m and the retaining projections 9 n, 9 n. The lower surface 84 a of the end portion 84 e of the electric circuit board on the opposite side (the second edge, the left side of FIG. 3 ) is supported by means of the support member 9 p.
[0058] As shown in FIG. 4 , the folded portions 70 a - 70 c of the flexible flat cable 70 pass between the seal member 87 and the seal member 88 , and the seal member 87 and the seal member 88 are adhered to each other around the periphery of the bend portions 70 a - 70 c.
[0059] The material of the aforementioned two seal members 87 , 88 is preferably water resistant so as to repel ink, and fire resistant so as to not start a fire when the electric circuit board 84 overheats. In addition, the material is preferably one which has little emitted gas, so as to avoid the occurrence of poor adhesion caused by gas emitted from the seal members 87 , 88 . Furthermore, in order to maintain a stable reaction force, a material is preferred which rarely creeps, such as for example polyether type polyurethane foam.
[0060] The aforementioned two seal members 87 , 88 can also be formed on only one of the cover 98 or the board 84 . For example, it is possible for only the seal member 88 to be attached to the inner surface 9 t of the cover 98 , the lower surface of the seal member 88 placed into contact with the electric circuit board 84 , and then the flexible flat cable 70 placed into contact with the electric circuit board 84 . In addition, it is possible for only the seal member 87 to be attached to the electric circuit board 84 , the upper surface of the seal member 87 placed into contact with the inner surface 9 t of the cover 98 , and then the flexible flat cable 70 placed into contact with the inner surface 9 t of the cover 98 .
[0061] In addition, the flexible flat cable 71 that connects the electric circuit board 84 with the control device on the ink jet printer main unit, can also be protected from the ink mist in the same way as described above and be connected to the electric circuit board 84 by means of one or both of the seal members 87 , 88 .
[0000] [Merits of the Best Mode]
[0062] (1) As noted above, if the ink jet head unit 99 of the aforementioned best mode is used, the seal member 87 and the seal member 88 lie within the gap 9 u between the inner surface 9 t of the cover 98 and the top surface 84 f of the electric circuit board 84 , and are disposed so as to surround the electric circuit 84 c formed on the top surface of the electric circuit board 84 . Thus, the ink mist can be reliably prevented from penetrating into the interior of the area surrounded by the seal member 87 and the seal member 88 , and the ink mist can be prevented from adhering to the electric circuit 84 c.
[0063] (2) Because the cover side seal member 88 is attached to the inner surface 9 t of the cover 98 , gaps between the inner surface 9 t of the cover 98 and the cover side seal member 88 can be eliminated. Ink mist can be prevented from penetrating from a gap formed between the inner surface 9 t of the cover 98 and the cover side seal member 88 . In addition, the task of attaching the seal member 88 on the inner surface 9 t of the cover 98 can be performed simply because there is no obstacle thereto such as the electric circuit 84 c.
[0064] (3) Because the board side seal member 87 is attached to the top surface of the electric circuit board 84 , gaps between the top surface 84 f of the electric circuit board 84 and the board side seal member 87 can be eliminated. Ink mist can be prevented from penetrating from a gap formed between the electric circuit board 84 and the seal member 87 . In addition, because the board side seal member 87 can be attached so as to surround the periphery of the area where the electric circuit 84 c is formed, the necessary components can be reliably sheltered.
[0065] (4) Because the flexible flat cable 70 passes between the cover side seal member 88 attached to the inner surface 9 t of the cover 98 , and the board side seal member 87 attached to the upper surface 84 f of the electric circuit board 84 , and because the cover side seal member 88 and the board side seal member 87 are in close contact around the periphery of the flexible flat cable 70 in the pass through location, ink mist cam be prevented from penetrating via a gap between the flexible flat cable 70 and the cover side seal member 88 and the board side seal member 87 , and can be prevented from adhering to the electric circuit 84 c.
[0066] (5) Because the folded portions 70 a - 70 c of the flexible flat cable 70 are adhered and fixed to each other by means of double sided tape 70 d, 70 e, the reaction force that attempts to return the flexible flat cable 70 to the state before it was folded can be suppressed. Thus, there will be no danger that a gap wilt be formed by means of that reaction force between the flexible flat cable 70 and the seal members 87 , 88 , and ink mist will penetrate from that gap.
[0067] In addition, ink mist can be prevented from penetrating from a gap between the folded portions 70 a - 70 c of the flexible flat cable 70 , and adhering to the electric circuit 84 c.
[0068] Furthermore, because there is not need to wait for an adhesive to dry such as when an adhesive is used, the folded portions 70 a - 70 c can be fixed together in a short period of time.
[0069] (6) Because the seal members 87 , 88 are resilient members, the ink mist sheltering effect can be improved even more because they can also be adhered to correspond to the recessed portions of the electric circuit board 84 , the cover 98 , and the flexible flat cable 70 .
[0070] In addition, because the seal members 87 , 88 are porous, it is not necessary to apply an excessive force to deform them, and a moderate reaction force can be obtained in order retain them in the close contact state.
[0071] In this embodiment, the present invention is applied to the ink jet head unit. The ink jet head unit is only one example of an apparatus for ejecting droplets of the present invention. The apparatus or ejecting droplets is not limited to the ink jet head unit. The apparatus for ejecting droplets is used in various technical fields. For example, a machine for forming a printed circuit board by ejecting droplets made of conductive material towards an insulating board is known. There is also known a machine for coating an adhesive layer by ejecting droplets made of adhesive material towards an object to be adhered. A machine for fabricating a three dimensional model by ejecting molten resin droplets towards the three dimensional model under construction is also known. These machines commonly use the apparatus for ejecting droplets, and the present invention may be applied to the the apparatus for ejecting droplets of various machines.
[0000] [Other Embodiments]
[0072] (7) The seal members 87 , 88 may surround only the necessary area of the electric circuit 84 c, such as an area where a high voltage is generated. Even when this construction is used, the effects of the best mode noted above can be achieved.
[0073] (8) The seal members 87 , 88 need not be formed in a continuous shape. For example, when arranged in a row with a predetermined gap, and sandwiched in the compressed state by means of the cover 98 and the holder 9 , the gap between adjacent seal members will be filled, and arranged so as to form a ring. Even when this construction is used, the effects of the best mode noted above can be achieved.
[0074] (9) An adhesive or the like other than double sided tape may be employed to fix the seal members 87 , 88 . Even when this construction is used, the effects of the best mode noted above can be achieved.
[0075] (10) Another cable other than the flexible flat cable 70 may be employed as the cable that electrically connects the electric circuit 84 c and the printing head 30 , such as for example a lead wire. Even when this construction is used, the effects (1) to (4) and (6) of the best mode noted above can be achieved.
[0076] (11) The flexible flat cable 70 is caved inside the holder 9 , and urges the electric circuit board 84 upward. The repulsive force of the flexible flat cable 70 will also contribute to bringing the seal members 87 , 88 firmly into contact with each other.
[0077] (12) The ink jet head unit 99 is also used as a carriage that reciprocates within the ink jet printer. Alternatively, the ink jet head unit 99 may be fixed within the ink jet printer. The present invention may be applied to the ink jet printer with the carriage of serial printing operation, and also may be applied to the ink jet printer with the fixed ink jet head unit of parallel printing operation.
[0078] (13) The piezoelectric actuator unit 32 is used for driving the ink jet head 30 . Another type actuator may be used for driving the ink jet head 30 . For instance an actuator of generating heat or applying electrostatic force may be used as the actuator for driving the ink jet head. The ink droplets may be ejected by heat or electrostatic force.
[0000] (Second Embodiment)
[0079] Next, a second embodiment for carrying out this invention will be described with reference to the figures. Only the structure that differs from the first embodiment will be described below, and duplicate disclosures will be omitted.
[0000] (Primary Structure of the Ink Jet Head Unit)
[0080] FIG. 5 shows an oblique view of the electric circuit board 84 removed from an ink jet head unit 199 of the second embodiment. FIG. 6 shows a cross-sectional view of the ink jet head unit 199 . FIG. 7 shows the A-A cross-sectional view of FIG. 6 .
[0081] As shown in FIG. 5 , an annular board side seal member 87 that runs along the outer periphery of the electric circuit board 84 is attached to the upper surface 84 f of the electric circuit board 84 . The board side seal member 87 extends around the area that is formed by the electric circuit 84 c. The seal member 87 has a transverse cross section that is square, and has a width that is sufficient to protect the electric circuit 84 c from the ink mist.
[0082] As shown in FIG. 6 , a cover side seal member is not arranged on the cover 98 . In stead, a local pressing member 9 w that serves to locally and firmly press the seal member 87 is arranged on the cover 98 . The local pressing member 9 w is formed in a bar shape in the left to right direction along the edge of the front side of the board side seal member 87 (the side on which the retaining member 29 is located), and is arranged to be integral with the cover 98 . The local pressing member 9 w projects downward from the cover 98 .
[0083] As shown in FIG. 5 , a coil spring 92 is arranged in a position adjacent to the wall 42 on the left side of the buffer tank 40 that is stored inside the holder 9 . The upper end of the coil spring 92 pushes against a ground contact point that is formed on the bottom surface 84 a of the electric circuit board 84 , and the bottom end thereof is fixed to the holder 9 . The coil spring 92 urges the electric circuit board 84 upward. The coil spring 92 is formed with a conductive material, and the lower end thereof is electrically connected with a ground terminal of the piezoelectric actuator unit 32 . The ground terminal of the piezoelectric actuator unit 32 is grounded by the ground contact point of the electric circuit board 84 by means of the coil spring 92 .
[0084] As shown in FIG. 6 , the seal member 87 is adjusted to a thickness that can be interposed in the compressed state in the gap 9 u between the inner surface it of the cover 98 and the top surface 84 f of the electric circuit board 84 , and press and fix the electric circuit board 84 . In other words, the thickness when the seal member 87 is in its natural shape is set to be thicker than the space of the gap 9 u formed between the inner surface 9 t of the cover 98 and the top surface 84 f of the electric circuit 84 when the cover 98 is fixed to the holder 9 .
[0085] Because the flexible flat cable 70 is curved and connected in a horizontal U-shape from the horizontal space 9 g downward from the electric circuit board 84 , it urges the electric circuit board 84 upward by means of the resilient force thereof, In addition, the coil spring 92 also urges the electric circuit board 84 upward.
[0086] One end 84 d of the electric circuit board 84 (the end on the rearward side, corresponding to the first edge, the right side in FIG. 6 ) is inserted between the support members 9 m, 9 m and the retaining projections 9 n, 9 n.
[0087] Because the electric circuit board 84 pivots around the one end 84 d inserted between the support member 9 m and the retaining projection 9 n as a fulcrum, in order to resist the aforementioned urging force and push downward the other end 84 e of the electric circuit board 84 (the end on the frontward side, corresponding to the second edge), a pressing force that is comparatively larger than the other portions outside the other end 84 e of the front side is needed
[0088] The other end 84 e side seal member 87 a is pressed by the local pressing member 9 w, and thus is more firmly compressed compared to the other portions of the seal member 87 when the cover 9 is placed thereon. As a result, the other end 84 e side of the electric circuit board 84 is pressed with a pressing force that is larger than the other portions.
[0089] When the cover 98 is fixed to the holder 9 , the other end 84 e of the electric circuit board 84 is pushed downward via the local pressing member 9 w and the seal member 87 . The lower surface of the other end 84 e of the electric circuit board 84 is supported by the support member 9 p.
[0090] The folded portion 70 a of the flexible-flat cable 70 is vertically sandwiched by means of the seal member 87 and the inner surface 9 t of the cover 98 .
[0091] The method of fixing the electric circuit board 84 will be described with reference to FIG. 8 . FIG. 8 is a partial cross-sectional view showing a method of attaching the electric circuit board 84 to the holder 9 .
[0092] First, the end (first edge) 84 d on the rear side of the electric circuit board 84 to which the flexible flat cable 70 is connected will be inserted between the support members 9 m, 9 m and the retaining projections 9 n, 9 n.
[0093] Next, in order to arrange the folded portion 70 a of the flexible flat cable 70 on the seal member 87 , the cover 98 will be placed thereon from above the electric circuit board 84 , and will press the other end 84 e of the electric circuit board 84 downward via the seal member 87 .
[0094] Then, the hook 9 r of the cover 98 will be engaged with the recess 9 s of the holder 9 ( FIG. 7 ), the seal member 87 will be retained as is in the compressed state, and the cover 98 will be fixed to the holder 9 .
[0000] [Effects of the Second Best Mode]
[0095] (1) As noted above, if the ink jet head unit 199 of the aforementioned best mode is used, the location of the seal member 87 that needs a comparatively large pressing force can be compressed more than other portions thereof by means of the local pressing member 9 w, and thus even when the electric circuit board 84 is pressed with the entire seal member 87 , the electric circuit board 84 can be fixed with a small force, and can be effectively sheltered from ink mist. Thus, because there is no need to firmly compress the aforementioned other portions, deformation of the cover 98 can be prevented by means of the resiliency of the seal member 87 , and the ink jet head unit 199 having an accurate ink discharge direction can be achieved.
[0096] (2) Because the local pressing member 9 w is arranged on the support member 9 p side that corresponds to the other end 84 e of the electric circuit board 84 that needs a comparatively large pressing force, even when the electric circuit board 84 is pressed with the entire seal member 87 , the local pressing member 9 w can fix the electric circuit board 84 with a small force, and can reliably protect the electric circuit 84 c from ink mist, because it can compress more firmly than the other portions.
[0097] In addition, because the one end 84 d of the electric circuit board 84 can be inserted between the support portion 9 m and the retaining projection 9 n, and the other end 84 e is supported by the support member 9 p, the electric circuit board 84 can be accurately fixed in a predetermined position.
[0098] (3) Even with a structure in which the electric circuit board 84 is urged in a direction away from the support members 9 m, 9 p by means of the curved flexible flat cable 70 , if the location of the seal member 87 that needs a comparatively large pressing force is pressed by means of the local pressing member 9 w in order to resist the urging, the local pressing member 9 w can fix the electric circuit board 84 with a small force and can reliably protect the electric circuit 84 c from ink mist more than when the electric circuit board 84 is pressed with the entire seal member 87 , because the local pressing member 9 w can compress more than the other portions.
[0099] (4) Even with a structure in which the seal member 87 is annularly disposed between the cover 98 and the electric circuit board 84 , and around at least a portion of an area of the electric circuit board 84 on which the electric circuit 84 c is formed, penetration of ink mist can be reliably prevented because no gaps are formed due to the deformation of the cover 98 .
[0100] (5) Because the local pressing member 9 w is integrally arranged on the inner surface 9 t of the cover 98 , the local pressing member will not shift position when the cover 98 is placed, and thus a predetermined location of the seal member 87 can be accurately pressed. In addition, if the local pressing member 9 w and the cover 98 are integral with each other, a separate structure for a local pressing member will become unnecessary, and thus manufacturing costs can be reduced.
[0101] (6) Because the seal member 87 is a porous material, it is not necessary to apply an excessive force to deform it, and a moderate reaction force can be obtained in order to fix the electric circuit board 84 . In addition, because the seal member 87 can be adhered so as to also deal with the concave and convex portions of the attachment location, the ink mist sheltering effect can be improved even more.
[0000] [Other embodiments]
[0102] (7) A shape other than a bar shape may be employed as the local pressing member. For example, a projecting portion of the inner surface 9 t of the cover member 98 may be arranged with a predetermined gap in a position that corresponds to a predetermined location of the seal member 87 a. Even when this construction is used, the effects of the best mode noted above can be achieved.
[0103] (8) The local pressing member 9 w is arranged on the cover 98 in the best mode described above, but a portion of a seal member may be used as a local pressing member. For example, a portion of the seal member 87 a whose thickness in the vertical direction and/or width in the horizontal direction was increased may be locally formed, and that portion may be used as a local pressing member. When this construction is used, the local pressing member will not shift position during pressing and thus can reliably press a predetermined location of the seal member. In addition, it can be easily produced because it is produce in an integral form. Even when this construction is used, the effects (1) to (4) and (6) of the best mode noted above can be achieved.
[0104] (9) The local pressing member may be manufactured as an independent item, and interposed as a spacer between the seal member 87 and the cover 98 . For example, a horizontal U-shaped local pressing member may be covered by the seal member 87 a. Even when this construction is used, the effects (1) to (4) and (6) of the best mode noted above can be achieved.
[0105] (10) The seal member 87 need not be formed in a continuous shape. For example, when arranged in a row with a predetermined gap, and sandwiched in the compressed state by means of the cover 98 , the gap between adjacent seal members will be filled, and arranged so as to form a ring. Even when this construction is used, the effects of the best mode noted above can be achieved.
[0106] (11) A seal member may be arranged an the cover side, and a local pressing member may be arranged on the board side.
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An apparatus for ejecting droplets is provided with a ejecting head for discharging droplets, an electric circuit board having an electric circuit formed on a surface of the electric circuit board, the electric circuit being connected to the ejecting head, a holder for supporting the ejecting head and the electric circuit board, and a cover that overlaps the surface of the electric circuit board when the cover is fixed to the holder. The apparatus for ejecting droplets is further provided with a seal member that fills a gap formed between a peripheral region of the surface of the electric circuit board and an inner surface of the cover. The seal member effectively prevents droplets mist from penetrating to the electric circuit.
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BACKGROUND OF THE INVENTION
This invention generally relates to a system and method for using a single intelligence circuit in both a digital camera and printer, and is specifically concerned with the use of a single PC card to perform the primary data processing operations in both a digital camera and printer to simplify the structure of a camera/printer imaging system.
Techniques for simplifying the structure of components used in digital imaging systems to reduce manufacturing costs are known in the prior art. For example, in the camera system disclosed in U.S. Pat. No. 5,506,617, and assigned to the Eastman Kodak Company, a digital camera is provided as a module that attaches to the signal bus of a PC compatible computer. This system advantageously eliminates the need for a separate intelligence circuit to be incorporated within the camera itself, as the camera in this system includes a PC-compatible interface connector for mating with a bus extension connector on the computer. Digitized data is directly transmitted from the camera to the signal bus of the computer so that the intelligence circuits of the computer can be used to perform all image processing, storage, and display functions. The elimination of the camera intelligence circuit not only simplifies the circuit architecture, but substantially reduces camera manufacturing costs as the microprocessor used in such circuits costs between $20.00 and $40.00 depending upon the speed and operating abilities required.
While the camera-computer system disclosed in the '617 patent represents a significant advance in the simplification of digital camera circuitry, its utility is limited since the digital camera must be continuously connected to the PC compatible computer during both the capturing and displaying of images.
Clearly, there is a need for a completely portable, untethered digital camera that is fully capable of recording images without its own dedicated and relatively expensive microprocessor. Ideally, such a camera could be used in conjunction with a relatively inexpensive thermal or ink-jet printer to produce hard copies of images in photographic form. Finally, it would be desirable if the circuit-simplifying design of the digital camera also allowed the circuitry of the printer to be similarly simplified so that even larger reductions in manufacturing costs could be realized.
SUMMARY OF THE INVENTION
Generally speaking, the invention is an electronic imaging system that utilizes a shared intelligence circuit to fulfill all of the aforementioned criteria. The system of the invention comprises first and second imaging components for capturing and rendering an image, respectively, each of which requires a primary intelligence circuit for operation, and an intelligence circuit that is detachably connectable to either of the imaging components during their operation. The system may, for example, comprise a camera having an imaging sensor for generating a stream of data representative of an image, a printer having a printhead for generating an image from a set of printer instructions, and a single intelligence circuit in the form of a PC card that is detachably connectable to either the camera or the printer for the operation of either. In the method of the invention, the intelligence circuit is first detachably connected to an image capturing component, which may be a camera, in order to convert data stream from an imaging sensor into stored image data. Next, the intelligence circuit is manually removed from the image capturing component, and detachably connected to the image rendering component, which may be a printer. The image rendering component in turn renders an image in accordance with instructions relayed from the intelligence circuit that are generated from the stored image data.
The use of a single intelligence circuit to operate both a camera and a printer of an imaging system advantageously simplifies the system by obviating the need for separate and largely redundant intelligence circuits presently used in both the camera and the printer, thereby reducing manufacturing costs. The use of a single intelligence circuit also enhances the overall reliability of the imaging system by reducing processing steps and component interfaces.
In the preferred embodiment, the intelligence circuit is a PC card having a liquid crystal display for displaying either a real-time or a stored image constructed from instructions generated by the microprocessor of the circuit. The PC card preferably includes manually operated controls for capturing, storing, erasing, and scrolling through images generated by the imaging sensor of the camera.
In one embodiment of the system, the intelligence circuit within the PC card not only stores data from the imaging sensor of the camera, but further includes stored camera and printer-model operating programs for both the camera and the printer that are specific to the particular model and make of the camera and printer. In an alternative embodiment, both the camera and the printer include their own individual stored operating programs in the form of EPROMs. The second embodiment of the system has the advantage of allowing the intelligence circuit to be more versatile, as it can be used in conjunction with a variety of different models of cameras and printers having different features and operational capacities, i.e., zoom lens capabilities, picture editing features, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the electronic imaging system of the invention, illustrating how a single, portable intelligence circuit is used to operate either a digital camera or a printer;
FIG. 2 is a schematic block diagram of the intelligence circuit of the system, and
FIG. 3 is a plan view of the PC card that houses the intelligence circuit of FIG. 2, illustrating the liquid crystal display and manual controls of the card.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to FIG. 1, wherein like numerals designate like components throughout all the several figures, the imaging system 1 of the invention may comprise a digital camera 3 , a printer 5 , and a shared PC intelligence card 7 which is detachably connectable to either the camera 3 or the printer 5 .
The digital camera 3 includes a lens unit 11 disposed within a movable tubular housing 12 for gathering reflected light from a subject 13 to be photographed. A lens focusing assembly 15 which includes a small DC motor 17 , battery pack 19 and gear train 21 is provided for reciprocally moving the tubular housing 12 of the lens unit 11 in a manner well known in the art.
Digital camera 3 further includes a flash unit 23 which is likewise powered by the battery pack 19 via connector wire 24 , and a photometer 25 for measuring the amount of ambient light in the vicinity of the subject 13 . Disposed behind the lens unit 11 are an electronic iris diaphragm 27 , electronic shutter 29 , infrared filter 31 , and imaging unit 33 , which may be a charged coupled device (CCD) sensor, such as KAF-400 full frame sensor manufactured by the Eastman Kodak Company located in Rochester, N.Y. While not shown in FIG. 1, components 27 , 29 and 33 are each connected to and driven by the battery pack 19 . In operation, light from a subject 13 is focused onto the surface of the imaging unit from the lens unit 11 . The imaging unit includes a 640×480 pixel matrix of individual light sensitive elements which collectively generate a data stream representative of the subject 13 .
The digital camera 3 may optionally have any erasable programmable read-only memory (EPROM) 36 which contains an operating program that coordinates the functions of the lens-focusing assembly 15 , the flash unit 23 , the electronic diaphragm 27 and shutter 29 , as well as the activation of the imaging unit 33 whenever the shutter 29 is activated. Finally, the camera 3 includes both a card-receiving slot 38 for receiving the flat, rectangular body of the PC card, as well as a terminal 40 for engaging a row of input and output contacts 41 disposed along an edge of the card 7 . In the preferred embodiment, the digital camera 3 may have a structure that is essentially identical to that of the Model DC110 or 220 digital camera manufactured by the previously-mentioned Eastman Kodak Company, the only differences being the replacement of the primary microprocessor and associated programming and memory circuits with the aforementioned card-receiving slot 38 and terminal 40 .
In this example, the printer 5 comprises a thermal printing unit 44 connected to control and power circuitry 46 , although ink-jet and other types of printers may be used as well. The printing unit 44 is formed from a ribbon advancing assembly 48 and a printhead mechanism 50 , both of which cooperate to thermally render an image onto a sheet of thermal printing paper 52 . A movable platen roller 54 supports the printing paper 52 as the printhead mechanism 50 sweeps over it to render an image thereon.
The ribbon-advancing assembly 48 includes a drive roller 56 connected to the shaft 57 of an electric motor 58 for unwinding a strip of thermal print ribbon 60 from an opposing spool roller 62 . The thermal print ribbon 60 is formed from serially connected portions 64 containing cyan, yellow, and magenta coloring agents, respectively. Thermal printing unit 44 further includes a thermal printhead 66 having a linear row of closely spaced heating elements 68 for depositing coloring agents from the thermal print ribbon 60 onto the thermal printing paper 52 by fusion. A paper moving mechanism 70 is provided for moving the thermal printing paper 52 across the thermal matrix printhead 66 while a selected pattern of the heating elements 68 are actuated in order to deposit an image-forming pattern of coloring agents onto the paper 52 . Like the drive roller 56 of the ribbon advancing assembly 48 , the paper moving mechanism 70 is mechanically powered by the output shaft 57 of the electric motor 58 .
The control and power circuitry 46 of the printer 5 includes a printhead driver and ribbon advance circuit 75 whose output is connected to the electric motor 58 via cable 76 . Circuitry 46 also has a printhead controller circuit 77 electrically connected to the heating elements 68 of the thermal matrix printhead 66 via a cable 78 . Finally, circuitry 46 includes a power supply 79 which is connected in parallel to the outputs of the circuits 75 and 77 . Essentially, the circuits 75 and 77 are power switching circuits formed from an array of power semiconductors whose outputs are modulated by the low-current printer instructions generated by the PC card. In addition to the circuits 75 , 77 , and 79 , the control and power circuitry 46 may further include a EPROM 81 containing an operating program which coordinates the movement of the drive roller 56 , paper moving mechanism 70 , and the actuation of the heating elements 68 . The inclusion of the optional EPROMs 36 to the camera 3 and 81 to the printer 5 advantageously allows the intelligence circuit within the PC card 7 to operate a variety of different imaging systems formed from cameras and printers having different features and capabilities, such as zoom lensing, various picture editing abilities, etc. Finally, similar to the digital camera 3 , the printer 5 likewise includes a card-receiving slot 83 for receiving the body of the PC card 7 along with a terminal 85 for engaging the input and output contacts 41 present along an edge of the card 7 . The overall structure of the printer 5 may be the same as a Model No. DS 8650 thermal printer manufactured by the Eastman Kodak Company with slot 83 and terminal 85 replacing its microprocessor and associated circuits. Alternatively, a Kodak Model No. HP890C ink jet printer may be used that has been modified in the same manner.
With reference now to FIG. 2, the intelligence circuit 90 disposed within the card 7 includes a microprocessor 92 , and a button-type battery pack 94 . Preferably, microprocessor 92 is one of the commercially available family of reduced instruction set computers (known in the art as RISC-type processors) that are relatively fast, math intensive, and application-specific. Examples of such processors include the Model 821 Power PC manufactured by Motorola Corporation located in Phoenix, Ariz., and the Model MIPSR-4000 Processor manufactured by NEC Electronics located in Tokyo, Japan. Such processors are fully capable of rapidly implementing the JPEG still image compression algorithm used to control digital cameras such as the previously-mentioned Model DC110 and 220.
The intelligence circuit 90 also includes an EPROM 96 for storing an operating program for the microprocessor 92 that allows it to convert the data stream received from the imaging unit 33 into printer instructions. Any one of a number of commercially available EPROM integrated circuits may be used for the EPROM 96 which preferably have a capacity of about 1 megabyte. In order to store the data generated by the imaging unit 33 of the camera 3 , the intelligence circuit further has a dynamic random access memory or DRAM 98 that is powered by the battery pack 94 . As the imaging sensor 33 preferably has a capacity of 640×480 pixels, the DRAM 98 should have a 20 megabyte capacity in order to store data for 20, one mega-pixel images or 100 compressed images. Examples of commercially available integrated circuits which can be used as the DRAM 98 include the Model MCM51LXXX DRAM manufactured by Motorola, or one of the series of AMD 29C600 DRAMs manufactured by Advance Micro Devices located in Beaverton, Oreg. In both cases, a total of three, 8 megabyte ICs may be used. Optionally, a flash RAM non-volatile memory may be substituted for the DRAM 98 , the advantage being that no button-type battery pack 94 would be necessary to preserve data captured in the memory of the intelligence circuit 90 .
The intelligence circuit 90 further includes both a display driver circuit 100 for providing instructions to a liquid crystal image display 104 , and a mechanical programmable controller 102 for providing operational commands to the mechanical systems of the digital camera 3 and the printer 5 , i.e., the lens focusing assembly 15 , and the printhead driver and ribbon advance circuit 75 . Driver circuit 100 is normally part of the liquid crystal display module that forms the image display 104 , while mechanical programmable controller 102 may be an application specific integrated circuit (ASIC) manufactured by the Eastman Kodak Company in accordance with known technology.
The intelligence circuit 90 includes a user interface circuit 106 that includes the manual controls and indicator LEDs present on the body of the card 7 . All of the components 92 , 96 , 98 , 100 , 102 , 104 , and 106 are interconnected via an address data and input/output bus 107 as is schematically indicated, and with the exception of DRAM 98 , all of these components are powered by the battery pack 18 of the camera 3 or power supply 79 of the printer 5 .
With reference now to FIG. 3, the card 7 includes a liquid crystal display (LCD) screen 108 . In the preferred embodiment, LCD screen is a low temperature, polysilicon-type screen, as such screens can be made with an overall thickness of approximately 1 millimeter and therefore not significantly contribute to the overall thickness of the body of the card 7 . The user interface 106 includes two light emitting diode (LED) indicators 109 a and 109 b for indicating whether or not either the camera or the printer is on or off, and further whether or not the button-type battery in battery pack 94 is running low, thereby jeopardizing the integrity of the images stored in DRAM 98 . Interface 106 further includes four manually operated arrow buttons 110 which may be used interactively with a control display 114 which appears in a comer of the LCD 108 when the card 7 is in operation. Finally, interface 106 includes an execute button 112 for executing a selected function in the display 114 .
In the example of the control display 114 illustrated in FIG. 3, the system operator has inserted the card 7 into the camera 3 and has further selected the “live picture” function at the top of the display 114 by manipulating bottom-most arrow buttons 110 . In such a mode, the LCD 108 acts as a view finder for the system operator, displaying the still frame that will be stored within the DRAM 98 upon the actuation of the electronic shutter 29 of the camera 3 . If the system operator wishes to use the card 7 to capture a selected image, he depresses the bottom-most arrow button 110 to light up the “capture” title in the display, and then depresses execute button 112 . The number of image frames remaining in the DRAM 98 is displayed in the “frame number” box of the display 114 . If the operator wishes to display the frames already stored within the DRAM 98 , then he again pushes the bottom-most arrow button 110 to light up the “scroll” box of the display 114 , whereupon captured images in the DRAM 98 may be serially scrolled through by manipulating the sideways arrow buttons 110 . Of course, a different control display 114 would be exhibited when the card 7 was inserted into the receiving slot 83 of the printer 5 . It should be noted that the previously described control scheme on the card 7 has the ergonomic advantage of teaching a first-time user how to operate the printer 5 as the user first learns how to operate the camera 3 , since the display, scrolling, and erase functions for both the camera and printer are executed in the same way.
Although the imaging system of the invention has been described with respect to a specific example, variations, additions, and modifications of this system will become evident to those of skill in the art. For example, while the imaging system has been described in terms of a camera and a printer, the system may be used with any other kind of imaging rendering device, such as an electronic photo-album, a PC video screen, a scanner, a transfer station, or an archive station. The camera may be still or video. While the intelligence circuit of the invention has been described in terms of a PC card, this circuit can assume the form of any portable module that is detachably connectable to both a digital camera or printer. Additionally, the intelligence circuit may perform all, most, or some of the intelligence functions of either the camera or the printer. As has been previously pointed out, the presence of an EPROM having a basic operational program in both the camera and the printer allows the card or other modular intelligence to be used in a number of different types of digital cameras and printers having different functions, i.e., zoom lens capacities, special print-editing functions, etc. All such variations, modifications, and additions are intended to be encompassed within the scope of this invention, which is limited only by the claims appended hereto.
PARTS LIST
1.
System of the invention
3.
Digital camera
5.
Printer
7.
Shared PC intelligence card
11.
Lens unit
12.
Tubular housing
15.
Lens focusing assembly
17.
Motor
19.
Battery
21.
Gear train
23.
Flash unit
24.
Connector wire
25.
Photometer
27.
Iris diaphragm
29.
Electronic shutter
31.
Infrared filter
33.
Imaging unit
36.
EPROM
38.
Card-receiving slot
40.
Terminal
41.
Output contacts
44.
Thermal printing unit
46.
Control and power circuitry
48.
Ribbon advancing assembly
50.
Printhead mechanism
52.
Thermal printing paper
54.
Platen roller
56.
Drive roller
57.
Shaft
58.
Electric motor
60.
Thermal print ribbon
62.
Spool roller
64.
C-Y-M portion
66.
Thermal matrix printhead
68.
Heating elements
70.
Paper moving mechanism
75.
Printhead driver and ribbon advance
76.
Control cable
77.
Printhead controller
78.
Control cable
79.
Power supply
81.
EPROM
83.
Card-receiving slot
85.
Terminal
90.
Intelligence circuit
92.
Microprocessor
94.
Battery pack
96.
EPROM
98.
DRAM
100.
Display driver
102.
Mechanical driver
104.
Image Display
106.
User interface
107.
Address data and input/output bus
108.
LCD screen
109.
LED indicator
110.
Function controls
112.
Execute button
114.
Control display
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A simplified electronic camera and printer imaging system is provided that includes a single intelligence circuit preferably in the form of a PC card that is detachably connectable to either the camera or the printer for converting a data stream generated by the imaging sensor of the camera into stored data when connected to the camera, and converting the stored data into printer instructions, and relaying the printer instructions to the printhead when connected to the printer. The use of a single intelligence circuit to operate both a digital camera and printer advantageously simplifies the structure of the system, reduces costs, and enhances reliability by minimizing processing steps and circuit interfaces. In the preferred embodiment, the PC card containing the intelligence circuit includes a liquid crystal display and manual controls for displaying stored or real time images, capturing or erasing images, scrolling through stored images, and commanding a printer to render the images in hard copy form.
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RELATED APPLICATION INFORMATION
[0001] This patent claims priority under 35 U.S.C. §119 from Provisional Patent Application No. 62/248,045, filed Oct. 29, 2015, titled DEAD-LATCHING SLAM BOLT LOCK which is expressly incorporated by reference in its entirety.
NOTICE OF COPYRIGHTS AND TRADE DRESS
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. This patent document may show and/or describe matter which is or may become trade dress of the owner. The copyright and trade dress owner has no objection to the facsimile reproduction by anyone of the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright and trade dress rights whatsoever.
BACKGROUND
[0003] Field
[0004] This disclosure relates to a door lock and more particularly, to a more robust dead-latching slam bolt door lock especially useful for safes and/or lockers placed inside larger safes.
[0005] Description of the Related Art
[0006] Safes, or high security containers, come in an infinite array of designs. One primary markets is commercial safes, where safes are often designed and manufactured to the client's requirements. Many of these safes are equipped with a conventional outer safe door, but also have locker(s) inside to facilitate different cash handling methods and processes. Electronic safe locks have evolved rapidly to replace mechanical systems since their introduction in the early 1990s.
[0007] There are two fundamental locking systems used in safes:
[0008] a. Boltwork Blocking: where a safe door is held closed by robust locking bolts, carried by a common carriage bar. The locking bolts are engaged behind a stationary jamb in the safe body. The boltwork is held in the locked position by a safe lock that prevents the articulation of the common carriage bar. These locks are typically “dead-latching,” meaning they can only be disengaged by the actuating the manual or electronic switch to open the lock. The carriage bar is articulated manually by a rotating or sliding handle mechanism.
[0009] b. Direct Locking: where a safe lock directly engages the stationary jamb in the safe body. The locks of this type typically include a spring-biased ramped locking bolt that is depressed as the bolt contacts and passes the stationary jamb, thus making it unnecessary to activate the lock to close the locker door. The bolt action of this type of lock would be similar to a conventional door knob-lock, except the retraction is effected by the electronic locking system controls. These locks are often referred to as “Slam Bolt Locks,” as the closing action causes the spring-biased bolt to push open, then spring back behind the jamb when the door is fully closed. The name signifies that you “Slam” the door to close and lock it without any need for lock articulation.
[0010] One problem with existing direct locking slam bolt-type locks is that the contents of a safe may interfere with opening of the lock. That is, a weight applied from inside the safe on the door tends to apply an outward load. The spring-biased bolt is thus pressed outward against the door jamb, which might interfere with its smooth opening. The resulting wear imposed on surfaces that were not intended to be structurally loaded may eventually lead to failure. Further, since the bolt must be free to push in as it contacts the jamb during door closure, it likewise can be pressed in against the spring force when the door is closed, and cannot be dead-latched. This is true for solenoid or knob actuated slam bolt locks and presents a security risk, as opening can be accomplished by using a fishing probe from any opening where access may be made. This is also in contrast to a dead-latching lock which can only be disengaged by actuating the manual or electronic switch to open the lock.
[0011] There is thus a need for a more robust dead-latching slam bolt lock.
SUMMARY OF THE INVENTION
[0012] The present application discloses a more robust dead-latching slam bolt lock that is relatively unaffected by outwardly-directed loads imposed on the door from inside the container. The lock includes a rotating dead-latching slam bolt which prevents attempts at breaking in without actuating the lock mechanism. A tongue or toggle acted on by the door jamb engages the bolt and initiates rotation thereof in the door closing direction, but is passive in the opening direction. The locking mechanism may be manual or electronic, and controls the position of a blocking element which alternately prevents and permits unlocking (rotation) of the rotating bolt. In a forward or blocking position, the blocking element prevents rotation of the bolt from a locked position, while in a retracted position the blocking element permits rotation of the bolt to an unlocked position. A spring detent plunger holds the rotating bolt in either its locked or unlocked positions.
[0013] The disclosed lock includes a tongue or toggle, and is specific to the direct-locking door application. The present lock works on the plane of intended action, and is engineered to provide greater holding strength. The present lock actuates in an axial direction following the direction of door travel. It is mechanically stronger in the direction of door motion. The present lock provides better actuation, as it uses a rotational actuation path for the bolt that follows the geometry of the closure mechanics. The present lock is held in the locked position by a strong spring detent plunger that prevents the unintended loads from hindering the lock actuation. The present lock bolt is a rotating component that is blocked by a solenoid or other manual or electro-mechanical actuator. When the actuator is energized, the door can be pulled with moderate force to cause the bolt to “toggle” to the unlocked position. The spring loaded detent plunger works in an “over-center” or “bi-stable” action to also hold the bolt in an unlocked condition one the door is pulled open. There is a spring loaded release bar in the bolt that contacts the jam during closure, which trips the rotating bolt back into the locking position. The present lock is dead-locking, and cannot be articulated without using the intended electronics to actuate the blocking device. Once the lock is actuated, the door is opened by simply pulling on a knob. Once the bolt is locked, it cannot be moved to an unlocked position unless the internal blocking actuator is activated to provide the freedom of motion to rotate open.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A is a horizontal sectional view through a door being closed showing a prior art slam bolt lock thereon, and FIG. 1B shows the bolt of the slam bolt lock engaged with a door jamb in a locked position;
[0015] FIG. 2A is a horizontal sectional view through a door being closed showing a toggle lock of the present application thereon, and FIG. 2B shows the bolt of the toggle lock engaged with a door jamb in a locked position;
[0016] FIGS. 3A-3D are elevational views of different sides of the exemplary toggle lock of the present application;
[0017] FIGS. 4A-4B are cutaway perspective views of the exemplary toggle lock from different angles and showing the mechanism in a locked configuration;
[0018] FIGS. 5A-5C are horizontal sectional views through a door having the toggle lock and showing a door closing sequence;
[0019] FIGS. 6A-6C are horizontal sectional views through a door having the toggle lock and showing a door opening sequence; and
[0020] FIGS. 7A-7B are cutaway perspective views of the exemplary toggle lock showing engagement of a tongue or toggle with the rotating bolt.
[0021] Throughout this description, elements appearing in figures are assigned three-digit reference designators, where the most significant digit is the figure number where the element is introduced and the two least significant digits are specific to the element. An element that is not described in conjunction with a figure may be presumed to have the same characteristics and function as a previously-described element having the same reference designator.
DETAILED DESCRIPTION
[0022] The present application discloses an improved direct-latching lock of the slam-bolt variety. The lock partly relies on a tongue or toggle, and thus will be termed a “toggle lock” herein. The toggle lock is especially beneficial for use on lockers placed within larger safes, but may also be used as a safe lock as well as a lock for any door closure. The bolt for the toggle lock preferably rotates, though a linearly-actuated bolt for a toggle lock otherwise having the same features is contemplated; thus the term “displacement” for the bolt encompasses any possible form of movement.
[0023] FIG. 1A is a horizontal sectional view through a door 20 being closed showing a prior art slam bolt lock 22 mounted thereon. The door includes a front panel 24 mounted on one or more hinges 26 to a door frame 28 , which forms a part of a safe, locker or other container of items to be secured. The slam bolt lock 22 engages a door jamb 30 on one side of the door frame 28 . In the step of closing the door 20 , a bolt 32 of the slam bolt lock 22 is pushed in by contact with the door jamb 30 . In particular, a rear face of the bolt 32 is curved or ramped so that the jamb 30 cams the bolt 32 laterally inward into the body 34 of the slam bolt lock 22 and against the resistance of an internal spring (not shown).
[0024] FIG. 1B shows the bolt 32 of the slam bolt lock 22 engaged behind the door jamb 30 in a locked position. That is, once the front outer corner of the bolt 32 clears the door jamb 30 , the internal spring pushes it back outward to its locked position. A flat front face of the bolt 32 then contacts the door jamb 30 , which interference prevents the door 20 from opening. Although not shown, an internal solenoid or other actuator may be used to retract the bolt 32 laterally into an unlocked position to enable opening of the door 20 . The lateral actuation direction of the bolt 32 to unlock it is shown.
[0025] As mentioned above, there are two main drawbacks to this simple design. First, the bolt 32 is not dead-latching, meaning it can be retracted laterally in the actuation direction into its unlocked position through the use of a thin tool or other such device (think of a credit card used to push back a conventional slam bolt lock in the door of a structure). Secondly, any loads imposed on the inside of the lock 22 or door panel 24 in the opening force direction tends to cause the bolt 32 to press against the door jamb 30 . This interferes with the operation of the opening solenoid and may even prevent the lock 22 from functioning properly or ultimately cause damage to the lock 22 .
[0026] FIG. 2A is a horizontal sectional view through a door 40 being closed showing a toggle lock 42 of the present application mounted thereon. As before, the door 40 includes a front panel 44 mounted on one or more hinges 46 to a door frame 48 , which forms a part of a safe, locker or other container of items to be secured. The slam bolt lock 42 engages a door jamb 50 on one side of the door frame 48 . In the step of closing the door 40 , a bolt 52 of the toggle lock 42 rotates from a retracted or unlocked position within a body 54 of the toggle lock 42 into an advanced or locked position as shown in FIG. 2B . It should be understood that the generic door configuration shown represents numerous locking door assemblies, and the present toggle lock will be useful in any number of such assemblies.
[0027] FIG. 2A shows a tongue or toggle 56 of the toggle lock 42 extending laterally out from the lock body 54 . As the door panel 44 closes, the toggle 56 eventually contacts an outer face of the door jamb 50 causing it to rotate; a counter-clockwise (CCW) direction in the orientation shown. As will be explained below, the toggle 56 internally engages the bolt 52 and causes rotation thereof from its retracted (unlocked) position to its advanced (locked) position. The bolt 52 simply rotates into the position of FIG. 2B behind the door jamb 50 , without contact therewith, while toggle 56 ends up in a resting state between the door jamb 50 and the toggle lock body 54 , just inside of the door panel 44 . As with the prior art slam bolt lock 22 described above, when in the advanced position a flat front face of the bolt 52 of the toggle lock 42 is juxtaposed against an inner face of the door jamb 50 and contacts the door jamb when an opening force is applied to the door panel 44 , which interference prevents the door 40 from opening.
[0028] FIGS. 3A-3D are elevational views of different sides of the exemplary toggle lock 42 of the present application. As mentioned, the toggle lock 42 includes a body 54 formed of high strength steel or the like. Typically the body 54 includes two somewhat similar halves securely joined together to form a hollow interior within which the locking mechanism is mounted. The toggle lock 42 is shown in its locked state with the bolt 52 extended from within the body 54 and the toggle 56 rotated to the position as seen in FIG. 2B .
[0029] The toggle lock body 54 preferably mounts to the door panel 44 via a mounting plate 58 extending out from the body and having holes through which a plurality of Allen bolts 60 extend. More preferably, the body 54 has a plurality of outwardly-extending flanges (not shown) with elongated holes that align with the mounting plate 58 holes so that the body 54 may be adjusted laterally with respect to the door panel 44 before the bolts 60 are tightened. A small pointer 64 on the mounting plate 58 registers with a series of position markings on the body 54 for this purpose.
[0030] FIG. 3D shows a pair of vertically stacked communication ports 62 opening rearwardly from the body 54 . Although not shown in FIGS. 2A and 2B , an electronic lock control such as a numeric touch pad will also be mounted to the door panel 44 or frame 48 and connected to the communication ports 62 to actuate the toggle lock 42 . There are numerous types of such electronic lock controls available, and the present application is not limited thereby. Furthermore, although the lock actuation described herein is electro-mechanical, purely manual lock controls may also be incorporated as will be appreciated by those of skill in the art. In this sense the term “lock control” refers to both manual and electro-mechanical versions.
[0031] FIGS. 4A-4B are cutaway perspective views of a front portion of the exemplary toggle lock 42 of the present application. The bolt 52 is shown extending out of an aperture in the body 54 in its advanced or locked position. The bolt 52 rotates about an axis 64 fixed with respect to the body 54 via a journal bearing or simple shaft and tube arrangement. The direction of rotation is shown by a double-headed arrow. Likewise, the toggle 56 rotates about the same axis 64 .
[0032] A spring-loaded detent plunger 66 has a lower end 68 rotatably mounted to a shaft stub (not numbered) carried by the bolt 52 and an upper end 70 rotatably mounted to another shaft stub (also not numbered) on a solenoid body 72 fixed within the toggle lock body 54 . The shaft stub axes are parallel to the axis 64 . The lower end 68 of the detent plunger 66 is thus carried by the bolt 52 when it rotates. The detent plunger 66 includes a piston 74 connected to its lower end 68 that slides within a cylinder 76 connected to its upper end 70 , with a relatively strong spring 78 interposed therebetween to bias the piston out of the cylinder. The shaft stub on the bolt 52 to which the lower end 68 mounts traces an arc of rotation 80 that comes closest to the shaft stub on the solenoid body 72 at about a mid-point of travel of the bolt 52 . In this way, the spring-loaded detent plunger 66 applies opposite rotational forces to the bolt 52 depending on whether the bolt is in its locked or unlocked positions. That is, the spring 78 causes the piston 74 to extend from the cylinder 76 and hold the bolt 52 in its locked and unlocked positions. The bi-stable nature of the detent plunger 66 keeps the bolts 52 advanced with the door is closed and retracted with the door is open.
[0033] FIGS. 5A-5C are horizontal sectional views showing snapshots of closure of the door having the toggle lock 42 . Initially, as in FIG. 5A , the bolt 52 is retracted into the lock body 54 with the detent plunger 66 rotated CCW past the mid-point of its travel so that is biases the bolt in that direction. As will be described, the toggle 56 is spring-biased as well in a CCW direction about the axis 64 so that it remains extending generally laterally from the lock body 54 in an extended position and in the path of the door stop 50 as the door panel 44 rotates closed.
[0034] FIG. 5B shows further closure of the door panel 44 at a point where the door stop 50 makes contact with the toggle 56 and rotates it CCW. Engagement between the toggle 56 and the bolt 52 causes likewise CCW rotation of the bolt, as shown by the movement arrow. The shape and rotational path of the bolt 52 allows it to rotate around to the back side of the door stop 50 with ease. In this moment the detent plunger 66 rotates CCW as well toward its mid-point of travel, at which time it will apply an opposite rotational bias to the bolt 52 . Closure of the door panel 44 in this regard thus must overcome the force of the spring 78 on the detent plunger 66 , but the weight of the door and its relatively large leverage overcomes the spring fairly easily. It should be noted that the rear face of the bolt 52 is curved as with conventional slam bolt locks, although the purpose is not for engagement with the door jamb 50 , rather the curved surface facilitates rotation in and out of the body 54 , and reduces the overall size of the lock 42 .
[0035] Finally, FIG. 5C shows the door panel 44 closed against the door jamb 50 and the toggle lock 42 locked. The bolt 52 is fully advanced to its locked position behind the door jamb 50 and is biased into this position by the detent plunger 66 . An inside face 81 of the bolt 52 travels past a point at which a solenoid shaft 82 may extend from the solenoid body 72 . See also FIG. 4B where the solenoid shaft 82 is shown engaged with a chamfer 84 having a ledge that limits travel of the shaft. The chamfer 84 is shown on the front of the bolt 52 in FIG. 3C but extends around to the back side.
[0036] Imposition of the solenoid shaft 82 behind the direction of travel of the bolt 52 prevents the bolt from rotating in a clockwise (CW) direction. The solenoid body 72 preferably has a direct drive solenoid coil and magnet within that has a relaxed state when the solenoid shaft 82 extends, and when energized pulls the solenoid shaft 82 back into its housing. The solenoid is actuated via signals received by the communication ports 62 . This linear movement of the solenoid shaft 82 may also be accomplished by a purely mechanical lock control, as mentioned, and the solenoid shaft 82 may rotate into its locked position rather than translate. Variations on these mechanisms are well known in the art, and the general term “blocking member” will be used to encompass the solenoid shaft 82 as well as other equivalent structures.
[0037] FIGS. 6A-6C are horizontal sectional views showing opening of the door panel 44 having the toggle lock 42 . Initially, the lock control is actuated so that the solenoid shaft 82 (or blocking member) retracts from within the rotational path of the bolt 52 . That is, the solenoid shaft 82 no longer abuts the inside face 81 of the bolt 52 . At this stage the bolt 52 remains in its locked position, but there is no longer anything preventing its movement other than the bias of the spring detent plunger 66 .
[0038] FIG. 6B shows the door panel 44 being opened such that the door jamb 50 contacts and rotates the bolt 52 in a CW direction about the axis 64 . Eventually the bolt 52 rotates far enough so that the detent plunger 66 passes the bi-stable point and consequently biases the bolt in the CW direction.
[0039] Finally, FIG. 6C shows the bolt 52 fully retracted within the lock body 54 and held in this position by the detent plunger 66 . The lock 42 is fully open. It should be noted that actuation of the solenoid will not cause extension of the solenoid shaft 82 because of the presence of the bolt 52 . In this manner the door panel 44 is not prevented from closing. Desirably, with an electronic lock control, an attempt to actuate the solenoid when the door is open returns an error message.
[0040] FIGS. 7A-7B are cutaway perspective views of the exemplary toggle lock 42 showing engagement of the toggle 56 with the rotating bolt 56 . As mentioned, both the bolt 52 and toggle 56 rotate about the axis 64 fixed on the body 54 . The toggle 56 is free to rotate with respect to the bolt 52 within limits, and is spring biased in the CCW direction relative to the bolt 52 . More specifically, a coil spring 90 secures at one end to a pin 92 on the inside of the bolt 52 and at the opposite end to a finger 94 extending rearwardly from the toggle 56 . Further, a small rearwardly-extending wedge-shaped projection 96 on the toggle 56 comes into contact with the inside face 81 of the bolt 52 , as best seen in FIG. 4B . When the toggle 56 rotates in a CCW direction from contact with the door jamb 50 , as seen in FIG. 5B , the wedge-shaped projection 96 rotates the bolt 52 as well. In this way, the toggle 56 and bolt 52 move together when the door is closed. Likewise, when the door opens the door jamb 50 forces the bolt 52 and toggle 56 to rotate CW in tandem. The spring 90 maintains the wedge-shaped projection 96 in contact with the inside face 81 of the bolt 52 so that the toggle does not swivel loosely and interfere with the subsequent door closing operation.
[0041] FIG. 7B illustrates a hard stop 98 for the bolt 52 . Specifically, the stop 98 comprises a cylindrical post fixed within the body 54 that is received in a similarly shaped recess 99 formed in the rear face 81 of the bolt 52 . CW rotation of the bolt 52 when opening the door eventually causes the plunger 66 to bias the recess 99 into contact with the post 98 , thus limiting further travel.
[0042] Some of the lock features and differences are:
[0043] a. The present lock works on the plane of intended action, and is engineered to provide greater holding strength. Conventional “Slam Bolt” locks are adaptations of Boltwork Blocking Lock designs, where the intended locking direction is lateral in the direction of the Boltwork travel. These locks were never intended to be used where the forces are imposed in the axial direction, only lateral. Consequently, they are weak and easily broken or defeated in locker door use. In contrast, the present lock actuates in an axial direction following the direction of door travel. It is mechanically stronger in the direction of door motion.
[0044] b. The present lock provides better actuation, as it uses a rotational actuation path that follows the geometry of the closure mechanics. Slam bolt locks are loaded in an unnatural direction when the locker doors are pulled. Many times, the doors retain contents like cash bags that impose a load on the inside of the door, pushing the slam bolt into the jamb, impeding the free motion of the bolt to retract, thus causing failed openings. Many slam bolt locks are actuated by a solenoid pulling the bolt into the unlocked position. The present lock is held in the locked position by a strong spring detent plunger that prevents the unintended loads from hindering the lock actuation. Further, in a Slam Bolt lock the bolt is retracted my one of two types of designs, 1) Manual Knob on the face of the door, and 2) by a direct-drive Solenoid that pulls the bolt to the unlocked position. The direction of loads and resulting wear are imposed on surfaces that were not intended to be structurally loaded. The present lock bolt is a rotating component that is blocked by a blocking element controlled by a manual or electro-mechanical actuator such as a direct-drive solenoid. When the actuator is energized, the door can be pulled with moderate force to cause the bolt to “toggle” to the unlocked position. The spring loaded detent plunger works in an “over-center” action to also hold the bolt in an unlocked condition one the door is pulled open. There is a spring loaded release bar in the Bolt that contacts the jam during closure, which trips the rotating bolt back into the locking position.
[0045] c. The present lock is dead-locking, and cannot be articulated without using the intended electronics to actuate the blocking device. With a Slam bolt lock, the bolt can be pressed in against spring force, and cannot be dead-latched because it must be free to push in as it contacts the jamb during door closure. This is true for solenoid or knob actuated slam bolt locks. This presents a security risk, as opening can be accomplished by using a fishing probe from any opening where access may be made. The present lock is actuated by the pulling on the door (a pull knob is present, not shown). Once the bolt is locked, it cannot be moved to an unlocked position unless the internal blocking actuator is activated to provide the freedom of motion to rotate open.
CLOSING COMMENTS
[0046] Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than limitations on the apparatus and procedures disclosed or claimed. Although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Acts, elements and features discussed only in connection with one embodiment are not intended to be excluded from a similar role in other embodiments.
[0047] As used herein, “plurality” means two or more. As used herein, a “set” of items may include one or more of such items. As used herein, whether in the written description or the claims, the terms “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” respectively, are closed or semi-closed transitional phrases with respect to claims. Use of ordinal terms such as “first”, “second”, “third”, etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements. As used herein, “and/or” means that the listed items are alternatives, but the alternatives also include any combination of the listed items.
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There is disclosed a dead-latching slam bolt lock that includes a rotating dead-latching slam bolt which prevents attempts at breaking in without actuating the lock mechanism. A tongue or toggle acted on by the door jamb engages the bolt and initiates rotation thereof in the door closing direction, but is passive in the opening direction. The locking mechanism may be manual or electronic, and controls the position of a blocking element which alternately prevents and permits unlocking (rotation) of the rotating bolt. In a forward or blocking position, the blocking element prevents rotation of the bolt from a locked position, while in a retracted position the blocking element permits rotation of the bolt to an unlocked position. A spring detent plunger holds the rotating bolt in either its locked or unlocked positions.
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BACKGROUND
Business organizations may use a multitude of computing systems, both internal and external to the business, for carrying out business processes (e.g., order processing, product delivery scheduling). A single business process may be carried out by various services, which may involve many types of computer systems, software applications or computing platforms. For example, a network terminal may serve as a first service for confirming receipt of an order. In the next step in the business process, a server may use a software package to query a datastore to determine if the order can be filled. A web page may serve as a third type of application for entering and tracking order specifics. Similarly, several other types of services may be required to complete the business process. Managing the performance of the business services may contribute to maintaining an efficient, profitable business.
Business-oriented management of web-based services may refer to the problem of understanding the impact of web-based services execution from a business perspective, and additionally, of correcting and optimizing web-based service executions based on business objectives. Addressing this issue may provide alignment between information technology (IT) operations and business goals. There may be an increasing need for closely controlling the IT infrastructure based on business needs. For example, a web-based service could offer operations that allow clients to order goods and request their delivery. The quality of the web-based service executions may have a direct effect on the quality of the business transactions, as well as on the relationships between clients and service providers. Consequently, it is desirable to monitor the services in a holistic manner that is meaningful to a business user.
Monitoring the execution of web-based services is closely related to monitoring business interactions with partners. Accordingly, the Service Level Agreements (SLA) stipulated by the service provider with the interacting party pose constraints on how web-based services should operate to meet the SLA's. Business-oriented management of web-based services exploits this link, using business metrics as the criteria based on which web-based services are be monitored and controlled. Business-oriented management may be achieved by collecting and analyzing Simple Object Access Protocol (SOAP) messages to provide business-meaningful metrics. For example, a company that may provide a web-based service allowing clients to purchase PCs, and also may provide an operation called order( ) as part of its Web Services Description Language (WSDL) interface. A business manager may consider a purchase transaction with a client to be successful if the order( ) operation returns in less than 30 seconds and has an output result of “accept”. If this information can be determined from the logged SOAP data, then it may be possible to determine historic success rates by querying such data.
While this approach may be viable, it may have many severe limitations. Specifically, it may require a large development and maintenance effort to implement the code-mapping execution data into business metrics, and it may suffer from performance problems whenever a large number of real-time reports are needed. However, the most severe limitation may be the lack of support for a holistic view of the interactions that occur through web-based services.
It may be desirable to obtain a complete picture of the external quality of the interactions, as perceived by the clients, and its relationships with the way services are executed internally. Further, it may be desirable to facilitate the rapid creation of custom metrics, without the need for intensive coding by the business user.
SUMMARY
A method and system are disclosed for monitoring the performance of web-based services. The method comprises receiving a transaction from a client and routing the transaction to an appropriate web service for execution of the transaction. During execution of the transaction, performance data relating to the execution of the transaction is monitored and logged. The collected performance data is then queried based on pre-defined performance metrics and web service performance reports are generated. A system for the foregoing method is also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of the embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIG. 1 illustrates a conceptual web service configuration in accordance with embodiments of the invention;
FIG. 2 illustrates a web-services management model in accordance with embodiments of the invention; and
FIG. 3 illustrates the web services manager of FIG. 2 in accordance with embodiments of the invention.
NOTATION AND NOMENCLATURE
Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, different companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”
The term “computer” is intended to mean a computing entity, which may be a server, terminal, personal or other computer, or a network of computing entities working together as a unit. The term “datastore” refers to a computing entity housing a collection of data organized for search and retrieval, such as relational databases, directory services, or in some instances even some types of defined or open format text files. The term “network” encompasses any of the various pathways computers or systems may use for communication with each other including Ethernet, token-ring, wireless networks, or the internet. The term “service” refers to one or more linked computing entities. The term “application” refers to an executable software package or program that can be run on a computing entity. The term “transaction” refers to an interaction between two computing entities, and more particularly, in a message-based event or command. The term “composition” refers to a set of transactions specific to the web services manager. The term “conversation” refers to a set of transactions between a client, or customer, and a composite web service.
DETAILED DESCRIPTION
The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure is limited to that embodiment.
FIG. 1 illustrates a conceptual web service configuration 100 , according to some embodiments. A client 110 may access a web service 120 from a program interface. The web service 120 may be a set of programs made available through the web. The web service 120 may provide a multitude of functions for carrying out a business process (e.g., a sale or order) for the client 110 , which may be a user within the business or an external customer. Web service 120 may be a composite web service, drawing information and interacting with other potentially external web services 122 , 124 , yet presenting responses to the client 110 through a single interface.
The client 110 may conduct an electronic conversation 130 with the web service 120 . The conversation 130 may comprise a plurality of exchanged messages 141 - 145 , the expected order and content of which may be defined by means of a conversation definition language. As an example, conversations can be described using the Web Services Conversation Language (WSCL) or using the Business Process Execution Language (BPEL). In an exemplary interaction, a client 110 may send a quote request message 141 to the web service 120 . The web service 120 may reply with a quote reply message 142 . If the quote is reasonable, the client 110 may choose to proceed with the order by sending an order message 143 , followed by a payment message 144 and a message 145 confirming delivery details, such as an address. Interactions between the client 110 and the web service 120 may be on a program-to-program basis. Conversation specifications may be advertised and made available to users, so that they are aware of how to correctly interact with the web service. Further, a business user may define metric benchmark values, and may use client inputs to set appropriate benchmarks.
In contrast to conversations, the internal implementation of a Web service may be private. The way a service is implemented may not be disclosed to clients who, in principle, may be unaware of whether the service is a composite service. If the service is a composite service, then its implementation may leverage service composition technologies. This may mean that the internal logic of the web service may be specified by way of a service composition language (e.g., BPEL), and its execution may be supported by a service composition engine.
FIG. 2 illustrates an embodiment of the web-services management model 200 , which may comprise components for conducting interactions between web services and a client. A Simple Object Access Protocol (SOAP) tracker 210 may log messages, information regarding who sent the messages, when the messages were sent, and with which parameters. A SOAP router 212 may accept messages coming from the client and determine the internal application (e.g., a web service 250 ) to which the messages should be directed. Application server 214 may aid in development and implementation of the web services 250 . The application server 214 may comprise workload-balancing features, and data recovery and data translation features, including parsing and data extraction between languages. Application server 214 may also comprise a service composition engine 218 .
Service registry 216 may contain definitions of services offered to a client, definitions of conversations, and a listing of services provided. Service composition engine 218 may be an internal component that executes a business process, e.g., calling other web services 250 as needed, as specified by the composition logic. Service execution logs 220 may record execution data from the composition engine 218 . Data extraction component 222 may acquire data, such as the definition of a web service's interface and conversation specification, from the service registry 216 , extracting it into the service execution logs 226 . Data extraction component 224 may have a similar function, pulling data from the service composition engine 218 and extracting it into the service execution logs 226 , which the web services manager (WSM) 230 may use as a basis for analysis.
The WSM 230 therefore may have access to data about a conversation from the service registry 216 , as well as data about compositions from the service composition engine 218 . SOAP router 212 , application server 214 , service registry 216 , service composition engine 218 and service execution logs 220 may be grouped together as components that facilitate and support the definition and execution of web services, and consequently, collectively form a web services platform 202 .
The WSM 230 of FIG. 2 may be illustrated in greater detail in FIG. 3 , which illustrates how the WSM may present data to a business user 304 via a web framework 332 . WSM components may comprise the WSM definer 310 , the WSM engine 314 , and the web framework 332 . An IT manager 302 may use a WSM definer 310 to define certain metrics, which are parameters to measure during execution of the business process, and may correspond to properties of web services and their executions that may be of interest to analysts. Typical metrics may include execution times, cost, and service availability.
The WSM definer 310 may be linked to a metric schema 312 , which may store the metric definitions as well as their implementation (i.e., how metrics are to be computed based on service execution data). For example, a user could define a metric “performance,” used to classify service executions into categories “acceptable” and “unacceptable.” The user could also define that a processing time of less than 5 seconds is acceptable, while more than 5 seconds is unacceptable. Similarly, a user could define a metric called “violation of service level agreement (SLA),” to measure whether a service execution failed to meet certain service-level guarantees stipulated with the client. The implementation of this metric may depend on how such guarantees are defined.
The implementation of metrics may be based on the conversation specification. For example, an SLA may require that the time between the execution of two operations within a certain conversation be less then a specified time interval. If a service execution exceeded that time, this would later be reported as failing to meet the SLA of the particular execution. The stored metrics definitions allow for the definition of custom metrics, in a way that is useful to a business user. The implementation of the metric may be a function defined with assistance from data formatting known to be present in the service execution logs.
Embodiments of the invention may allow a user to define a metric without coding by using a metrics construction model and various functions from the metrics library. For example, the WSM of at least some embodiments may comprise a built-in function that computes whether the time between the execution of two operations O 1 and O 2 in the same conversation is greater than a threshold T. This function may be used to define a variety of metrics, such as the example described above and related to SLA's. By pre-building such functions into the WSM, users do not have to write code when defining a new metric. A user can merely specify that a metric implementation uses a certain built-in function with certain parameters. The metrics construction model may include an algorithm or coding that facilitates the construction of a custom metric from one or more functions and one or more parameters. For instance, on a web-based interface, a business user may be able to select desired function(s) and parameter(s) from an onscreen menu. The metrics construction model could then assemble a metric based on the choices and then report values associated with the metric, based on historical data.
The provision of readily usable built-in functions may be because the WSM assumes that the service execution logs contain certain information structured in a certain way. Specifically, some embodiments assume that the information in the service execution logs comprises service interface definitions specified in WSDL, and conversation definitions and service compositions specified in BPEL. These embodiments may further assume that messages are exchanged using the SOAP conventions. Since the service execution logs data model may be known, it may be possible to write functions that access the logs and compute metric values from stored performance data. The service execution logs may store performance data, such as service availability, maintenance costs, and time to complete a transaction, in a format such that the web services manager can easily extract relevant data. The functions can be reused by a variety of metrics, so that when users define a new metric, they do not have to write code, but can just use a function from the built-in library. For example, a user may construct a custom metric by selecting one or more functions from the function library, assigning a set of parameters and relying on the metrics construction model to generate a custom metric from these components. A function from the function library may be used multiple times to construct a number of custom metrics.
Referring again to FIG. 3 , the WSM engine 314 may be a runtime component that receives inputs from the metric schema 312 , as well SOAP data 316 , interface and conversation definitions 318 , and composition service definition and execution data 320 . The WSM engine 314 may periodically read the metric definitions and data from the input components 316 , 318 , 320 . The WSM engine 314 may then apply the metric implementation functions to the data contained in the service execution logs to produce on output to the measures and reports component 322 . The measures and reports component 322 may serve to package the output of the WSM engine 314 into reports that are viewable on a web framework 332 that may be hosted by an application server 330 . In some embodiments, measures and reports (e.g., whether a service execution has violated an SLA) may be stored in a relational database. As such, they can be accessed with reporting tools to provide users with charts and statistics on the computed measures.
In at least some embodiments, the functionality of the composite web service, as well as each message in a conversation, can be monitored and measured, since the WSM has knowledge of the data model of the service execution logs. As explained above, high-level metrics, such as cost and quality, can be defined and monitored. The web framework 332 may allow access to the reports by means of an ordinary web browser. A WSM user may make reports on the computed measures available to other users via a web browser. To make this possible, the WSM may comprise a Java object that receives input and the name of a user-defined metric and return images (e.g., in GIF format) showing charts that provide statistics on the particular metric.
Exemplary reported statistics may include averages, maximums, minimums, and standard deviations. Images in GIF format may be embedded in a web page. Consequently, it is possible to develop web pages that display the results as computed by WSM. By viewing the information presented on the web framework 332 , a business user, such as a business or IT manager 304 , can quickly assess the status and performance of messages within a conversation, as well as interactions between the various web service management components and systems. It will be understood that the components disclosed in FIGS. 2 and 3 may comprise computing hardware, software applications stored on a readable storage medium and/or coding scripts for running within a software application instance.
Metrics regarding conversations and compositions can be defined and correlated. As previously mentioned, a service interacts with client applications according to a conversation specification, but the internal logic that implements the conversation may be defined by a composition. Users may define metrics on conversations to study how clients perceive the execution of the service. However, business users may define metrics on compositions to analyze the internal execution quality of a service.
It may be useful to analyze how external and internal quality are associated. To this end, the WSM of at least some embodiments allow the correlations of metrics defined for conversations with metrics defined for the compositions. For example, a metric associated with a conversation may be intended to compute whether a conversation (i.e., an interaction with a client) has met a stipulated SLA, and a metric associated to composition may be meant to measure an internal execution cost. Analysts may then be interested in correlating these two metrics to discover how the execution cost affects the ability to deliver the service in accordance with the stipulated SLA. In accordance with some embodiments, the WSM is programmed with knowledge of the formatting of the service execution logs data model. As such, the WSM may determine which composition instance (i.e., an execution of the composition) corresponds to which conversation instance (i.e., a certain message exchange with a client). Accordingly, the WSM may correlate metrics computed for a composition with measures computed for the conversations that these compositions supported.
The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, instead of presenting data via a web framework 332 , the metrics information could be downloaded into a file and viewed on a software application, such as a spreadsheet. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A method and system are disclosed for monitoring the performance of web-based services. The method comprises receiving a transaction from a client and routing the transaction to an appropriate web service for execution of the transaction. During execution of the transaction, performance data relating to the execution of the transaction is monitored and logged. The collected performance data is then queried based on pre-defined performance metrics and web service performance reports are generated. A system for the foregoing method is also disclosed.
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This application is a division of application Ser. No. 09/435,177, filed Nov. 5, 1999.
BACKGROUND OF THE INVENTION
Paper coating compositions are used by the paper industry to impart the desired strength and cosmetic properties to finished paper. The coating composition is typically an aqueous dispersion consisting mainly of mineral pigments, such as clay, calcium carbonate, silica, and titanium dioxide, and pigment binders, such as starch and synthetic polymer emulsions. Coating compositions may also contain low levels of additives, such as thickeners, humectants and lubricants.
The coating compositions are usually applied to a continuous web of cellulosic material, such as paper, by high speed coating machines, such as blade coaters, air knife coaters, rod coaters and roll coaters. There are trends to use faster coaters to increase productivity and to use higher solids coating compositions to decrease drying costs and improve binder distribution which enhances paper quality.
Coatings which contain fine particle size pigments, such as calcium carbonate, have been shown to be particularly useful in improving the properties of ink jet recording paper. U.S. Pat. No. 5,643,631 (Donigian et al., 1997) and U.S. Pat. No. 5,783,038 (Donigian, et al., 1998) disclose thermal ink jet recording paper, incorporating heat aged precipitated calcium carbonate and a binder, such as poly(vinyl alcohol), starches, and carboxymethyl cellulose. Treatment of paper with a coating composition of a slurry of fine particle size calcium carbonate in a poly(vinyl alcohol) or starch solution resulted in improved optical density of ink jet print. An example of an appropriate poly(vinyl alcohol) binder was Airvol® 107 poly(vinyl alcohol) which is 98 to 98.8% hydrolyzed. The binders were “cooked” to obtain a solution prior to addition of the pigment slurry.
The use of poly(vinyl alcohol) and its derivatives as binders in ink jet coating systems are well known in the art. For example, an article by C. A. Finch in Polyvinyl Alcohol—Developments, Wiley, 1992, pages 555-556, describes the use of poly(vinyl alcohol) as a binder for ink-jet printing paper. Poly(vinyl alcohol), 98-99% hydrolyzed and a 4% viscosity of 25-31 cP (Poval-PVA-117) was reported to be generally used.
An article in Tappi Journal, Vol. 80, No.1, January 1997, pp. 68-70, by John Boylan, entitled, “Using Polyvinyl Alcohol in Ink-Jet Printing Paper,” describes the use of various grades of poly(vinyl alcohol) for coating paper. It is noted that partially hydrolyzed grades of poly(vinyl alcohol) provide the best printability in terms of ink optical density and dry time when used with silica pigments in paper coatings. However, the final viscosity of poly(vinyl alcohol)/silica coatings increases sharply with small increases in solids. Because of the viscosity increase, the maximum solids is about 25 to 30%, depending on the grade of poly(vinyl alcohol). Partially hydrolyzed low/medium molecular weight grades allow for the highest level of coating solids.
There are many patents on the use of poly(vinyl alcohol)as a pigment binder for paper coatings. For example:
U.S. Pat. No. 4,478,910 (Oshima et al., 1984) discloses ink jet recording paper comprising a base sheet with a specific sizing degree having a coating layer comprising a water-soluble polymeric binder and fine silica particles. The silica particles have a specific surface area of more than 200 m 2 /g and poly(vinyl alcohol) or its derivatives are desired as binder because of their optical density. PVA 117, manufactured by Kuraray, was used in the examples.
U.S. Pat. No. 4,780,356 (Otouma et al., 1988) discloses a recording sheet comprising a sheet of paper with porous particles on the paper surface. The porous particles (e.g., silica, silica-alumina, alumina, and silica-boria) have an average pore size of 10 to 5000 Å, a pore volume of 0.05 to 3.0 cc/g, and an average particle size of 0.1 to 50 μm. Poly(vinyl alcohol) may be used as a binder for the particles in an amount of 5 to 60% (preferably 20 to 40%) by weight based on the total weight of binder and particles. PVA 117, manufactured by Kuraray, was used in the examples.
U.S. Pat. No. 5,057,570 (Miller et al., 1991) discloses a method of preparing a high solids, aqueous paper coating composition in which dry particulate solids of a partially hydrolyzed, low molecular weight poly(vinyl alcohol) is added to a high solids, aqueous pigment dispersion and mixed, without external heating, until dissolved. The aqueous pigment dispersion typically contains clay and/or calcium carbonate at solids levels of 70 to 76%.
U.S. Pat. No. 5,270,103 (Oliver, 1993) discloses a receiver sheet having a coating and suitable for printing with aqueous based inks, comprising a pigment, poly(vinyl alcohol) binder, and an additional binder component. The poly(vinyl alcohol) is at least 87 mole % hydrolyzed, preferably at least 99 mole % hydrolyzed.
JP 11-4983 (1999) discloses mixing poly(vinyl alcohol) with an organic and/or inorganic powder, and combining the mixture with water to obtain a non-lumping dispersion having a high concentration of poly(vinyl alcohol). The dispersion is reported to be useful adhesives and paints. The poly(vinyl alcohol) powder has an average particle of 500 μm or less, a degree of polymerization of 500 to 3000 (preferably 100 to 2500), and is 75 to 95 mole % (preferably 75 to 90 mole %) hydrolyzed. The two materials are blended in a volume ratio of 1/0.2 to 1/15 poly(vinyl alcohol)/organic and/or inorganic particles. Examples of inorganic particles are clays, silica, calcium carbonate, and barium sulfate.
As noted above, fine particle size calcium carbonate has been shown to be a particularly useful pigment in coating compositions for ink jet recording paper; however the fine particle size results in a very high viscosity in the low shear rate range after the particles are put into a slurry at the levels needed for inkjet paper coating compositions. The high viscosity in this low shear rate range presents problems in handling the dispersion during the coating process.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to producing a paper coating composition having improved low shear viscosity at a high solids level of fine particle size calcium carbonate. The improvement in low shear viscosity is achieved by dissolving, without heating and without adding water, a fine particle size, partially hydrolyzed, low molecular weight poly(vinyl alcohol) powder in an aqueous slurry of pigment particles which is predominantly fine particle size calcium carbonate. The poly(vinyl alcohol) has an average particle size of 200 μm or less, is 85 to 90 mole % hydrolyzed, and has a degree of polymerization of 50 to 600. The slurry, containing 0.1 to 50 parts poly(vinyl alcohol) per 100 parts pigment particles, can then be formulated with other components to produce a paper coating composition for specific applications such as ink jet paper coatings.
There are several advantages to preparing a coating composition by first mixing fine particle size, partially hydrolyzed, low molecular weight poly(vinyl alcohol) powder directly to the fine particle size calcium carbonate slurry. They include:
the poly(vinyl alcohol) does not need to be solubilized prior to mixing with the calcium carbonate slurry, thus eliminating the problem of adding more water to the slurry and reducing the amount of solids;
the poly(vinyl alcohol) can be solubilized in the calcium carbonate slurry without heating;
the low shear viscosity of the calcium carbonate slurry is significantly reduced, thus allowing greater mixing efficiency, improved filterability, and improved pumping efficiency of the final coating formulation;
the solids level of the pigment slurry can be increased without increasing the shear viscosity, thus enabling easier handling of the final coating formulation;
binding of the calcium carbonate to a cellulosic substrate, despite its high surface area, is accomplished with a relatively small amount of poly(vinyl alcohol); e.g., as low as 5 to 15 parts of poly(vinyl alcohol) per 100 parts pigment;
no additional binders are needed in the final coating formulation; and
the poly(vinyl alcohol)/calcium carbonate coating formulation, when applied to a paper substrate as an ink jet paper coating, provides excellent ink jet printability.
DETAILED DESCRIPTION OF THE INVENTION
The aqueous pigment dispersion typically consists of at least about 90% by weight fine particle size calcium carbonate at solids levels ranging from 10 to 50%; preferably 20 to 30%. Up to about 10% of other paper pigments such as clays, silica, and titanium dioxide may also be present.
The fine particle size calcium carbonate has a mean surface area of at least 50 m 2 /g; preferably at least 80 m 2 /g. Fine particle size calcium carbonate can be prepared by heat aging and/or milling precipitated calcium carbonate, such as the method described in U.S. Pat. Nos. 5,643,631 and 5,783,038. Calcium carbonate having a mean surface area of 80 m 2 /g is available commercially tinder the trademark JETCOA™ 30 Specialty PCC from Specialty Minerals.
Suitable fine particle size, low molecular weight, partially hydrolyzed poly(vinyl alcohol) powder for use in this invention can be 70 to 90, preferably 85 to 90, and most preferably 87 to 89 mole % hydrolyzed, have a degree of polymerization (DPn) of 50 to 600, preferably 150 to 300, and an average particle size of 200 μm or less; preferably, 180 μm or less. An example of a preferred poly(vinyl alcohol) powder is Airvol® 203S poly(vinyl alcohol) supplied by Air Products and Chemicals, Inc. The poly(vinyl alcohol) used in this invention can be prepared by synthesis and saponification techniques well-known to those skilled in the art of manufacturing poly(vinyl alcohol). A fine particle size of the poly(vinyl alcohol) can be achieved by grinding the poly(vinyl alcohol) particles and passing the particles through a mesh.
The fine particle size, low molecular weight, partially hydrolyzed poly(vinyl alcohol) powder is slowly added to an agitated calcium carbonate slurry at a rate that does not cause clumping of the poly(vinyl alcohol). Typically, adding poly(vinyl alcohol) at a rate of 1% of poly(vinyl alcohol) in 10 seconds is sufficient to prevent clumping. Mixing is continued until the poly(vinyl alcohol) is solubilized; typically, mixing is continued at least 15 minutes. Mixing of the calcium carbonate slurry with the dry fine poly(vinyl alcohol) powder is preferably carried out at high shear rates. The amount of poly(vinyl alcohol) can range from 0.1 to 50 parts/100 parts of pigment; preferably 3 to 25 parts of poly(vinyl alcohol)/100 parts pigment. Amounts of 5 to 15 parts of poly(vinyl alcohol)/100 parts fine particle size calcium carbonate have been found to efficiently bind the pigment. Solubilization of the poly(vinyl alcohol) can be carried out at ambient temperature, i.e., 20° C. Heating is not required to solubilize the poly(vinyl alcohol).
Low shear viscosity is the viscosity of a fluid (for example, calcium carbonate slurry containing 28 to 32% solids and 3 to 25 parts low molecular weight, partially hydrolyzed poly(vinyl alcohol) per 100 parts calcium carbonate) which results from the shear rate generated by a Brookfield viscometer (No.3 spindle at 100 rpm).
The high solids aqueous pigment dispersion containing poly(vinyl alcohol) can be used to prepare ink jet paper coating compositions or can be used directly as an ink jet paper coating composition. No additional binders or dispersants are needed in the coating composition. A typical coating composition for ink jet paper applications contains:
90 to 100 parts fine particle size calcium carbonate;
0 to 10 parts secondary pigment;
0.1 to 50 parts poly(vinyl alcohol);
0 to 3 parts cationic dye fixatives such as polyethyleneimine or poly(diallyldimethyl ammonium chloride); and
0 to 0.3 parts defoamer.
The invention will be further clarified by a consideration of the following examples, which are intended to be purely exemplary of the invention.
EXAMPLE 1
Viscosity Modification Effect
The viscosity modification effect of low molecular weight, partially hydrolyzed, fine particle size poly(vinyl alcohol) on slurries of fine particle size calcium carbonate was measured. An aliquot of Jet Coat™ 30 precipitated calcium carbonate (500 g in a slurry containing 25 to 30 % solids) was agitated with a high shear Dispersator type laboratory mixer. Various amounts of Airvol® 203S poly(vinyl alcohol) powder, in which 99% of the powder particles have an average particle size of less than 180 μm, were added to the agitated mixture at a rate of 1% per 10 seconds. Agitation of the mixture was continued for 15 minutes after addition of the Airvol 203S. In a comparative example, 0.3 g of tetrasodium pyrophosphate (TSPP) dispersant was added to the calcium carbonate slurry. The Brookfield Viscosity was measured at 10, 20, 50, and 100 rpm. Results of the measurements are shown in Table 1.
TABLE 1
0.3 pt
5 pts
10 pts
20 pts
TSPP
Jet Coat
A 203S
A 203S
A 203S
(dispersant)
30*
per
per
per
per
Solids
28.50%
28.04%
29.72%
31.64%
27.70%
Brookfield
Viscosity
10 rpm
6960
1530
990
900
5870
20 rpm
3980
810
545
550
3090
50 rpm
2008
358
264
318
1308
100 rpm
1152
209
165
223
690
*Supplied by Specialty Minerals as a slurry.
With most coatings, as solids increase, low shear viscosity increases. However, unexpectedly, addition of the Airvol 203S to the Jet Coat 30 resulted in a substantial reduction in low shear viscosity. Reduction of low shear viscosity leveled out at 20 parts Airvol 203S/100 parts calcium carbonate. The results obtained with the Airvol 203S were much better than those obtained with the TSPP dispersant.
EXAMPLE 2
Binding Effect
The effect of Airvol 203S as a binder for fine calcium carbonate particles on paper was measured. An uncoated base sheet of paper was secured to a glass plate with tape. The coating formulation was poured over the top width of the paper. A wire wound rod was placed at the top of the coating and drawn down the length of the paper applying a uniform application of the coating formulation across the length of the paper. The wet coated sheet was then dried in a forced air oven at 250° F. for 2 minutes.
The binding effect (IGT Pick Strength) was measured using Tappi Method T514 pm-82, “Surface Strength of Coated Paperboard.” Table 2 presents the results of IGT pick strength measurements.
TABLE 2
10 pts
20 pts
Jet Coat 30
A 203S per
A 203S per
0.3 pts TSPP
(no A 203S)
100
100
(dispersant)
IGT Pick
No bonding
9
14
No bonding
Strength
* VVP = viscosity velocity product (kilopoise-centimeters/second)
These data show that binding improved as the amount of Airvol 203S increased from 10 to 20 parts/100 parts Jet Coat 30. No bonding occurred using Jet Coat 30 alone or Jet Coat 30 with TSPP.
EXAMPLE 3
Printability
The ink jet printability of paper coated with a combination of Jet Coat 30 and Airvol 203S poly(vinyl alcohol) was measured by applying the coating formulation with a wire wound rod to an uncoated base sheet and drying the coating at 250° F. for 2 minutes. Coat weights were between 8 and 10 g/m 2 . Airvol 203S alone and a mixture of 0.3 pt. TSPP with Jet Coat 30 were used as comparative examples. The coated paper was printed on an Hewlett Packard HP 560 ink jet printer using a test pattern developed by Hewlett Packard. The optical density was measured with a Tobias IQ 200 Densitometer. The results are presented in Table 3.
TABLE 3
Base Sheet
A203S
10 pts
20 pts
0.3 pts TSPP
Comp Black
0.57
0.75
0.94
0.96
Magenta
0.77
N/A
1.14
1.1
Dusting
Yellow
0.61
N/A
0.85
0.83
Cyan
1.03
1.11
1.48
1.4
Mono Black
0.86
0.94
1.32
1.24
Ink jet printability of a binder used for ink jet paper coatings is very important. The binder must be hydrophilic enough to allow the ink vehicle to penetrate into the coating while allowing the ink to remain at the surface of the coating with the pigment. In addition, the binder must not contain undesirable surfactants which adversely effect the surface energy of the coating causing the ink to spread creating high ink dot gain leading to poor letter and image formation. One measure of ink jet printability is the ink optical density. The greater the density, the deeper the color shade produced.
The data in Table 3 show that the combinations of Jet Coat 30 and Airvol 203S provide significantly better optical density of ink jet printing than A203S alone. Airvol 203S is shown here to provide the hydrophilic property and it does not contain undesirable surfactants.
EXAMPLE 4
Comparison to other Pigments
The example compares the effect of Airvol 203S on the low shear viscosity of several pigments typically used for paper coating applications. An aliquot of pigment slurry was weighed out and water was added, if necessary to obtain the desired solids level. Agitation was then begun with a laboratory type mixer. Airvol 203S was slowly added to the agitating pigment slurry and mixing was continued for about 30 minutes. Complete solubilization of the Airvol 203S was checked by rinsing a small sample through a 325 mesh screen and checking for unsolubilized poly(vinyl alcohol). When the poly(vinyl alcohol was completely dissolved, the final solids was measured via the microwave technique. The viscosity of the mixture was then measured with a Brookfield viscometer at 100 rpm. Results are presented in Table 4.
TABLE 4
Run
Pigment Type
Pigment
%
Airvol 203S
Brookfield
1
Calcium Carbonate-A
12.6
70
0
85
2
Calcium Carbonate-A
12.6
70
5
775
3
Calcium Carbonate-A
12.6
70
10
3252
4
Calcium Carbonate-A
12.6
70
20
4560
5
Calcium Carbonate-A
12.6
30
0
15
6
Calcium Carbonate-A
12.6
30
5
19
7
Calcium Carbonate-A
12.6
30
10
25
8
Calcium Carbonate-A
12.6
30
20
40
9
Calcium Carbonate-B
7.1
70
0
204
10
Calcium Carbonate-B
7.1
70
5
400
11
Calcium Carbonate-B
7.1
70
10
2240
12
Calcium Carbonate-B
7.1
70
20
2830
13
Calcium Carbonate-B
7.1
30
0
14.4
14
Calcium Carbonate-B
7.1
30
5
18
15
Calcium Carbonate-B
7.1
30
10
25.1
16
Calcium Carbonate-B
7.1
30
20
39
17
Jet Coat 30 Calcium
80
30
0
1152
Carbonate
18
Jet Coat 30 Calcium
80
30
5
209
Carbonate
19
Jet Coat 30 Calcium
80
30
10
165
Carbonate
20
Jet Coat 30 Calcium
80
30
20
223
Carbonate
21
Clay
15
70
0
241
22
Clay
15
70
10
2140
23
Clay
15
30
0
17.2
24
Clay
15
30
10
31
25
Titanium Dioxide
7-30
70
0
125
26
Titanium Dioxide
7-30
70
10
288
The pigments of run no. 1-16 and 21-26 had low viscosities at 30% solids due to the greater particle size or reduced surface area of these pigments compared to the Jet Coat 30 (run no. 17-20); i.e., the Jet Coat 30 particles have a mean surface area which is 5 to 8 times the mean surface area of the other pigments in the example. It is well known that as the surface area of pigment particles increase, the viscosity of pigment slurries increase and addition of a binder, such as poly(vinyl alcohol), will result in a further increase in viscosity. However, unexpectedly, when Airvol 203S was added to the Jet Coat 30 calcium carbonate slurry (run no. 17-20), there was a substantial decrease in viscosity. In contrast, the viscosity increased when Airvol 203S was added to the other pigment slurry samples (run no. 1-16, 21-26).
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Production of a paper coating composition having improved low shear viscosity at a high solids level of fine particle size calcium carbonate. The improvement in low shear viscosity is achieved by dissolving a fine particle size, partially hydrolyzed, low molecular weight poly(vinyl alcohol) powder in an aqueous slurry of pigment particles containing predominantly fine particle size calcium carbonate. Dissolution of the poly(vinyl alcohol) is achieved without external heating or adding water to the slurry. The slurry can then be formulated with other components to produce the ink jet paper coating composition which, when applied to a paper substrate, provides excellent ink jet printability.
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BACKGROUND OF THE INVENTION
1. Field of Invention:
The present invention relates to snow poles which can be installed in connection with an existing delineator along a road side, particularly where snow accumulations can exceed the height of the delineator and thereby obscure its vision.
More specifically, the present invention relates to removable snow poles which can be installed or withdrawn in accordance with the seasons.
2. Prior Art:
Highway delineation devices are an integral part of virtually every well-traveled roadway. This is particularly true at curved sections of the road where night receptors mounted to delineators provide advance warning to motorists of a change of direction.
The most common delineator device on the open highway is generally referred to as a "hat-section" post. This name was acquired by its association with the hat-like cross-section of the post, as is illustrated in FIGS. 1 and 3. The post is typically fabricated of steel and includes two side walls 10 and 11, each having a mounting flange 12 and 13 to facilitate attachment of a reflector plate 14. These respective side walls 10 and 11 and flanges 12 and 13 resemble a side view of a hat, with the top of the hat being formed by the back plate 15. The interior of the hat would be comparable to the channel 16 formed between side walls 10 and 11.
These delineators vary in length from five to seven feet and are positioned along the road side at a height of approximately four to five feet above ground level. The reflective plate 14 may extend from three to 12 inches in length, defining a tubular enclosure 16a formed in combination with the channel 16. The channel configuration for the hat-section post closely resembles a trapezoid with side walls 10 and 11 and primary and secondary bases formed by reflector plate 14 and back plate 15. The elevation of the reflector plate 14 at approximately four feet provides correct angular orientation with respect to headlight reflection for night travelers.
During winter seasons, snow accumulations may exceed the height of the delineator and thereby obscure both day and night view of the delineator structure. Such snow accumulation may be by natural snowfall or snow drifting, or may be piled along the road side by snow plows during normal operation. In any event, concealment of the subject delineation devices poses extreme hazards to the driver, particularly at night.
Accordingly, it has been common practice to attach a snow pole extension to give added height to the delineator. Typically, this is done by utilizing a slat or rod which is somehow anchored to the existing delineator (such as the hat section of FIG. 1). This rod may extend to any desired height above the delineator, depending upon expected snow accumulation. Methods of attaching the snow pole to the delineator have varied from merely inserting of the rod or strap into the tubular opening 16a and extending channel in a "free-moving" manner, or by bolting or wiring the snow pole to the delineator body for more secure positioning.
These respective methods each have disadvantages which represent increased expense in connection with maintenance of a snow pole system. For example, utilization of a strap bolted to the delineator body is labor intensive, requiring significant effort to insert and tighten bolts through properly aligned holes in the snow pole and delineator. Also, vibration in the strap body arising from constant wind buffeting causes the strap to wear and fail at the bolted location. When one considers the hundreds of thousands of delineators which require snow pole extensions, the extreme cost of making such modifications or affecting repair becomes significant. In contrast, if the snow pole is merely inserted in free-moving manner, it is easily stolen, or may be knocked free by action of a snow plow, wind or incidental contact with projecting objects from trucks and other vehicles. Finally, and most important, public safety demands that the risk of injury or loss of human life be minimized by proper delineation. Accordingly, the seriousness of maintaining effective delineation despite snow accumulation and/or removal becomes even more serious.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefor an object of the present invention to provide an improved snow pole extension which enhances survivability of the snow pole despite adverse conditions.
A further object of the present invention is to provide an improved snow pole extension which can be quickly inserted or withdrawn, thereby reducing labor costs.
A further object of this invention is to facilitate installation of a snow pole extension by means which discourage vandalism and theft.
A still further object of the present invention is to provide a device which may be attached to existing snow poles to facilitate their insertion with respect to existing delineators.
These and other objects are realized with a snow pole extension device which comprises a coupling device attachable to the base of a snow pole to facilitate a friction-fit insertion within the tubular cross section and opening of an existing delineator. This coupling device includes a tubular sleeve member which has a tubular opening suited for attachment around the base of the snow pole extension. This tubular opening has a corresponding geometric configuration similar to the external configuration of the snow pole to which it is to be attached. Its dimensions and size are structured to provide a friction fit for the sleeve as a base attachment device around the external configuration of the snow pole base. At the same time, the exterior configuration of the sleeve is slightly oversized as compared to the delineator tubular cross-section and tubular opening to fit snugly but removably therein, while being sufficiently small to enable friction fit of the sleeve member within the tubular opening of the delineator.
Other objects and features of the present invention will be apparent to those skilled in the art in view of the following detailed description, taken in combination with the accompanying drawings.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a perspective view of a prior art delineator of hat-section design, with a modified snow pole in a superior position for insertion within and attachment to the delineator.
FIG. 2 shows an end view of a coupling device which facilitates the attachment of the snow pole to the delineator.
FIG. 3 illustrates a top end view of the coupling device in its attached and inserted configuration with respect to a hat-section delineator post.
FIG. 4 shows an alternate embodiment of a coupling device for attaching a round snow pole to a hat-section delineator post.
FIG. 5 shows yet another embodiment for enabling attachment of a T-shaped snow pole with respect to a hat-section delineator post.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a conventional hat-section post described in the prior art section of this disclosure, with a snow pole 10 prepared for insertion within the tubular cross section 16a of the delineator. The snow pole 10 has been modified by use of an insert coupling device 20 which has been attached to a base end of the snow pole 10. As is common to both the snow pole and delineator construction, the respective dimensions are uniform along the pole or post length. The upper end of the snow pole (not shown) is adapted for giving visual delineation of the roadway which may otherwise be concealed under snow. The lower end (illustrated in FIG. 1 as item 10) should be of sufficient strength to support attachment of the upper end of the snow pole to the roadside delineator.
The coupling device 20 includes a sleeve member having a tubular body configured (i) at an interior face 21 for a frictional fit around the body of the snow pole 10. The exterior surface or perimeter of the sleeve 20 is configured and dimensioned to fit snugly but removably within the tubular cross section and opening 16a of the delineator, such as is illustrated in FIG. 3. In a preferred embodiment such as illustrated in FIG. 1, the tubular opening 21 has a corresponding geometric configuration with the external configuration of the snow pole to which it is attached. The dimensions of the tubular opening when positioned within the delineator should be no greater in size than the external configuration of the snow pole to insure a snug, friction-tight fit.
It will be apparent from the drawings that a variety of snow pole configurations can be adapted with the present invention. For example, FIG. 1 illustrates a snow pole configured as a slat with rectangular cross section. The sleeve member may be a flexible, elastic form of material which conforms to take the shape of the snow pole body. FIGS. 2 and 3 illustrate a sleeve member 25 which is geometrically configured at its tubular opening 26 to conform to a snow pole slat 27 of triangular cross section. Additional embodiments are illustrated in FIGS. 4 and 5, depicting a round 42 or oval type of snow pole, as well as a snow pole of general "T" cross section 43.
The tubular sleeve members 40 illustrated in FIG. 4 are structured as tabs which slide over the snow pole 32 and 43. As illustrated in FIG. 4, each tab has a tubular opening 44 having a corresponding geometric configuration with the external configuration of the snow pole 42. A tubular sleeve 41 is shown in FIG. 5 and represents a foam rubber construction which is capable of being compressed within the delineator channel 16a for an enhanced frictional fit. These sleeve members 40, 41 are further configured with an exterior configuration (represented by perimeter 45) which matches the configuration of the tubular opening 16a within the delineator body. The sleeve member exterior configuration 45 has dimensions when positioned within the delineator which are no less in size than the configuration of the tubular opening 16a, but sufficiently small to enable snug insertion of the sleeve member 40 within the tubular opening 16a of the delineator. In this case, the external configuration is that of a trapezoid. Whereas FIG. 5 illustrates a tubular sleeve 41 with a tight friction fit over the snow pole body 43, FIG. 4 illustrates the use of spacer elements 46. These spacer elements 46 slide telescopically over the snow pole 42 and prevent displacement of tab elements 40 which also slide over the snow pole body 42 in alternating fashion.
In the tab embodiment of the present coupling device, each tab element includes opposing tab faces 48 and 49, a perimeter edge 45 defining the exterior surface as previously mentioned, and a tubular opening 44 formed along an axis 47 which is parallel or common with the axis of the snow pole 42. This axis is approximately perpendicular to the tab faces 48 and 49 and facilitates use of a plurality of such tabs to form an exterior contacting surface 50 corresponding to the tubular opening 16a of the delineator.
In use, the snow pole structure of FIG. 4 would be oriented in a manner similar to that orientation in FIG. 1 for snow pole 10. In this instance, the plurality of tab members 40 would fit snugly within the tubular enclosure 16a by virtue of corresponding trapezoidal shape. Tab elements 40 of FIG. 4 are formed of flexible polymer material and are of slightly larger dimension at their respective perimeters 45 such that the tab is forced to deflect within the tubular enclosure 16a for a tight, frictional fit. By shortening the spacer 46 between the respective tabs 40, increased surface area and frictional contact can be provided.
In contrast with the solid core design of FIGS. 4 and 5, FIGS. 1, 2 and 3 illustrate the use of vertical flange elements to provide the desired frictional fit. In this embodiment, the sleeve member includes outward projecting flange elements 30, 31 and 32. These are respectively coupled at their proximal ends to the sleeve body 34. These flanges are structured in size and length to provide location of their distal sides in close proximity to an imaginary geometric configuration 35 which corresponds with the cross sectional opening of the delineator 16a. This exterior surface configuration 35 is slightly oversized as compared to the delineator tubular opening 16a to thereby flex the flange elements 30 into compression upon forced insertion into the tubular opening as illustrated in FIG. 3. This provides a tight, frictional fit between the snow pole and the delineator body. Snow pole 27 and delineator body 10. As is illustrated in FIGS. 2 and 3, the respective flanges 30 and 31 are spaced apart to allow sufficient distance for each flange to collapse in frictional contact with a portion of the interior tubular opening of the delineator. Generally, these will be spaced apart such that their respective collapse does not result in substantial contact with adjacent flange elements. This leaves some room for further flexing to enable the twist and withdrawal of the snow pole from within the delineator when risk of snow fall has passed.
The specific embodiment illustrated in FIGS. 1, 2 and 3 for the sleeve member orient the primary flanges 30 and 31 in forward and rearward directions. This imposes most of the frictional contact on the front plate 14 and rear plate 15. Lateral flanges 32 are of only minimal size and operate primarily to maintain orientation of the front and rearward flanges 30 and 31. By decreasing the distance between flange elements and by increasing the number of flanges, greater frictional contact can be established, providing more secure attachment of the snow pole.
Typically, the length of the sleeve 20 will extend the full length of the reflector plate 14. This may range from as much as three inches on smaller plates to almost a foot for longer plate configurations. In some cases, as with the sleeve of FIG. 5, it may be positioned within the delineator opening 16a such that the sleeve opening 52 allows insertion and removal of the snow pole as needed without removal of the coupling device.
Numerous advantages arise by virtue of application of the present inventive concepts. For example, the use of flexible flanges and flanges 30 and 31, and flexible tabs 40 and 41 provide resilience to the snow pole. Therefore, upon impact by snow from a snow plow or objects extending from vehicles, the snow pole cushioned and spaced from the steel delineator wall and is less likely to shear. The coupling device also tends to reposition itself with the pole in upright orientation. Vibrational energy is absorbed in the coupling device, thereby reducing wear. The present construction permits rapid insertion with a forceful push, and permits withdrawal of the device by twisting and pulling the pole free.
The device enables use of existing configurations for not only hat-section posts but other geometries as well. Furthermore, the same snow poles which have been applied by prior art techniques may now be modified by attachment of the described sleeve or coupling device to the base. Therefore, existing snow poles can be mounted in existing delineators without the need for additional capital investment beyond purchase of a coupling device.
It will be apparent to those skilled in the art that other modifications and variations can be developed in connection with the present inventive principles. It is therefore to be understood that the scope of the present invention is not to be limited by way of examples previously set forth, but only by the following claims.
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A snow pole extension device for attachment to road side delineators wherein at least a section of the delineator includes a tubular cross section and opening having a substantially uniform geometric configuration. The device includes an insert coupling for attachment to a base end of the snow pole to facilitate its insertion within the tubular opening of the delineator. This insert coupling is configured as a sleeve member having a tubular opening similar in geometric configuration with the external configuration of the snow pole to facilitate snug, friction fit attachment. The sleeve member is formed with an exterior configuration and dimension sufficiently small to enable insertion and retention of the sleeve member therein by means of a tight, frictional fit.
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FIELD OF THE INVENTION
[0001] The present invention is generally directed to an interlocking modular mat or tile and method of use in the field of flooring surfaces. The novel features of the mat or tile panels allow them to be cut along several locations to expose the internal ramp structure within each panel, providing the assembled mat system with ramps along the borders of the assembled mat. A method of interconnecting an arrangement of mat or tiles and exposing the ramped portions to provide a flooring surface or covering is also disclosed.
BACKGROUND ART
[0002] Modular floor mats or tiles are often used as components on the construction of a flooring system. A mat or tile system may be designed as a floor covering for an entire room, or a floor covering for a section of a room. Typically, the mat or tile system components may be manufactured from, for example, semi-rigid, plasticized, virgin polyvinyl chloride, virgin/reclaimed polyvinyl chloride mixtures and also materials such as recycled rubber, or from compression molded thermoplastic materials such as, thermoplastic polyurethane (TPU), or thermoplastic rubber, for example. Other materials include thermoplastic co-polyesters or thermoplastic polyamides, elastomeric alloys, polyolefin blends (TPE-o) and the like.
[0003] The mat or tile system, when used as a floor or ground covering, is suitable to withstand inclement weather, harsh environments, heavy traffic, and resist damage when exposed to harsh chemicals. Primary uses for the modular floor tiles of the present invention include providing lateral support, and providing comfort and reduction of fatigue during walking or standing. In the prior art, the use of molded mats, e.g., polyurethane foam molded mats, in industrial and commercial applications is well known. These foam mats are advantageous because of the resiliency and cushioned support that the foam provides for workers when the workers are engaging in tasks that require an excessive amount of standing in a given location.
[0004] Various types of modular floor tiles have increased in popularity due to their versatility. A free-standing modular floor mat system typically provides a non-slip modular system that optionally is self-draining and has multiple configuration capabilities.
[0005] The mat system is typically assembled from mat elements or units, herein referred to as mat or tiles. Typically, each mat or tile comprises interlocking members which connect adjacent panel members. Male and female portions are typically employed in the form of hole and peg structures, such as set forth in U.S. Pat. No. 8,006,443, or in jigsaw or tooth type structures as exemplified in U.S. Pat. No. 4,287,693. Conventionally, mats or tiles are assembled into a structure covering a floor or surface with a shape adapted to the intended shape of the mat or tile system. For example, the assembled mat or tile system can be simply a closed rectangular shape or a rectangular shape with inner open areas, or any overall shape that can be constructed with mat panel or tile member structures.
[0006] Further, a ramped mat component is typically attached to the periphery of the mat system, during or after assembly of the internal mat or tile components. The manner of attachment of the ramp portion is generally similar to the manner of male-female manner of attachment of the internal mat panel or tile elements, noted above. The ramp portion serves to allow a smooth transition between the upper surface of the mat or tile system and the existing flooring surface. Aside from aesthetics, the ramped portions provide a measure of safety against tripping by the user. For example, Pre Grant Publication 2009/0205269, Pre Grant Publication 2013/0291457, and U.S. Pat. No. 6,966,155, are illustrative of mat systems with attachable ramp components. These types of mat systems conventionally require separate ramp pieces and/or connectors to be purchased or modified to provide inside and outside corners when interlocked with the mat edges. For example, modifications by trimming ramp pieces to provide inside and outside corners, inherently weakens the integrity of the abutting ramp portions.
[0007] Further, another demand in the workplace is that floor mats need to be easily configured and reconfigured. Such prior art systems are not readily modified as they often require new ramp pieces or connectors, which may not be readily available. Further, mat systems using separate connectors have not worked well in practice because they get lost or make alignment between adjacent mats difficult during reinstallation.
[0008] In any of these mat systems, the ramped portion is affixed to a side of a mat, is and therefore not held in place as well as other internal mat members, which reinforce one another. Instead, the prior art ramp portions, being small and light relative to the mat, rely substantially upon frictional engagement between the ramp portion and a portion of the perimeter of the mat body to hold the ramp portion in place. Therefore, these designs are susceptible to being dislodged accidently by improper force moments by machinery or other devices typically used on these mats.
[0009] In light of the drawbacks noted above in prior art mat designs, a need exists to provide improved mat construction, particularly, in the area of how the mats are constructed or reused to form even greater mat areas. The present invention responds to this need with an improved mat or tile panel, as well as a method of assembling and tailoring the inventive mats or tiles into a mat system facilitating to the provision of a secure ramped border around entire mat system assembly.
SUMMARY OF THE INVENTION
[0010] Accordingly, it is one object of the invention to provide an improved interlocking mat panel or tile element design which minimizes the number of unique mat panel or tile units that are required for assembly into the desired mat system or configuration with a ramped border.
[0011] Along these lines, it is another object of the invention to provide an improved interlocking mat panel or tile element design requiring only a single repeating mat panel or tile unit for assembly into the desired mat system or configuration having a ramped border.
[0012] Yet another object of the invention is a method of assembling and tailoring the assembled mat or tile system with the desired ramped border using a single cutting operation after assembly of the mat system, or tailored while the mats are assembled to expose the ramp borders.
[0013] Still another object of the invention is a method of modifying an existing mat system by removal and relocation of mat panel or tile elements and then cutting of mat panels along provided cut lines to expose new ramped portions within the mat panel to provide new borders around the mat system.
[0014] Other objects and advantages will become apparent as a description of the invention proceeds.
[0015] In satisfaction of the foregoing objects and advantages, the invention, in one mode, comprises a molded mat or tile panel which overall, is generally planar, has a top and bottom and sides.
[0016] In this application, the word “tile” is synonymously used with the term “mat”, which, in turn, are also referred to as mat or tile “panels”, “members”, “units” or “structures”. The terms “mat system” or “tile system”, “mat assembly”, and “tile assembly” are meant to define an assembly of mats or tiles to provide a covering for the floor or ground.
[0017] The mat of the present invention is fabricated with an inner core structure, designed to support traffic and, optionally, allow ventilation and drainage of liquids through the mat system. The internal core structure, for example, includes projection elements extending between said upper and lower portions of the internal core structure. The projection elements are exemplified by knoblike, peg like, conical, truncated conical members which distribute traffic loadings from the upper to the lower core portions, along the surface of the inner core structure. Further, ventilation and drainage is accommodated, for example, by a series of apertures or openings provided in the upper portion of the inner core structure, which is subjected to foot traffic.
[0018] Importantly, the inner core structure is provided with a tapered ramp structure formed around its sides, preferably during the molding process. This tapered ramp structure is further integrally connected to the outer panel structure by an attachment structure, which effectively bridges the inner core structure, having ramped sides, with the outer panel structure. The attachment structure effectively bridges the inner core structure with the outer panel structure and is formed by a channel, trough or groove molded into the upper and lower portions of the mat, adjacent to the ramped edge of the mat core structure.
[0019] Also possible is that the attachment structure can be discontinuous along the channels. For example, a series of tab members or segments, which are positioned around the internal core structure, can be used to secure the internal core structure to the outer panel structure.
[0020] Again, the attachment structure is preferably molded concomitantly with the internal core structure and outer panel structure, during the molding or formation of the mat. Therefore, the attachment structure is integral with the panel and to both inner core structure and outer panel structures, providing a secure coupling between the internal core and outer panel structures.
[0021] Further, the attachment structure of the present invention is designed to be readily severable, preferably by cutting operations, from the inner core structure and outer panel structures to allow exposure of the ramped profile along the periphery of the inner core structure, either before or after assembly of the mat system. To facilitate the severability of the mat, the mat can include one or more channels, troughs, or grooves, hereinafter channels. The channel can exist in the top or the bottom of the mat or both. The channel can be formed in the mat during its manufacture or exist as a result of the manner in which the side and corner panels are attached to the inner core structure. That is, a channel would exist where an end of a ramped surface of the inner core structure meets with a side panel. Similarly, such a channel would exist where the end of a ramped surface of a side panel meets with an underside of a corner panel. When employing a channel in the top of the mat, two ramped surfaces could exist for the inner core structure or side panel. The channel provides a guide along which a cutting implement or tool, e.g., a knife or the like, could be used to sever the side and/or corner panel of the mat to form a ramp-containing peripheral side. The shape of the channel formed by the junction of the end of the ramped surface and the underside of a side or corner panel is a function of the configuration of the underside of the side or corner panel. When this underside is raised from an overall bottom surface of the mat, the channel would be more v-shaped. If the underside of the corner or side panel would be aligned with the overall bottom of the mat, the channel would be more like a slit. Thus, the shape of the channel when existing in an underside of the mat can vary depending on the configuration of the underside of the side and/or corner panels.
[0022] In a further preferred embodiment, the channel, whether on the top and/or bottom can extend in a generally straight lines from each of the peripheral edges of the inner core structure to the outer perimeter of the outer panel structure. This effectively partitions the outer panel structure into side panels which oppose each side of the internal core structure and corner panels which abut adjacent side panels. In the preferred embodiment of a square or rectangular mat panel, there would be four side panels in parallel with each side of the inner core structure and four corner panels which abut adjacent side panels.
[0023] Additionally, the ramped profile of the peripheral sides of the inner core continues their shape, extending in straight lines through adjacent side panels towards the periphery of the edge of the mat. In this preferred embodiment, the entire panel can be completely cut along any of cutting channels to sever the attachment means bridging the inner core structure and side panel and/or between the side and corner panels. This novel design of the inventive mat panels allows for the inner core structure, side or corner panels to be simply cut out of the mat assembly to form the desired ramp portions around the border of the mat system, during or after installation of the mat system.
[0024] Since the attachment structure is integral and therefore formulated with the same materials as both the internal core and outer panel structures, it is important that the materials used to form the mat panels, preferably by molding operations, be soft enough to allow removal of the panels by cutting operations to expose the ramped border. To this effect, it is preferred to employ PVC, rubber, TPE or the like, which are resilient yet provides a resilient cushioned mat which can be trimmed by cutting with a blade, knife, or cutting tool. Other thermoplastic or thermosetting polymers can be used in the present invention to the extent they are suitable for a mat and with the proviso they can be easily cut by a blade or knife or other cutting tool. The detailed description provides additional details as to the softness of the preferred mat material to facilitate cutting operations.
[0025] Another aspect of the present invention is the requirement that unique panel members, described above, interlock with each other in order to be assembled into a mat system with ramped borders.
[0026] Any number of interlocking techniques can be applied to the instant invention. However, for the sake of illustration, the various drawings depict a series of outwardly projecting female couplings which interconnect with complementary male couplings, located on the underside of the mat. Male and female interlocking couplings serve to connect adjacent mats to form a mat system.
[0027] A further embodiment locates female connectors on two adjacent sides of the mat, with symmetrically opposed male connectors located on the remaining adjacent sides.
[0028] However, it is important to recognize that the novelty of this invention does not rely on a particular mat interlocking scheme. For example, while preferred, the female connector locations do not have to reside on two adjacent sides of the mat. For example, the female connector locations can alternate with the male connector locations in any desired pattern. Any conventional manner of interlocking can be also applied to join adjacent mats to the extent it cooperates with the novel ramp exposure design provided by the mat of the present invention.
[0029] Another aspect of the invention is a method of constructing the mat using the novel mats of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1A illustrates a top surface of an upper portion of a mat or tile according to the present invention
[0031] FIG. 1B is a perspective view of FIG. 1A , showing the upper portion of the mat in an embodiment of the invention.
[0032] FIG. 1C is a perspective view of an underside or lower portion of the mat structure of FIG. 1A .
[0033] FIG. 2A is a cross-sectional view of along the line I-I of FIG. 1A .
[0034] FIG. 2B is an enlarged perspective view of a mid-portion of the mat of FIG. 1B along lines II-II.
[0035] FIG. 2C is an enlarged view of section B of the mat of FIG. 2B .
[0036] FIG. 3 shows a perspective view of the underside of the mat section of FIG. 2B .
[0037] FIG. 4A illustrates a top view of a section of a system of interconnecting mats after selected portions of outer panel members have been removed to expose selected internal ramp structures bordering the mat system.
[0038] FIG. 4B illustrates an underside view of FIG. 4A .
[0039] FIG. 5A and FIG. 5B show an alternative embodiment, wherein the attachment structure that links the inner core structure and outer panel structure is not continuous.
[0040] FIG. 6 shows an alternative attachment structure for the mat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] For the purposes of this disclosure, the word “tile” is used synonymously with the term “mat”. The terms, “mat” or “tile”, for the purposes of this disclosure, also are also referred to as “mat” or “tile”, “panels”, “members”, “units” or “structures”. The terms “mat system” or “tile system”, “mat assembly”, “tile assembly” are meant to define an assembly of mats or tiles to provide a covering over a floor or ground
[0042] FIG. 1A illustrates a top surface of an upper portion of mat 1 according to the present invention. Mat 1 is substantially planar and is designed to support traffic, provide a traction surface on the upper portion exposed to foot traffic and allow ventilation and drainage of liquids through the assembled mat system.
[0043] Referring to FIGS. 1A and 1B , the mat 1 comprises an inner core structure 2 , and an outer panel structure “A”, highlighted in the shaded area, surrounding inner core structure 2 .
[0044] FIGS. 1A and 1B also illustrate traction surfaces 6 in a pattern of ridges or elevations to increase friction on the surface, in this case, the top surface of an upper portion, of the mat inner core structure 2 . However, these ridges and various top surface designs are optional, and are not known to be critical. In embodiments of the present invention, the top surface of the mat, particularly the inner core structure 2 , may comprise a friction promoting surface coated thereon, as well as or in place of ridges and/or apertures 7 .
[0045] The top surface of mat 1 , particularly the inner core structure 2 , may comprise any number of patterns of holes or apertures 7 to allow the passage of air or a liquid. These mat or tiles are also suitable for wet working environments. Further, as mentioned above, apertures 7 also serve to provide a degree of slip resistance to complement traction surfaces 6 . Although apertures 7 are depict apertures of the present invention, it is to be understood that any suitable shaped or sized aperture could also be used, inasmuch it serves to provide the requisite drainage, traction and structural integrity of the mat and assembled mat system.
[0046] FIG. 1C depicts the underside of mat 1 . Shown in FIG. 1C are support legs 8 , which extend between the upper portion and lower portions of mat 1 . Note that in a preferred embodiment, support legs 8 are provided on the underside of the entire mat 1 in both the inner core and outer panel structures. Legs 8 support load on the surface of the mat, distributing loads from the upper to lower portions of the mat 1 , and ultimately to the flooring or ground upon which the mat rests.
[0047] The support legs 8 are exemplified by knoblike, peg like, conical, truncated conical members. However, any conventional supporting shaped structures can be used in place of those mentioned above.
[0048] Also, FIG. 1A shows a series of outwardly projecting female connectors 9 , which interconnect with complementary male connectors 10 of FIG. 1 C, located on the underside of mat 1 . Male connectors 10 and female connectors 9 serve to interlock adjacent mats to form a mat system.
[0049] The term “male” refers to knob, pin or peg-type components. The term “female” refers to the components that have a socket or lug-type compartment that is sized and spaced to accommodate the “male” component. The “male” and “female components are complimentary to one another in the sense that the “male” components may be securely inserted into the “female” components in a way that provides a mechanism for holding adjacent tiles to one another. As described herein, “male” components may be used to assist in providing vertical support to the mat, whether coupled to a “female” component of an adjacent tile or not. Typically, all male components provide some type of vertical support to the mat.
[0050] Referring to FIGS. 1B and 1C , included in the mat 1 are side panels 4 and corners panels 5 , At least one set of outer female connectors 9 are connected to and preferably projecting away from the mat along at least a portion of the peripheral edges of the side panels 4 or corner panels 5 are provided. The female connectors 9 each has a side thickness less than the mat thickness and are substantially flush with the bottom of the mat so as to create a step upon which a corresponding male connector of complementary thickness rests so as to result in an interlocked mat system of substantially equal thickness. When designating adjacent side or corner panels, the prime “′” designator is used to more easily identify the specific panels being identified.
[0051] Complimentary male connectors 10 are provided and they project below a top surface of the side panels 4 and corner panels 5 . Further, each male connector 10 is along an edge of the mat opposite to the side of the mat having a corresponding female connector. The male connectors 10 are adapted to engage recesses of the female connectors 9 of an adjacent mat and the recesses of each female connector are adapted to receive inner male connectors of an adjacent mat to link one or more adjacent mats together.
[0052] An embodiment illustrated in FIG. 1B or 1C depict female connectors located on two adjacent sides of the mat, and male connectors symmetrically located on the remaining adjacent sides ( FIG. 1C ). However, it is important to recognize that the novelty of the invention does not rely on the manner in which panels are interlocked. For example, while preferred, the female connector locations do not have to be on two adjacent sides of the mat. For example, the female connector locations can alternate with the male connector locations in any desired pattern. Any conventional manner of interlocking techniques can be applied to interlock adjoining mats to the extent they cooperates with the novel ramp exposure design provided by the mat of the present invention.
[0053] A key feature of the present invention is a ramp structure 20 , which comprises a pair of ramped surfaces 11 and 13 and is depicted in FIG. 2A as a cross section of mat 1 along line I-I of FIG. 1A . Ramp surfaces 11 and 13 surround the inner core structure 2 and form a tapered profile from the upper portion of mat 1 to the lower portion of mat 1 . This tapered ramp structure 20 is preferably molded into the mat 1 to form a peripheral edge or a number of discrete of sides of the inner core structure 2 . The peripheral edge or sides of the inner core structure 2 are connected to the outer panel structure “A” (shaded area “A” in FIG. 1A ) by an attachment structure 14 , which effectively bridges the ramped surface 11 and 13 of the inner core structure 2 , with the side panels 4 ′ and 4 ″, see FIG. 2A .
[0054] FIG. 1B , depicts a perspective top view an upper portion of rectangular mat 1 , illustrating four side panels 4 , and four corner panels 5 , comprising the outer panel structure A and surrounding inner core structure 2 . The side panels 4 and corner panels 5 , in the outer panel structure A are defined by channels 3 , which can also be characterized as troughs or grooves and can be molded into the upper and lower portions of the mat forming said attachment structure 14 . FIG. 1B illustrates four channels 3 molded into the upper portion of the mat 1 with the mat being rectangular in shape.
[0055] Referring to FIGS. 1A and 1B , in a preferred embodiment, the profile of the ramped side structure of inner core structure 2 extends in straight lines along the channels 3 of the inner core structure 2 to delineate the side panes. The channels 3 continue to extend to the periphery of the edge of the mat 1 , thereby effectively forming the side panels 4 and corner panels 5 . With reference to FIG. 2A , the ramped structure as surfaces 11 and 13 is thereby formed on side panels 4 ′ and side panel 4 ″ adjacent to inner core structure 2 .
[0056] Ramped surfaces 11 and 13 are disposed on the sides of the side panels 4 ′ which face corner pieces 5 ′. With reference to FIG. 2B , an attachment structure 14 bridges and connects the ramped surfaces 11 and 13 of side panels 4 ′ with corner panels 5 ′.
[0057] Referring to FIG. 2B and 2C , channels 3 and 3 ′ (see FIG. 2C ) are molded into the upper and lower portions of the mat, respectively, which form said attachment structure 14 . Channel 3 , which dips below the top surface of the mat, forms one portion of attachment means 14 bridging a ramped surface 11 of the inner core structure 2 with adjacent side panel 4 ′″.
[0058] In FIG. 3 , an underside of the mat of FIG. 2B illustrates the second channel 3 ′ situated between ramp surface 13 and a bottom surface of either side panel 19 ′ or corner panel 19 , for example. Second channel 3 ′ forms another portion of attachment structure 14 .
[0059] FIG. 2C further illustrates the width W 1 of upper channel 3 and depth D 1 of upper channel 3 measured from the top of the upper portion of mat 1 . Further, depth D 2 is a measure of the thickness of the attachment structure 14 , connecting side panel 4 ′ to corner panel 5 ′ and also connecting the inner core structure 2 to opposing side panels 4 ′″. Finally, depth D 3 is representative of the overall mat thickness. Upper channel W 1 minimum widths are chosen to accommodate the dimension of an edge of a knife, blade or other cutting tool used to sever selected panels from the mat 1 . Maximum widths are generally dictated by the slope of ramped surfaces 11 and 13 and depths D 1 and overall thickness D 3 of mat 1 . Channel depth D 1 is dictated by the selected upper channel width W 1 and slope of ramped surfaces 11 and 13 . The thickness D 2 of the attachment structures 14 is optimized to allow easy and accurate cuts through attachment structure 14 and along ramped surfaces 11 and 13 . Smaller thicknesses D 2 facilitate cutting and accuracy of cuts along ramped surfaces 11 and 13 . Larger D 2 thicknesses, in comparison, offer a more rigid attachment between the inner core structure 2 and the side panels 4 , and between the side panels 4 and corner panels 5 . Larger mat thicknesses D 3 require larger attachment structure thicknesses D 2 to support the side panels to the inner core structure 2 , for example. For the purposes of this invention, the overall mat thickness D 3 is from about 0.1 inches to 1.0 inches, more preferably, from 0.1 to 2.0 inches. The attachment structure D 2 thickness ranges from 0.1 to 0.2 inches, preferably 0.05 to 0.5 inches. Channel widths W 1 preferably range from 0.1 to 1.0 inches.
[0060] Of course, one of ordinary skill in the art would be able to determine optimum values of D 2 for a particular mat material, given a desired target mat thickness D 3 and selected slope along ramped surfaces 11 and 13 .
[0061] It is also possible that the bridge attachment structure 14 in FIGS. 2B and 2A , respectively, can be discontinuous when viewed from the upper portion of the mat panel. Put another way, the attachment structure 14 would be continuous and an opening would be provided in the channel 3 such that the ramp surface (the ramp surfaces 11 and 13 are interrupted by the attachment structure until the channel is severed to form the complete ramp border for the mat) would be continuous from the top to the bottom of the mat. FIGS. 5A and 5B illustrate this embodiment. FIG. 5A shows a section of a channel 3 between a side portion of the inner core structure 2 and a side panel 4 . Opening 3 b are formed to create spaced apart tab segments 3 a, which form the attachment structure to link the inner core structure 2 to the side panel 4 . The spacing of the tab segments 3 a can vary with the proviso that there should not be too many openings 3 b so as to comprise the integrity of the attachment structure linking the inner core structure 2 to the side panels 4 . The openings could also be used between the side panels and corner panels if so desired.
[0062] A typical tile of the present invention may be manufactured by injection or compression molding, and typically comprise a thermoplastic material such as flexible thermoplastic polyurethanes (TPU), or semi-rigid polyvinyl chloride or theuuoplastic elastomer. Additionally a thermosetting plastic such as rubber may be used. Basically any material that is semi-rigid, semi-flexible, or elastomeric (e.g., flexible PVC, thermoplastic elastomers) that are capable of being injection molded can be used. Additionally, thermosetting rubbers and thermosetting elastomers capable of being compression molded can be used. Alternatively, the side and corner panels could be linked to the inner core structure using an adhesive technique, which would still maintain the integrity of the attachment structure and its link between the inner core structure and the side and corner panels and provide an alternative method of making the mat to molding.
[0063] The plastic or rubber material should exhibit some degree of conformability so as to provide comfortable footing and mating of the tiles. Additionally, the material should exhibit a reasonable degree of structural integrity so as to support personnel and light industrial traffic. One of ordinary skill in the art can chose a material based on many desired characteristics of the resulting tile. For example, a material may be that is resistant to oils, greases, weak solvents, and chemicals typical of an industrial environment. A material may be chosen to exhibit a reasonably high coefficient of friction so as to reduce the risk of slipping. Additionally, embodiments of the present invention may also be conditioned to withstand inclement weather or other harsh environments, heavy traffic, and to resist damage when exposed to harsh chemicals.
[0064] In this invention, a further requirement is that the selected mat or tile material be soft enough to be easily severed or cut by a knife or blade or other cutting implement to facilitate removal of the mat elements to expose desired ramp borders in the final mat system or assembly. This requirement therefore defines which of the material or formulations of the materials can be preferably used.
[0065] Since the attachment structure 14 is integral and therefore preferably formulated with the same materials as both the internal core and outer panel structures, it is important that the materials used to form the mat panels, preferably by molding operations, be soft enough to allow cutting operations, preferably with a hand operated cutting tool. Mat compositions which provide cushioning with few exceptions are amenable to being cut with a knife or blade. It is preferred to use thermoplastic for the mat composition, satisfying structural requirements above and are easily cut using a knife or blade. However, any conventional thermoplastic or thermosetting polymer material meeting the mat requirements earlier above with the proviso that the Shore Hardness of the formed mat is in the range of from 50 to 95 A to facilitate cutting of the mats to expose a ramped border around the periphery of the assembled mat system.
[0066] While FIG. 2A shows the attachment structure between the ramp surfaces 11 and 13 , the attachment structure could be formed so that it is flush with a top surface of the mat so that there would be only one ramp surface 13 instead of two ramps surfaces 11 and 13 , see FIG. 6 , wherein the attachment structure 14 ′ would be severed along line 23 to separate the panel 25 from the inner core structure 27 . This embodiment does not provide the channel 3 on the top surface of the mat embodiment shown in Figure lb for cutting through the attachment structure and would require the mat to be ideally cut from the bottom. Alternatively, the mat surface could be molded with some indicator, e.g., a raised protrusion or slight indent so that the cut could be made through attachment structure 14 ′ from the top. An example of such a protrusion is shown as 29 in FIG. 6 .
[0067] In yet another embodiment, the mat would be made so that the underside of the corner panel or side panel could extend so that it is aligned with the underside of the inner core structure. In this embodiment, the channel would extend upwardly with the one ramp surface still existing and be more like a slit than the v-shape depicted in the drawings when the underside of the side panel or corner panel does not extend so as to align with the bottom of the mat. With the underside of the corner panels and side panels extending to the bottom of the overall mat, the channel could be formed from the top surface and the attachment structure would be at the bottom of the mat rather than at the top as shown in FIG. 6 .
[0068] Another aspect of the invention is a method of constructing the novel mat of the present invention into a mat assembly or mat system having a ramped border.
[0069] First, the mats of the present invention are interconnected on adjacent sides to form a desired pattern. Either during or after assembly, internal core, side or corner panels to be simply cut out of the mat along any of the channels to expose the desired ramp surface around the periphery or border of the mat system.
[0070] Referring to FIG. 1B , cutting along channels 3 , situated in the upper mat portion, for example, severs the attachment structure 14 which bridges the inner core structure 2 with side panels 4 and/or attachment structure 14 bridging the side panels 4 and corner panels 5 . Cutting away the side or corner panels from the mat 1 , preferably along edge 16 of cutting channel 3 (See FIG. 2C ), thereby exposes the ramped surfaces 11 and 13 of the inner core structure 2 and sides panels 4 , thereby creating a ramped border around the edge of a mat system. Alternatively, the mat side and corner panels can be cut from the underside of the mat, if so desired.
[0071] FIG. 4A shows an example of a cutting, wherein only a portion of the entire mat system is illustrated. This Figure illustrates the connection of 8 mats with corner panels and side panels removed to expose a ramped border along lines “C”.
[0072] FIG. 4B shows an underside of a portion of the completed mat system of FIG. 4A and which also illustrates the interconnection of adjacent mats according to the present invention.
[0073] As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides a new and improved interlocking modular mat with an integral ramp feature and method of use.
[0074] Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claim.
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The present invention is generally directed to an interlocking modular mat or tile and method of use. The mat comprises a severable core structure with a ramp around its periphery and a connected outer structure. The outer structure surrounding the inner core structure is partitioned into side and corner panels also having ramps internally disposed therein. The novel features of the mat allows it to be cut along several locations to expose the internal ramp structure within each panel, providing a assembled mat system with a secure border around the entire mat. A method of constructing an array of the novel mat panel members involving cutting to expose the internal ramped structure is also disclosed to provide a flooring surface.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of pending U.S. patent application Ser. No. 12/502,603, filed on Jul. 14, 2009 and entitled “Magnetic catalyst and method for manufacturing the same”, which claims priority of Taiwan Patent Application No. 98115299, filed on May 8, 2009, the entirety of which is incorporated by reference herein.
TECHNICAL FIELD
[0002] The technical field relates to a hydrogen releasing catalyst, and in particular relates to the magnetic hydrogen releasing catalyst, the preparation thereof, and the application thereof
BACKGROUND
[0003] One major trend of green energy development is hydride for releasing hydrogen. The catalysts of a hydrogen releasing mechanism can be roughly categorized as noble metals such as ruthenium (Ru), palladium (Pd), platinum (Pt), and the likes, or non-noble metals such as copper (Cu), iron (Fe), cobalt (Co), nickel (Ni), and the likes. As for noble metals, mass production thereof is hindered due to high costs. If the used catalyst can be unified and conveniently recycled by specific method, it will be reused to reduce the cost. Also, currently, there is no commercially available catalyst for hydride to release hydrogen. There are several noble metal catalyst preparations which have been disclosed to collocate with a fuel cell which is applied in small electronic products. However, commercialization is hindered by high cost and lack of lower cost solutions, such as recycling.
[0004] U.S. Pub. No. 2006/0292067 discloses a catalyst carrier using nickel. Several kinds of metal are grown on a carrier to prepare a multi-metal composite catalyst. The metals include cobalt, ruthenium, zinc, manganese, titanium, tin, chromium, and the likes. In forming the catalyst carrier, 50 g of a composite of 50% sintered nickel powder and 50% compressed nickel fiber is cut to a square plate (0.25 inch*0.25 inch). 6.31 g of CoCl 2 .6H 2 O and 1.431 g of RuCl 3 .H 2 O are weighted and dissolved to form a metal salt solution (about 30 mL). The nickel square plate is dipped in a metal salt solution, and heated to 70° C. to gradually evaporate the water. After the water is evaporated, different ratios of CoCl 2 ·6H 2 O and RuCl 3 .H 2 O are deposited on the nickel carrier. The nickel carrier with metal salt surface deposits is charged in a furnace for sintering at 240° C. To reduce metal ion, the 20 mL/min of hydrogen is simultaneously and continuously introduced into the furnace for 3 hours. Thereafter, the composite catalyst of ruthenium (1.2 wt %) and cobalt (3 wt %) is completed. The composite catalyst can be applied in a boron hydride solution to release hydrogen. The bi-metal composite catalyst prepared by high temperature sintering has a hydrogen release rate of about 37 mL/minute·g in a solution of 3 wt % sodium hydroxide and 20 wt % boron hydride. If the metal composite catalyst is fastened in a fixed bed to react with 200 mL of a solution (3 wt % sodium hydroxide and 20 wt % boron hydride) at a flow rate of 20 g/minute, and at pressure of 55 to 88 psig for 6 to 8 hours, the conversion ratio of the hydrogen releasing may reach 90%. According to the relationship of time versus temperature, enhancing the pressure may shorten the system initiating time. Although the metal composite catalyst has a fast initiating time for hydrogen release in the boron hydride solution, its preparation needs high temperatures. Furthermore, the prepared catalyst has no magnetic properties.
[0005] Taiwan Pat. No. 079936 discloses a promoted nickel and/or cobalt catalyst, application thereof, and a process utilizing the same. For forming the catalyst, a carrier is dipped in an RuCl 3 .H 2 O solution, wherein the carrier is an activated aluminum oxide having an internal surface area of 10 to 1000 m 2 g −1 and coated by 4 wt % to 40 wt % nickel or cobalt metal oxide. After dipping, the catalyst intermediate is dried and blown by hydrogen at 200° C. to 300° C., such that ruthenium ion is reduced to ruthenium metal and the nickel/cobalt oxide is optionally reduced to nickel/cobalt metal to complete the catalyst used in dehydrogenation and/or hydrogenation. However, preparation also needs high temperatures and the aluminum oxide carrier easily collapses in high alkalinity conditions.
[0006] For solving the high temperature sintering problem during preparation, inventors of this disclosure have disclosed a method in Taiwan Appl. No. 96150963. In the application, the nano ruthenium catalyst is grown on the polymer carrier surface by ion exchange at room temperature. Thus, high temperature preparation is not needed. However, the ruthenium catalyst is still not magnetic.
[0007] Accordingly, a novel hydrogen releasing catalyst is called to improve recycling properties.
SUMMARY
[0008] One embodiment of the disclosure provides a magnetic catalyst, comprising a carrier; and a first nano metal shell wrapping the carrier surface, wherein the first nano metal shell is iron, cobalt, or nickel.
[0009] One embodiment of the disclosure provides a magnetic catalyst, comprising a carrier; a first nano metal shell wrapping the carrier; and a second nano metal shell wrapping the first nano metal shell, wherein the first and second nano metal shells have different compositions, and at least one of the first and second nano metal shells is iron, cobalt, or nickel.
[0010] One embodiment of the disclosure provides a method for forming a magnetic catalyst, comprising providing a carrier; and forming a first nano metal shell wrapping the carrier surface, wherein the first nano metal shell is iron, cobalt, or nickel.
[0011] One embodiment of the disclosure provides a method for forming a magnetic catalyst, comprising providing a carrier; forming a first nano metal shell wrapping the carrier surface; and forming a second nano metal shell wrapping the first nano metal shell, wherein the first and second nano metal shells have different compositions, and at least one of the first and second nano metal shells is iron, cobalt, or nickel.
[0012] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The disclosure can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0014] FIG. 1 is a magnetic analysis diagram of the magnetic catalyst in one embodiment of the disclosure;
[0015] FIG. 2 is a thermo gravity analysis diagram of the cobalt amount chelated on the magnetic catalyst surface in one embodiment of the disclosure;
[0016] FIG. 3 shows the relationship between hydrogen releasing rate versus temperature of the magnetic catalyst in an NaBH 4 solution in one embodiment of the disclosure;
[0017] FIG. 4 shows the relationship between hydrogen releasing rate versus time of the magnetic catalyst in an NaBH 4 solution in one embodiment of the disclosure;
[0018] FIGS. 5A-5D show the relationships between hydrogen releasing rate versus time of the recycled magnetic catalysts in an NaBH 4 solution in one embodiment of the disclosure;
[0019] FIGS. 6A-6D show the relationships between hydrogen releasing amount versus time of the recycled magnetic catalysts in an NaBH 4 solution in one embodiment of the disclosure;
[0020] FIG. 7 is a magnetic analysis diagram of the magnetic catalyst in one embodiment of the disclosure;
[0021] FIG. 8 shows the relationship between hydrogen releasing rate versus time of the magnetic catalyst in an NaBH 4 solution of different concentration in one embodiment of the disclosure;
[0022] FIGS. 9A-9D show the relationships between hydrogen releasing rate versus time of the recycled magnetic catalysts in an NaBH 4 solution in one embodiment of the disclosure; and
[0023] FIGS. 10A-10D show the relationships between hydrogen releasing amount versus time of the recycled magnetic catalysts in an NaBH 4 solution in one embodiment of the disclosure.
DETAILED DESCRIPTION
[0024] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.
[0025] The disclosure adopts a chemical reducing and/or electroless plating process to form magnetic catalysts having a single or multi layered nano metal shell.
[0026] First, an anionic exchange resin having strong acid (e.g. —SO 3 H) or weak acid (e.g. COOH) groups on the surface is provided as a carrier. In one embodiment, the anionic exchange resin is ball-like with a diameter of about 100 μm to 200 μm. A suitable anionic exchange resin of the disclosure can be Amberlite IR-120 in hydrogen form commercially available from Supelco Chemical Co. (Bellefonte, Pa., USA) or Dowex® 50WX8 in hydrogen form commercially available from Dow Chemicals. In one embodiment, the anionic exchange resin can be other manners such as pillar-like, plate-like, or other general catalyst manners (e.g. porous zeolite).
[0027] The anionic exchange resin is added to a metal salt solution and stirred to chelate the metal ion to the acidic function groups on the resin surface. The metal salts include iron, cobalt, or nickel ions, and they become magnetic atom type after reduction. The metal salt solution concentration depends on the resin weight, and its concentration is one to five times the theoretical chelate amount. If the concentration is lower than this range, the chelate amount will be insufficient.
[0028] Subsequently, the resin is washed by deionized water to remove the unchelated metal ion. This step may improve the dispersity of the metal ion on the resin surface.
[0029] The washed resin is charged in a reducing agent solution, such that the chelated metal ion is reduced to atom type. As such, the nano metal shell of iron, cobalt, or nickel is formed to wrap the resin surface. The reducing agent includes sodium boronhydride, potassium boronhydride, dimethylamino borane, B 2 O 6 , hydrazine, formaldehyde, formic acid, sulfite, sodium hypophosphite, glucose, or sodium citrate.
[0030] The carrier of the disclosure is not only the anionic exchange resin, but also metal (such as stainless web, nickel web, or brass sheet) or surface activated non-metal (such as silicon dioxide, carbonanotube, or polymer). The non-metal surface can be activated by plasma or SnCl 2 /PdCl 2 solution. The consideration for shape and the size of the metal and non-metal materials are similar to the described anionic exchange resin. The electroless plating solution is prepared as below. The metal salts of iron, cobalt, or nickel, the sodium citrate, and the maleic acid are dissolved to form a solution. The solution is added NaOH (aq) to tune its pH value to 9.5, heated to 80° C., and added a little reducing agent to complete the electroless plating solution. The metal or surface activated non-metal is added to the electroless plating solution to react and form a magnetic catalyst, wherein the thickness of the single-layered nano metal shell is controlled by the reaction time.
[0031] In addition to the single-layered magnetic catalyst, the disclosure may further form bi-layered or multi-layered magnetic catalysts by the electroless plating process.
[0032] First, the described anionic exchange resin, metal, or surface activated non-metal is provided as carrier. The carrier surface is then wrapped by a nano metal shell such as copper, iron, cobalt, nickel, ruthenium, palladium, or platinum, by described chemical reducing or electroless plating.
[0033] The electroless plating solution is prepared as follows. The metal salts of copper, iron, cobalt, nickel, ruthenium, palladium, or platinum, the sodium citrate, and the maleic acid are dissolved to form a solution. The solution is added NaOH( aq ) to tune its pH value to 9.5, heated to 80° C., and added a little reducing agent to complete the electroless plating solution.
[0034] The carrier having a surface wrapped by the nano metal shell is added to the electroless plating solution to react for forming another nano metal shell wrapping the original nano metal shell. The magnetic catalyst is washed to remove residue solvent and dried to complete a magnetic catalyst having a bi-layered nano metal shell. Note that at least one of the inner and outer shells must be magnetic metal such as iron, cobalt, or nickel to form the magnetic catalyst. The catalyst has both advantages of the two metals. For example, ruthenium is the most efficient hydrogen releasing catalyst known and iron, cobalt, and nickel are magnetic. The magnetic catalyst prepared by the method of the disclosure, having the nano nickel inner-shell and the nano ruthenium outer-shell, will simultaneously have the advantages of fast hydrogen releasing rate and being magnetic. In another embodiment, the magnetic catalyst has the nano ruthenium inner-shell and the nano nickel outer-shell, and the nickel outer-shell only partially wraps the ruthenium inner-shell to prevent decreasing the catalyst effect of the ruthenium.
[0035] Furthermore, the magnetic catalyst having tri-layered, terta-layered, or more layered nano metal shells can be prepared by repeating the electroless plating process. However, because diminished catalyst activity for the wrapped part of the inner metal shell, the shell number can be less than five.
[0036] The magnetic catalyst can be applied in a hydrogen supply device. The hydrogen supply device with the magnetic catalyst of the disclosure has stable hydride solution in an alkalinity condition therein, and releases hydrogen after the magnetic catalyst of the disclosure is added. The hydride solution includes LiAlH 4 , NaAlH 4 , Mg(AlH 4 ) 2 , Ca(AlH 4 ) 2 , LiBH 4 , NaBH 4 , KBH 4 , Be(BH 4 ) 2 , Mg(BH 4 ) 2 , Ca(BH 4 ) 2 , LiH, NaH, MgH 2 , or CaH 2 . In one embodiment, the hydride is a mild hydride such as NaBH 4 , KBH 4 , NH 3 BH 3 , and the likes. Other hydrides reacting violently with water are used to assist an initial hydrogen releasing rate, and not for stable and long-term hydrogen releasing rate purposes
[0037] The described hydrogen supply device can be further connected to a fuel cell or other device needing hydrogen. The magnetic catalyst is easily recycled by a magnet after use. The recycled magnetic catalyst is ready to be reused after simply washing the catalyst surface to remove the deposition from the hydride.
[0038] Below, exemplary embodiments will be described in detail with reference to accompanying drawings so as to be easily realized by a person having ordinary knowledge in the art. The inventive concept may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity, and like reference numerals refer to like elements throughout.
EXAMPLES
Example 1
[0039] 30 g of an anionic exchange resin (IR-120, commercially available from Supelco Chemical Co.) was added to a cobalt chloride solution (CoCl 2 .6H 2 O, 8.992 g/dL), and stirred for 60 rpm at room temperature, such that the acidic function of the resin surface chelated the cobalt ion. The unchelated cobalt ion on the resin surface was then washed by deionized water. The washed resin was added to an NaBH 4 solution to reduce chelated cobalt ion, thereby forming a nano cobalt shell wrapping the resin surface. The resin was then washed by deionized water and dried at room temperature, and analyzed by SEM and XPS to determine the magnetic catalyst having a single-layered nano cobalt shell.
[0040] The magnetic performance of the catalyst was shown in FIG. 1 . As shown in FIG. 2 , the chelated cobalt amount on the catalyst surface was about 30%. While the magnetic catalyst was added in 1.32N of the NaBH 4 solution, the hydrogen releasing reaction occurred in different rates at different temperatures as shown in FIG. 3 . The hydrogen releasing system without control of the temperature thereof had a rate versus time relation as shown in FIG. 4 .
[0041] The magnetic catalyst was recycled after the hydrogen releasing reaction was completed. The recycled magnetic catalyst was washed by deionized water to repeat the described hydrogen releasing reaction. As shown in FIGS. 5A-5D , the first hydrogen releasing reaction ( FIG. 5A ), the second hydrogen releasing reaction after the magnetic catalyst was recycled once ( FIG. 5B ), the third hydrogen releasing reaction after the magnetic catalyst was recycled twice ( FIG. 5C ), and the fourth hydrogen releasing reaction after the magnetic catalyst was recycled three times ( FIG. 5D ) all had similar hydrogen releasing rate. As shown in FIGS. 6A-6D , the first hydrogen releasing reaction ( FIG. 6A ), the second hydrogen releasing reaction after the magnetic catalyst was recycled once ( FIG. 6B ), the third hydrogen releasing reaction after the magnetic catalyst was recycled twice ( FIG. 6C ), and the fourth hydrogen releasing reaction after the magnetic catalyst was recycled three times ( FIG. 6D ) all had almost 100% hydrogen releasing amount before 2000 seconds of the hydrogen releasing reaction.
Example 2
[0042] 25 g of an anionic exchange resin (50WX8, commercially available from Dow Chemicals) was added to 0.25L of a ruthenium chloride solution (RuCl 3 .xH 2 O, 2 g/dL), and stirred for 60 rpm at room temperature, such that the acidic function of the resin surface chelated the ruthenium ion. The unchelated ruthenium ion on the resin surface was then washed by deionized water. The washed resin was added to an NaBH 4 solution to reduce chelated ruthenium ion, thereby forming a nano ruthenium shell wrapping the resin surface. The resin was then washed by deionized water and dried at room temperature, and analyzed by SEM and XPS to determine the magnetic catalyst having a single-layered nano ruthenium shell.
[0043] Subsequently, 2.62 g/dL of NiCl 2 .H 2 O, 4 g/dL of sodium citrate (Na 3 C 6 H 5 O 7 .2H 2 O) as a complexing agent, and 0.8 g/dL of maleic acid as a protective agent were weighted and dissolved in water to form 0.1 L of a solution. The solution was added NaOH (aq) or NH 3(aq) to tune its pH value to 8.5 to 9.5, heated to 80° C., and added 2.5 mL/dL of hydrazine (N 2 H 4 .H 2 O) as a reducing agent to complete the electroless plating solution.
[0044] The magnetic catalyst having a single-layered nano ruthenium shell was added to the electroless plating solution to react for 60 minutes, thereby forming a nano nickel shell on the nano ruthenium shell. The resin was then washed by deionized water and dried at room temperature, and analyzed by SEM and XPS to determine the magnetic catalyst having a bi-layered nano ruthenium-nickel shell.
[0045] Subsequently, 2.62 g/dL of RuCl 3 .H 2 O, 4 g/dL of sodium citrate (Na 3 C 6 H S O 7 .2H 2 O) as a complexing agent, and 0.8 g/dL of maleic acid as a protective agent were weighted and dissolved in water to form 0.1 L of a solution. The solution was added NaOH (aq) or NH 3 (aq) to tune its pH value to 8.5 to 9.5, heated to 80° C., and added 2.5 mL/dL of hydrazine (N 2 H 4 .H 2 O) as a reducing agent to complete the electroless plating solution.
[0046] The magnetic catalyst having a bi-layered nano ruthenium-nickel shell was added to the electroless plating solution to react for 60 minutes, thereby forming a nano ruthenium shell on the nano nickel shell. The resin was then washed by deionized water and dried at room temperature, and analyzed by SEM and XPS to determine the magnetic catalyst having a tri-layered nano ruthenium-nickel-ruthenium shell.
[0047] The magnetic performance of the catalyst was shown in FIG. 7 . While the magnetic catalyst was added in 1 wt % to 25 wt % of an NaBH 4 solution, a stable hydrogen releasing reaction occurred as shown in FIG. 8 .
[0048] The magnetic catalyst was recycled after the hydrogen releasing reaction. The recycled magnetic catalyst was washed by deionized water to repeat the described hydrogen releasing reaction. As shown in FIGS. 9A-9D , the first hydrogen releasing reaction ( FIG. 9A ), the second hydrogen releasing reaction after the magnetic catalyst was recycled once ( FIG. 9B ), the third hydrogen releasing reaction after the magnetic catalyst was recycled twice ( FIG. 9C ), and the fourth hydrogen releasing reaction after the magnetic catalyst was recycled three times ( FIG. 9D ) all had similar hydrogen releasing rate. As shown in FIGS. 10A-10D , the first hydrogen releasing reaction ( FIG. 10A ), the second hydrogen releasing reaction after the magnetic catalyst was recycled once ( FIG. 10B ), the third hydrogen releasing reaction after the magnetic catalyst was recycled twice ( FIG. 10C ), and the fourth hydrogen releasing reaction after the magnetic catalyst was recycled three times ( FIG. 10D ) all had almost 100% hydrogen releasing amount before 2000 seconds of the hydrogen releasing reaction.
[0049] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed methods and materials. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
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Disclosed is a magnetic catalyst formed by a single or multiple nano metal shells wrapping a carrier, wherein at least one of the metal shells is iron, cobalt, or nickel. The magnetic catalyst with high catalyst efficiency can be applied in a hydrogen supply device, and the device can be connected to a fuel cell. Because the magnetic catalyst can be recycled by a magnet after generating hydrogen, the practicability of the noble metals such as Ru with high catalyst efficiency is dramatically enhanced.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 10/075,090, filed Feb. 12, 2002 now U.S. Pat. No. 6,746,285, which claims priority to U.S. Provisional Ser. No. 60/270,084, filed Feb. 20, 2001, both of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
This invention relates generally to an electrical connection and more specifically to an electrical connection for an automotive vehicle employing a grounding stud.
It is common to arc weld an elongated circular end of a threaded metal stud onto a sheet metal body panel of an automotive vehicle. Various parts are then inserted upon the single threaded stud and an internally threaded nut is rotationally inserted onto the stud. Conventional threaded weld studs have also been employed as electrical grounding points for a vehicle wire harness to an engine compartment frame or body panel. It is also known to employ a grounding weld stud that has a threaded portion, a circular flanged portion and a hexagonal shoulder portion for receiving an eyelet. This hexagonal shoulder configuration, however, provides undesirably large corner-to-corner and flat-to-flat dimensions across the shoulder in order to fit within standard stud welding machinery which can only handle a certain maximum outside diameter of stud; thus, the hexagonal shoulder leads to insufficient cross sectional area for electrical conductivity.
Screws have also been used to retain an electrical eyelet to a grounding panel. Conventional eyelets, having a circular inside aperture, often require upturned tabs to prevent rotation of the eyelets during installation of nuts for the stud construction or where screws are installed. This adds extra cost and complexity to the eyelet and installation process. Wire orientation is important for engine compartment use to prevent vehicle vibration from rotating the wire and loosening the nut, and to prevent wire pinching. One such example of a conventional orientation configuration is U.S. Pat. No. 5,292,264 entitled “Earthing Stud” which issued to Blank on Mar. 8, 1994, which discloses a threaded weld stud, interlocking plastic orientation part, and a cable terminal or eyelet; this patent is incorporated by reference herein. Another traditional construction is disclosed in EP 0 487 365 B1 to Rapid S.A.
SUMMARY OF THE INVENTION
In accordance with the present invention, a preferred embodiment of an electrical connection employs a stud having a patterned segment, a shoulder and a flange. In another aspect of the present invention, the shoulder has seven or more predominantly flat faces. In a further aspect of the present invention, the shoulder has an octagonal cross sectional shape. Still another aspect of the present invention provides a nut which is threadably engaged with the patterned segment of the stud and an eyelet secured between the nut and the flange of the stud. Yet another aspect of the present invention allows the stud to be welded onto an automotive body panel or the like for use as a grounding stud.
The stud and electrical connection of the present invention are advantageous over traditional devices in that the present invention maximizes the electrical contact area between the stud and the eyelet while also providing a set angular orientation to the eyelet and wire once the nut has been fastened onto the stud. The present invention also improves the electrical cross sectional area through the stud while also allowing for the manufacture of the stud in conventionally sized equipment. The preferred octagonal cross sectional shape of the shoulder advantageously increases automatic alignment of the eyelet, especially when the eyelet has a matching octagonal internal aperture shape, as compared to stud shoulders having six or less flat faces. The stud of the present invention advantageously accepts both an octagonally apertured eyelet for use as a grounding stud or a circularly apertured eyelet for use in other electrical stud connections such as to a junction box, battery or the like. Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an engine compartment of an automotive vehicle employing the preferred embodiment of a stud and electrical connection of the present invention;
FIG. 2 is an exploded view showing the preferred embodiment stud and electrical connection;
FIG. 3 is a side elevational view, taken partially in cross section, showing the preferred embodiment stud and electrical connection mounted to a vehicle body panel;
FIG. 4 is a side elevational view, taken partially in cross section, showing the preferred embodiment stud and electrical connection;
FIG. 5 is an end elevational view showing the preferred embodiment stud and nut;
FIG. 6 is a true elevational view showing the preferred embodiment of an eyelet employed with the stud and electrical connection of the present invention;
FIG. 7 is a cross sectional view showing the preferred embodiment stud and electrical connection; and
FIG. 8 is a true elevational view showing an alternate embodiment eyelet employed with the stud and electrical connection of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a stud electrical connection 21 of the present invention employed in an engine compartment 23 of an automotive vehicle 25 . Stud electrical connection 21 is operable to conduct electricity from an electrical component, such as a battery 27 , direct current window wiper motor 29 , horn 31 , power distribution box 32 or the like, to a conductive metal panel or frame 33 of the vehicle.
Referring to FIGS. 2–7 , the preferred embodiment of stud electrical connection 21 includes a grounding weld stud 51 , a nut 53 , and a female electrical connector 55 . Electrical connector 55 includes a wire 57 , branching from a wire harness 59 (see FIG. 1 ), with a stamped metal eyelet 61 crimped onto an end thereof. Wire 57 is made of a flexible copper inner wire surrounded by an insulative casing.
Stud 51 includes a securing segment 62 , a flange 63 , a shoulder 64 , a patterned segment 65 , an inwardly tapered segment 67 and an anti-cross threading lead-in end segment 68 . Securing segment 62 has a hexagonal cross sectional shape with a centrally raised button. This portion forms the weld pool of material when stud 51 is drawn arc welded to panel 33 . Flange 63 has a circular peripheral shape and transversely extends beyond the rest of stud 51 . A unthreaded and reduced diameter neck 122 of stud 51 is located between the threaded segment and the shoulder, as shown in FIG. 4 . The neck is somewhat different than the to a major diameter of the threaded segment and a cross-sectional area of the shoulder.
Shoulder 64 is defined by a set of generally flat faces 71 that are connected together and surround a longitudinal centerline 73 of stud 51 . It is important that shoulder 64 has more than six distinctly separate and angularly offset faces that are connected together in a polygonal manner when viewed in cross section. It is preferred that faces 71 of shoulder 64 define an octagonal shape in cross section. Rounded upper corners 73 are located between portions of each adjacent pair of faces 71 . The distance D between opposed faces 71 is preferably between 6.13 and 6.0 millimeters. Patterned segment 65 has a M 6.0×1.0 millimeter spiraling thread. The thread defines an external engagement pattern on the stud. Stud 51 is made as an integral single piece from 10B21, heat treated class 8.8 steel. Anti-cross threading segment 68 is of the type disclosed in one or more of the following U.S. Pat. No. 6,162,001 entitled “Anti-Cross Threading Fastener” which issued to Goodwin et al. on Dec. 19, 2000; U.S. Pat. No. 6,022,786 entitled “Anti-Cross Treading [sic] Fastener Lead-In Point” which issued to Garver et al. on May 16, 2000; and U.S. Pat. No. 5,730,566 entitled “Anti-Cross Threading Fastener” which issued to Goodwin et al. on Mar. 24, 1998; all of which are incorporated by reference herein.
The preferred embodiment eyelet 61 has an internal aperture 75 defined by an octagonally shaped edge. Aperture 75 of eyelet 61 closely matches the size of shoulder 64 ; close dimensional tolerances of aperture 75 and shoulder 64 are important.
Nut 53 has a circular-cylindrical, enlarged section 81 and a coaxial, reduced section 83 . A hexagonal cross sectional shape is externally provided on reduced section 83 while a spiral thread is internally disposed within reduced section 83 for engaging the threads of stud 51 . Enlarged section 81 has a flanged end 85 which abuts against and compresses eyelet 61 against flange 63 of stud 51 , when nut 53 is rotatably tightened by a torque wrench or the like upon stud 51 . In the fully fastened position, enlarged section 81 of nut 53 externally surrounds and covers at least part of shoulder 64 . Alternately, nut 53 is of a progressive torque, crown lock variety.
In the electrical grounding stud application, stud 51 , with nut 53 preassembled to prevent e-coat and paint incursion, is first welded to panel 33 . Subsequently, nut 53 is removed. Next, eyelet 61 is manually placed around threaded segment 65 of stud 51 . Nut 53 is thereafter rotatably driven onto stud. The rotation of nut 53 will cause the octagonal aperture 75 of eyelet 61 to become automatically aligned with the matching faces of the octagonal shoulder 64 , thereby allowing a fixed orientation of eyelet 61 and wire 57 relative to stud 51 . Nut 53 is then fully torqued onto stud. It is believed that the octagonal shape maximizes the face-to-face dimension D and also the corner-to-corner dimension of shoulder 64 . Notwithstanding, the cross sectional dimensions of shoulder 64 still allow for manufacturing of stud 51 in conventionally sized processing equipment. Additionally, the octagonal cross sectional shape of shoulder 64 allows for reduced circumferential rotation or angular displacement of the corresponding eyelet before alignment is achieved, especially compared to hexagonal or square cross sectional shapes.
An alternate embodiment eyelet 91 is shown in FIG. 8 . This eyelet 91 has a circular internal aperture 93 which fits around octagonal shoulder 64 . This eyelet configuration is more suitable for non-grounding electrical connections, such as for junction boxes or batteries, where locked in wire orientation is not as important.
While the preferred embodiment grounding stud and electrical connection have been disclosed, it should be appreciated that other aspects can be employed within the scope of the present invention. For example, the securing segment of the stud can alternately have a screw thread, be suitable for spot welding or have an interference fit type push in configuration to the adjacent panel or member. Additionally, the internal nut threads can be replaced by inwardly projecting formations that are in a non-spiral configuration. Furthermore, nut 53 can be replaced by a crimped on collar. The stud electrical connection can also be used for non-automotive apparatuses such as household appliance, power tools or industrial machines. While various materials have been disclosed, other materials may be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.
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A preferred embodiment of an electrical connection employs a stud having a patterned segment, a shoulder and a flange. In another aspect of the present invention, the shoulder has seven or more predominantly flat faces. In a further aspect of the present invention, the shoulder has an octagonal cross sectional shape.
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FIELD OF INVENTION
[0001] This invention generally relates to shade systems, and more specifically, to trough-style supports in conjunction with shade systems.
BACKGROUND OF THE INVENTION
[0002] A variety of shade systems currently exist to deploy and retrieve a shade fabric over an area where shading is desired. Such systems often comprise a shade fabric wrapped around a roller tube, with supports located at the ends of the roller tube. However, the weight of the wound-up shade fabric may cause the support tube to bow, particularly in the middle of the tube. To avoid this undesirable condition, larger diameter, thicker, and/or stronger support tubes may be provided, or the amount of shade fabric may be reduced. These solutions restrict the amount of area that may be shaded, add further costs and increase the weight of the shading system. Therefore, a strong need exists for a shade system capable of deploying a larger area of shade fabric, wide, high, and monumental shades, while minimizing deflection of the shade tube and corresponding wrinkling of the shade fabric.
SUMMARY OF THE INVENTION
[0003] A trough shade system and method of use is disclosed. In one embodiment, the shade system comprises a roller tube having a roller axis; a shade material wound on the roller tube; a support cradle configured to support the roller tube; and, a floating plate configured to allow the roller axis of the roller tube to move a limited range along a first axis of movement with respect to the support cradle, and/or to move a limited range along a second axis of movement with respect to the support cradle. The shade system may also comprise a motor plate affixed to the roller tube and received into a first channel of the floating plate to allow the roller axis of the roller tube to move a limited range along a first axis of movement, and an end cap having rollers received into a second channel of the floating plate to allow the roller axis of the roller tube to move a limited range along the second axis of movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The accompanying drawings, wherein like numerals depict like elements, illustrate exemplary embodiments of the present invention, and together with the description, serve to explain the principles of the invention. In the drawings:
[0005] FIG. 1 illustrates an exploded view of a trough shade system in accordance with an exemplary embodiment of the present invention;
[0006] FIG. 2 illustrates a cut-away view of a trough shade system showing the roller tube having various portions of the shade material wound around the roller tube and the roller tube resting within the support cradle, in accordance with an exemplary embodiment of the present invention;
[0007] FIG. 3A illustrates a cut-away view of a trough shade system comprising various control linkages and support plates, in accordance with an exemplary embodiment of the present invention; and
[0008] FIG. 3B illustrates an isometric view of a trough shade system comprising various control linkages and support plates, in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0009] The detailed description of exemplary embodiments of the invention herein shows the exemplary embodiment by way of illustration, diagrams, charts and various processing steps including the best mode. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that logical and mechanical changes may be made without departing from the spirit and scope of the invention. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not limited to the order presented.
[0010] Moreover, for the sake of brevity, certain sub-components of individual components and other aspects of the system may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships, wireless connections or physical couplings may be present in a practical system. Such functional blocks may be realized by any number of components configured to perform specified functions.
[0011] Trough shade system 100 is configured to deploy and retrieve a shade fabric wrapped around roller tube 102 , while enabling movement of the roller tube 102 within a support cradle 108 such that the shade fabric is deployed and retrieved in a sufficiently constant plane. With reference to FIG. 1 , and in accordance with an exemplary embodiment, trough shade system 100 comprises a roller tube 102 , housing 104 , support cradle 108 , end cap 110 , floating plate 112 , motor plate 116 , rollers 114 and 118 , and motor 130 (not shown).
[0012] Continuing with reference to FIG. 1 , and in accordance with an exemplary embodiment, roller tube 102 comprises a structure configured to receive and support shade material in a winding manner. In one embodiment, roller tube 102 comprises a metal alloy, a composite structure, a plastic structure, a carbon fiber structure, or other suitable material configured to receive and support shade material in a winding manner. Roller tube 102 may include grooves, flanges, trenches, or other portions configured to facilitate attachment of shade material to roller tube 102 . Moreover, roller tube 102 may be configured in any suitable manner for receiving and supporting shade material.
[0013] In one embodiment, roller tube 102 is coupled to motor 130 . Through operation of motor 130 , a portion of shade material is unrolled from roller tube 102 and/or rolled around roller tube 102 . In other exemplary embodiments, roller tube 102 may be rolled using manual force via, for example, a chain. Roller tube 102 may be operated in any appropriate manner and via any appropriate mechanism to cause shade material to unroll from and/or roll onto roller tube 102 .
[0014] Any appropriate shade material, such as fabrics comprising polyester, cotton, nylon, Teflon, high density polyethelyene (HDPE), polyvinyl chloride (PVC), thermoplastic olefin (TPO), fiberglass, room darkening and/or blackout fabrics with a laminated or black-out coating, and the like, and/or any combination of the above, may be used with roller tube 102 . Further, shade material may be any type of material used for facilitating control of solar glare, daylighting, brightness, contrasting brightness, luminance ratios, room darkening, blackout, solar heat gain or loss, UV exposure, uniformity of design and/or for providing a better interior environment for the occupants of a structure supporting increased productivity, and the like.
[0015] With reference to FIGS. 1 and 2 and in accordance with an exemplary embodiment, housing 104 comprises a structure configured to partially or fully encase roller tube 102 and/or other components. Housing 104 may function as the main body of trough shade system 100 . Housing 104 may comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. Housing 104 may also comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. Further, housing 104 is configured for mounting on a building or other surface. Accordingly, housing 104 may be coupled to a building, such as by mounting hardware, e.g., screws and/or other mechanical fasteners. Moreover, housing 104 may be mounted to any appropriate surface via any suitable technique to secure housing 104 in place. Housing 104 is coupled to end cap 110 and to support cradle 108 . Housing 104 may also be coupled to various other components, including fascia 106 and the like.
[0016] Housing 104 may comprise multiple portions. For example, a first portion of housing 104 may be coupled to a building. A second portion of housing 104 may be coupled to the first portion via one or more support clips 132 . Moreover, portions of housing 104 may be coupled together in any appropriate manner configured to secure the portions of housing 104 in place.
[0017] Fascia 106 (not shown) comprises a structure configured to partially or fully hide a subset or all of the components of system 100 . In one embodiment, fascia 106 is configured to couple with housing 104 . Fascia 106 may partially or fully comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. Fascia 106 may also comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. Further, fascia 106 may protect the inner portions of trough shade system 100 from exposure to dirt, debris, and other foreign matter which may impair the operation of trough shade system 100 . Moreover, fascia 106 may comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. In one embodiment, fascia 106 is coupled to housing 104 via a snap fit. In other embodiments, fascia 106 may be coupled to housing 104 via adhesives, mechanical fasteners, slip fits, and the like.
[0018] Returning to FIGS. 1 and 2 , in one embodiment, support cradle 108 comprises a structure configured to support a roller tube, such as roller tube 102 , having shade material wound thereon. Support cradle 108 may partially or fully comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. Support cradle 108 further comprises a low-friction coating in order to facilitate easier deployment (unrolling) and retrieval (rolling) of shade material from roller tube 102 . In other exemplary embodiments, support cradle 108 partially or fully comprises a low-friction material, such as high-density polyethelyne (HDPE), ultra-high molecular weight polyethelyne (UHMW-PE), polyoxymethelyne (e.g., Delrin®), polytetrafluoroethylene (e.g., Teflon®), polyethylene terephthalate, and the like, or any combination thereof. Further, support cradle 108 may comprise any base material having desirable strength and/or weight characteristics. The base material may then be partially or fully coated with a low-friction material to achieve desired properties for support cradle 108 . Support cradle 108 may be coupled to housing 104 . Moreover, support cradle 108 may be continuously supported by housing 104 . In this manner, shade material wound on a roller tube may be supported across the length of the shade for improved safety.
[0019] In one embodiment, with reference to FIGS. 1 and 2 , support cradle 108 is configured to partially or fully support shade material wound around roller tube 102 . For example, support cradle 108 may be symmetrical, asymmetrical, curved, arc-shaped, crescent-shaped, parabolic, hyperbolic, and the like. Support cradle 108 may also be comprised of multiple segments, such as segments having a flat face. Individual segments with a flat face of various inclinations may be coupled together to form support cradle 108 . As used herein, the side of support cradle 108 nearer to the area where shade material is deployed from trough shade system 100 is referred to as the “feed side”. The side of support cradle 108 opposite the feed side is referred to as the “rear side”.
[0020] As best shown in FIGS. 1 and 2 , in various embodiments, support cradle 108 is partially or fully configured with bull nose 134 at the feed side. Bull nose 134 may partially or fully guide shade material during unrolling. Further, bull nose 134 may partially or fully prevent roller tube 102 and wound-up shade fabric from moving out of support cradle 108 during operation of trough shade system 100 , and may assist in keeping roller tube 102 and wound-up shade fabric centered in support cradle 108 . In an exemplary embodiment, bull nose 134 at the feed side of support cradle 108 extends a sufficient distance from the center of shade tube 102 to cause the shade fabric to be deployed and retrieved in a sufficiently constant plane. Moreover, bull nose 134 at the feed side of support cradle 108 may comprise a roller bearing, a solid shape, or any other component or components configured to prevent roller tube 102 and wound-up shade material from rolling out of support cradle 108 and/or allow or the smooth movement of fabric during operation of trough shade system 100 .
[0021] In another exemplary embodiment, support cradle 108 is configured with a stop or tube dam at the feed side. The tube dam may comprise a roller bearing which partially or fully extends the length of support cradle 108 . Alternatively, the feed side tube dam may comprise a solid shape or any other component or components configured to prevent roller tube 102 and wound-up shade material from rolling out of support cradle 108 and/or allow or the smooth movement of fabric during operation of trough shade system 100 . The feed side tube dam may guide shade material during unrolling. Further, the feed side tube dam may partially or fully prevent roller tube 102 and wound-up shade fabric from moving out of support cradle 108 during operation of trough shade system 100 , and may assist in keeping roller tube 102 and wound-up shade fabric centered in support cradle 108 .
[0022] In one embodiment, support cradle 108 is configured with a stop tube dam at the rear side. The rear side tube dam may comprise a roller bearing which partially or fully extends the length of support cradle 108 . In another embodiment, the rear side tube dam may comprise a continuous bearing, a moulded shape, and the like. Further, the rear side tube dam may partially or fully prevent roller tube 102 and wound-up shade fabric from moving out of support cradle 108 during operation of trough shade system 100 , and may assist in partially or fully keeping roller tube 102 and wound-up shade fabric centered in support cradle 108 .
[0023] Returning to FIGS. 1 and 2 and in one embodiment, end cap 110 comprises a structure configured to partially or fully couple with housing 104 . End cap 110 may partially or fully comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. End cap 110 may also partially or fully comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. In one embodiment, end cap 110 is configured to couple with housing 104 , and with floating plate 112 via roller 114 . Further, fascia 106 may also be coupled to end cap 110 . End cap 110 may be configured for partially or fully mounting to a building or other surface, such as by mounting hardware, e.g., screws and/or other mechanical fasteners. Moreover, end cap 110 may be mounted to any appropriate surface via any suitable technique to secure end cap 110 in place.
[0024] Continuing to reference FIGS. 1 and 2 and in one embodiment, floating plate 112 comprises a structure configured to enable movement of roller tube 102 . Floating plate 112 is configured to partially or fully couple with rollers 114 and 118 . Floating plate 112 may partially or fully comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. Floating plate 112 may also partially or fully comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. Floating plate 112 is coupled to end cap 110 via roller 114 . Further, floating plate 112 is coupled to motor plate 116 via rollers 118 . Floating plate 112 may also be coupled to motor plate 116 via other low friction assemblies.
[0025] In accordance with one embodiment, floating plate 112 includes one or more channels, grooves, or any other configuration or device which allows roller tube 102 to move. In one embodiment, floating plate 112 includes four channels, including two vertical channels and two horizontal channels all separated by a block. In another embodiment, floating plate 112 includes three channels, including one vertical channel 120 separating two horizontal channels 124 , 126 . Moreover, floating plate 112 may include any suitable number of channels, grooves, or other configurations or devices which allow roller tube 102 to move.
[0026] Floating plate 112 is configured to allow roller tube 102 to move in a vertical direction responsive to guidance from roller 114 . Further, floating plate 112 is configured to allow roller tube 102 to move in a horizontal direction responsive to guidance from rollers 118 . In this manner, the ends of roller tube 102 are confined to a limited range of movement with respect to support cradle 108 . However, roller tube 102 may move within support cradle 108 , such as in response to forces generated during winding or unwinding shade material. The ends of roller tube 102 may move in a vertical and/or horizontal direction, thereby reducing bowing, bending, and other deformation of roller tube 102 .
[0027] In another exemplary embodiment, roller tube 102 may be allowed to move in a horizontal and/or vertical direction with respect to support cradle 108 through use of an inclined guide rail coupled to the ends of roller tube 102 . In one embodiment, roller tube 102 may be allowed to move in a horizontal and/or vertical direction with respect to support cradle 108 through use of a pivoting arm assembly.
[0028] With further reference to FIGS. 1 and 2 and in one embodiment, end cap 110 includes at least one roller 114 which is partially or fully received into floating plate 112 . Roller 114 may comprise bearings, low friction guides, enclosed or encapsulated bearings, and the like. Roller 114 is configured to allow roller tube 102 to have a limited range of vertical movement. Roller 114 is received into vertical channel 120 of floating plate 112 such that roller 114 allows roller tube 102 to translate vertically within a limited range. In one embodiment, the limited range is defined by the length of vertical channel 120 within floating plate 112 . Roller 114 may thus roll within vertical channel 120 , but the vertical motion is stopped when roller 114 hits the top or bottom of vertical channel 120 . The vertical movement of roller tube 102 causes motor plate 116 to impact the top or bottom portion of the horizontal channels within floating plate 112 , thereby causing vertical movement of floating plate 112 around roller 114 .
[0029] In another embodiment, the limited range is defined by the length of two collinear vertical channels within floating plate 112 . The two vertical channels within floating plate 112 are divided by a block such that two vertical channels are formed within floating plate 112 , thereby allowing each roller 114 to roll within a respective channel, but the vertical motion is stopped when a roller 114 hits the block between the vertical channels.
[0030] Continuing with reference to FIGS. 1 and 2 and in one embodiment, motor plate 116 comprises a structure configured to couple with floating plate 112 via rollers 118 . Motor plate 116 may be configured to couple with motor 130 (not shown). Motor plate 116 may partially or fully comprise aluminum, steel, copper, magnesium, titanium, or other suitable durable metal, and/or various alloys of or variations on the same, such as stainless steel, A36 steel, galvanized steel, duralumin, silumin, 6061 aluminum, and the like, or any combination thereof. Motor plate 116 may also partially or fully comprise a composite structure, a plastic structure, a carbon fiber structure, or other suitable material. Motor plate 116 may be partially or fully received into floating plate 112 via one or more rollers such as rollers 118 .
[0031] Rollers 118 are partially or fully received into the horizontal channels 124 , 126 of floating plate 112 such that rollers 118 enable roller tube 102 to translate horizontally within a limited range. In one embodiment, the limited range is defined by the length of the horizontal channels 124 , 126 within floating plate 112 . In one embodiment, the horizontal channels 124 , 126 within floating plate 112 are divided by a block such that two horizontal channels 124 , 126 are formed within floating plate 112 , thereby allowing each roller 118 to roll within a respective channel, but the horizontal motion is stopped when a roller hits the block between the channels. In another embodiment, the horizontal channels 124 , 126 within floating plate 112 are divided by vertical channel 120 such that two horizontal channels 124 , 126 are formed within floating plate 112 , thereby allowing each roller 118 to roll within a respective channel, but the horizontal motion is stopped when a roller 188 reaches the end of a respective channel. Rollers 118 may comprise bearings, low friction guides, enclosed or encapsulated bearings, and the like. Rollers 118 are configured to allow roller tube 102 to have a limited range of horizontal movement. Further, motor plate 116 is configured to allow roller tube 102 to move in a horizontal direction responsive to guidance from rollers 118 . In this manner, the ends of roller tube 102 are confined to a limited range of horizontal movement with respect to support cradle 108 . However, roller tube 102 may move within support cradle 108 , such as in response to forces generated during winding or unwinding of the shade material.
[0032] Motor 130 (not shown) may be coupled to motor plate 116 and to roller tube 102 . Motor 130 may comprise any suitable device configured to provide rotational force to roller tube 102 , such as, for example, a brushless direct current (DC) motor, a brushed DC motor, a coreless DC motor, a linear DC motor, and the like. Motor 130 may also comprise an alternating current (AC) motor, an induction motor, a cage rotor motor, a slip ring motor, a stepper motor, and the like. Moreover, any motor or similar device presently known or adopted in the future to drive shade tube 102 within trough shade system 100 falls within the scope of the present invention. In other exemplary embodiments, motor 130 may be replaced with another suitable power generation mechanism capable of moving roller tube 102 . In various exemplary embodiments, motor 130 comprises a tubular motor inserted into roller tube 102 and coupled to motor plate 116 .
[0033] In one exemplary embodiment, motor 130 may be configured as any type of stepping motor capable of moving roller tube 102 at select, random, predetermined, increasing, decreasing, algorithmic or any other increments. For example, motor 130 may be configured to move roller tube 102 in 1/16-inch or ⅛-inch increments. Further, motor 130 may also be configured to have each step and/or increment last a certain amount of time. The time of the increments may be any range of time, for example, less than one second, one or more seconds, and/or multiple minutes. In one embodiment, each ⅛-inch increment of motor 130 may last five seconds. Motor 130 may be configured to move roller tube 102 at a rate which results in virtually imperceptible movement of the shade fabric. For example, motor 130 may be configured to continually iterate finite increments, thus establishing thousands of intermediate stopping positions across a shaded area. The increments may be consistent in span and time or may vary in span and/or time across the day and from day to day in order to optimize the comfort requirements of the space and further minimize abrupt window covering positioning transitions, such as those which may draw unnecessary attention from the occupants of a building.
[0034] Motor 130 (not shown) may be activated to cause rotation of roller tube 102 in order to unroll a portion of shade fabric. Shade fabric may be deployed from the feed side of trough shade system 100 . A portion of the shade fabric may move across the feed side edge of support cradle 108 , such as bull nose 134 . In this manner, shade fabric may be guided as it exits the trough shade system 100 . Moreover, shade fabric may be deployed without moving across the feed side edge of support cradle 108 . In various exemplary embodiments, shade fabric is deployed from trough shade system 100 in a sufficiently constant and consistent plane with respect to the shaded surface. Moreover, shade fabric may be deployed from trough shade system 100 in a plane controlled by the location of the bull nose in support cradle 108 .
[0035] In other exemplary embodiments, the distance between the shade fabric and the shaded surface may vary, e.g., as a result of variation in the amount of shade fabric remaining in a wound condition on roller tube 102 , as a result of the location of bull nose 134 , and the like. Friction on the shade fabric may thus be reduced, as the shade fabric may contact bull nose 134 during only a portion of the shade deployment and/or retrieval.
[0036] In an exemplary embodiment, motor 130 may be activated to cause rotation of roller tube 102 in order to roll up a portion of shade fabric. Shade fabric may be retrieved at the feed side of trough shade system 100 . A portion of the shade fabric may move across the feed side edge of support cradle 108 , such as bull nose 134 . In this manner, shade fabric may be guided as it returns into trough shade system 100 and is wound on roller tube 102 . Moreover, shade fabric may be retrieved without moving across the feed side edge of support cradle 108 . In an exemplary embodiment, shade fabric is retrieved into trough shade system 100 in a sufficiently constant plane with respect to a shaded surface. In other exemplary embodiments, the distance between the shade fabric and the shaded surface may vary, e.g., as a result of variation in the amount of shade fabric collected in a wound condition on roller tube 102 .
[0037] In accordance with various exemplary embodiments, trough shade system 100 comprises a double shade. For example, two shades may be provided in a back to back arrangement, an over/under arrangement, and the like. The first shade may be a room darkening/blackout shade. The second shade may be a sunscreen shade. Moreover, the first and second shade may be any appropriate shade material. The shades may be deployed, retrieved, and/or operated individually and/or together.
[0038] A shade may comprise side channels to minimize edge-of-shade light leaks (such as those occurring due to distance between the edge of a fabric shade and the end of support cradle 108 ). Moreover, smooth deployment of a shade fabric without changing the location of the shade fabric in relation to side channels or windows may allow long, high shades to be inserted into side channels. Additionally, use of a floating bearing design may enable reduction of the gap between the end of a shade and the end of a support trough.
[0039] A sunscreen shade may comprise a solar protection shade fabric. The solar protection shade fabric may be installed as a single shade. The solar protection shade fabric may also be installed as a series of individual shades, for example shades adjacent to each other and having a space between shades of between approximately ¼ inch to ¾ inch, or a wider space as appropriate in order to compliment or mimic the module of one or more windows intended to be covered. Individual shades coupled to a single roller tube 102 will operate together as a single unit.
[0040] Trough shade system 100 may also comprise a triple shade, a four-shade system, and the like. Any suitable number of shades may be provided, as desired.
[0041] In accordance with various exemplary embodiments, trough shade system 100 may be provided and installed in at least two portions. For example, a housing/support portion may be installed first. At least one trough portion may then be attached to and supported by the housing/support portion. Internal leveling devices may be provided in order to level and adjust the trough to assist with uniform operation and tracking of the shade bands. Moreover, internal attachments, such as Z-type clips, may facilitate installation and/or removal of one or more trough portions from the support/housing portion.
[0042] With reference now to FIGS. 3A and 3B , and in accordance with an exemplary embodiment, trough shade system 300 comprises mounting clip 302 , housing 306 , support cradle 308 comprising anti-friction coating 309 , roller tube end portion 310 , first mounting plate 312 , horizontal control linkages 314 , bearings 316 , second mounting plate 318 , vertical control linkages 320 , and motor 322 (not shown).
[0043] Mounting clip 302 may be mounted to any appropriate surface. Mounting clip 302 is coupled to housing 306 . Mounting clip 302 may also comprise ceiling tile support hanger 304 .
[0044] Housing 306 is coupled to support cradle 308 . Housing 306 may provide support to support cradle 308 throughout the length of support cradle 308 . Shade fabric wound around a roller tube coupled to roller tube end portion 310 may be supported via support cradle 308 . Support cradle 308 may comprise an anti-friction coating in order to reduce friction between support cradle 308 and shade fabric. Support cradle 308 may further comprise various components on the feed side and/or rear side, such as a bull nose, a roller bearing, a tube dam, and the like.
[0045] Motor 322 (not shown in the figures) is coupled to roller tube end portion 310 . In this manner, force provided by motor 322 may be translated into movement of at least one shade fabric coupled to a roller tube.
[0046] Continuing to reference FIGS. 3A and 3B , roller tube end portion 310 is in turn coupled to a first mounting plate 312 . First mounting plate 312 is coupled to at least two horizontal control linkages 314 via a series of bearings 316 . Horizontal control linkages 314 may be configured to allow a roller tube to move in a substantially horizontal direction.
[0047] Horizontal control linkages 314 are coupled to second mounting plate 318 . Second mounting plate 318 is in turn coupled to housing 306 by way of at least two vertical control linkages 320 . Vertical control linkages 320 may be configured to allow a roller tube to move in a substantially vertical direction. Reactive torque loading from operation of motor 322 may thus be distributed via horizontal control linkages 314 and vertical control linkages 320 .
[0048] Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of any or all the claims of the invention. It should be understood that the detailed description and specific examples, indicating exemplary embodiments of the invention, are given for purposes of illustration only and not as limitations. Many changes and modifications within the scope of the instant invention may be made without departing from the spirit thereof, and the invention includes all such modifications. Corresponding structures, materials, acts, and equivalents of all elements in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claim elements as specifically claimed. The scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given above. Reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, and C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, Band C, or A and B and C.
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A trough shade system and method of use provide improved support for a roller tube and shade material. The roller tube and wound shade material are located within a support cradle to minimize unwanted deflection by the roller tube and associated wrinkling and deformation of the shade material. Various mechanisms allow the roller tube a limited range of movement within the support cradle. The system is suitable for shading larger areas than other shading systems which rely on roller tubes with fixed supports at the ends.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61265742, filed on Jan. 10, 2010.
GOVERNMENT RIGHTS
[0002] This invention was not made with Government support. The Government does not have any rights in this invention.
BACKGROUND OF THE INVENTION
[0003] Boats typically are purchased with a predetermined number of seats, and a fixed location of seats. However, if there are only one or two people in the boat, and 4 seats, then there may be wasted space occupied by the unused seats. In addition, if there are two or four seats in the boat, and one person in the boat, then the boat would normally be leaning to the right or left if the two or four seats are disposed on the left and right side of the boats.
[0004] A company named “Rivtech” has an adjustable boat seating system described at its web site, “http://www.rivtechdriftboats.com/standard-features/adjustable-removable-drift-boat. However the seats of this product are secured to a bench that is raised above the floor, and secured to the sides of the boats. The seat can be in a fixed position on the bench, or it may slide on a rail that is on the bench.
[0005] As can be seen, there is a need for a boat to have a seat or accessory that is moveable or relocateable to various positions on the floor of the boat to accommodate the number of people in the boat, and the desired space.
[0006] There is also a need for a seat or accessory that is removably attached to a floor of a drift boat. The seat being disposed on the floor provides a lower center of gravity, and thus more safety.
[0007] There is also a need for a boat to have accessories other than seats, such as counsels, cooler, refrigerators, or containers that are moveable or relocateable about the boat floor.
BRIEF SUMMARY OF THE INVENTION
[0008] One aspect of the present invention is a relocateable accessory ( 10 ), comprising: the accessory ( 10 ) having a front side ( 60 ) and a rear side ( 70 ); a first extension ( 30 ) that extends downwardly to a second extension ( 80 ); said first extension ( 30 ) secured to said front side ( 60 ); a floor ( 170 ) having a second extension slot ( 20 ), and a finger slot ( 150 ); said second extension ( 80 ) capable of being disposed through said second extension slot ( 20 ); and a locking member ( 160 ) secured to said rear side ( 70 ), said locking member ( 160 ) can bias from a secured position ( 210 ) and an unsecured position, and a portion of said locking member ( 160 ) is removably displaced through said finger slot ( 150 ).
[0009] Another aspect of the present invention is a relocateable accessory ( 10 ), comprising: a front side ( 60 ); a rear side ( 70 ) opposed from said front side ( 60 ); a first extension ( 30 ) secured to a lower edge ( 65 ) of said front side ( 60 ), said first extension ( 30 ) extending downwardly to a second extension ( 80 ) that is angled away from said accessory ( 10 ) and an angle ( 140 ) of about 40 degrees; a locking member ( 160 ) secured to a lower edge ( 65 ) of said rear side ( 70 ), said locking member ( 160 ) having a finger ( 40 ) that can be biasly disposed through a finger slot ( 150 ) of a floor ( 170 ), said finger ( 40 ) being biasly disposed between a secured position ( 210 ) and an unsecured position; and said floor ( 170 ) having a second extension slot ( 20 ) that is capable of receiving said second extension ( 20 ) therethrough.
[0010] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a pictorial of one embodiment of the present invention.
[0012] FIG. 2 is a pictorial view of one embodiment of one step of how the present invention may be installed on a boat.
[0013] FIG. 3 is a pictorial view of one embodiment of a second step of how the present invention by be installed on a boat.
[0014] FIG. 4 is a pictorial of a first extension and second extension;
[0015] FIG. 5 is a pictorial of a locking member;
[0016] FIG. 6 is a pictorial view of the second extension disposed through the second extension slots in the floor of the boat;
[0017] FIG. 7 is a pictorial view of the locking member with the finger disposed through the finger slot;
[0018] FIG. 8 is a pictorial of a portion of an adjustable seat with a front side having a first extension and second extension, whereby the second extension is disposed through the second extension slot;
[0019] FIG. 9 is a pictorial view showing an embodiment of an adjustable seat disposed on the boat floor by use of the locking member;
[0020] FIG. 10 is a pictorial of another embodiment of a locking system of the present invention;
[0021] FIG. 11 is a pictorial of another embodiment of a locking system of the present invention;
[0022] FIG. 12 is a pictorial of the embodiment of the locking system with the enlarged portion; and
[0023] FIG. 13 is a pictorial of an embodiment with a plurality of first extensions 30 and second extensions 80 on one side of the seat.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
REFERENCE NUMERALS
[0000]
10 adjustable seat
20 second extension slot
30 first extension
40 finger
50 tab
60 front side
65 lower edge
70 rear side
80 second extension
90 hook portion
100 tip
110 bottom side of floor
120 bottom of seat
130 pivot
140 angle between first extension and second extension
150 finger slot
155 finger pivot
160 locking member
170 floor
180 vertical upward force
190 inward direction
200 outward direction
210 secured position of the locking member
220 spring
225 fixed end
[0050] FIG. 1 illustrates one embodiment on the present invention. A front side 60 may have a first extension 30 that may extend downwardly to a second extension 80 . The second extension 80 may be removably disposed through a second extension slot 20 . The second extension 80 may extend away from the first extension 30 at an angle 140 , as seen in FIG. 3 . In one embodiment, that angle 140 may be about 45 degrees. In another embodiment, that angle may be between about 30 degrees to about 60 degrees. Thus, the seat 10 or component 10 cannot be removed solely by a vertical upward force 180 .
[0051] FIG. 1 also illustrates the floor 170 with the finger slot 150 . In one embodiment, the finger slot 150 may be disposed substantially perpendicular to the second extension slot 20 .
[0052] FIG. 2 illustrates one embodiment of a method of using the present invention 10 , and the structure of one embodiment of the present invention 10 . A locking member 160 may be disposed on a rear side 70 . The locking member 160 may removably secure the seat 10 or component 10 to a floor 170 . In one embodiment, the locking member 160 may have a tab 50 that can be displaced inwardly along an inwardly direction 190 , which may cause a finger 40 to be displaced outwardly in an outwardly direction 200 . The finger 40 may extend downwardly to a hook portion 90 . The hook portion 90 may terminate at a tip 100 . In one embodiment, the locking member is J-shaped. For example, the finger 40 , the hook portion 90 , and the tip 100 may be J-shaped. FIG. 3 illustrates a seat 10 or component 10 that is secured to a floor 170 . In FIG. 3 , the locking member 160 is illustrated in the secured position 210 .
[0053] As illustrated in FIGS. 3 and 5 , in one embodiment, the hook portion 90 and tip 100 may be disposed below the floor 170 when the seat 10 is secured to the floor 170 , which is also referred to as the secured position 210 . When the seat 10 is secured to the floor 170 in this manner, the locking member 160 is in the secured position 210 . In one embodiment, the tab 50 can be displaced inwardly, such as by pushing it with a thumb with enough force to overcome the force of any spring that may biasly push the tab 50 outwardly, or the spring may force the finger 40 inwardly. The locking member 160 is in the unsecured position when the finger 40 is displaced outwardly, then the tip 100 would be displaced outwardly, which would cause the tip 100 from being below the floor 170 , to being below or within the finger slot 150 so that the front side 60 of the accessory 10 can be lifted upwardly until the second extension 80 is substantially vertical. At which point the second extension 80 can be lifted through the second extension slot 20 . For example, the rear side 70 may be lifted so that the second extension 80 is substantially vertical, so that the second extension 80 can be removed through the second extension slot 20 , and then the seat 10 or component 10 can be removed or relocated and repositioned to the floor 170 . In one embodiment, the first extension 30 is secured to a lower edge 65 of the front side 60 .
[0054] As seen in FIGS. 3 and 5 , the locking member 160 may have a finger pivot 155 disposed below the tab 50 , and above the finger 40 to enable the tab 40 to bias inwardly as the finger 40 biases outwardly. Likewise, the finger pivot 155 may allow the tab 50 to bias outwardly as the finger 40 may bias inwardly. In one embodiment, a spring may exert an outward force above the finger pivot 155 , so that the finger 40 has a hook portion 90 secured through a finger slot 150 , to secure the seat 10 or component 10 to the floor 170 .
[0055] As seen in FIGS. 3 , 5 , and 7 , in one embodiment the locking member 160 may have a hook portion 90 that can fit within a finger slot 150 , and then the tip 100 of the hook portion 90 may contact the bottom side of the floor 110 to secure the adjustable seat 10 in place. The first extension 30 may have a second extension 80 extending therefrom at an outward angle 140 . In one embodiment, this angle is called the angle between the first extension and the second extension 140 . In one embodiment, this angle 140 may be about 45 degrees.
[0056] Therefore, as seen in FIGS. 2 , 4 , and 6 , in operation, the second extension 80 may be disposed within a slot 20 , then the bottom of the seat 120 may be placed on the floor 170 , then the hook portion 90 may be placed within the slot 20 . The hook portion 90 may be adjusted or manipulated via a tab 50 that can be displaced in one direction, forcing the hook portion 90 to be displaced because of the pivot 130 .
[0057] FIG. 8 further illustrates the seat 10 or component 10 disposed on a floor 170 . The front side 60 is shown having a first extension 30 extending downwardly to a second extension 80 , and the second extension 80 and first extension 30 may be disposed whereby there is an angle 140 between them. In one embodiment, this angle 140 may be about 45 degrees. In one embodiment the angle 140 may be between 30 degrees and 60 degrees. The second extension 80 may be removably disposed through the second extension slot 20 .
[0058] FIG. 9 illustrates the seat 10 or component 10 secured to a floor 170 by means of the locking member 160 . The locking member 160 is illustrated in the secured position 210 . The locking member 160 may be disposed on the rear side 70 . The finger 40 may be removably disposed through the finger slot 150 of the floor 170 .
[0059] FIG. 10 illustrates another embodiment of the locking member 160 . The locking member may pivot about a pivot 130 . The pivot 130 of this embodiment may be rotatably disposed to a locking member housing 230 . The pivot 130 may be disposed above the floor 170 , and beneath a fixed end 225 . A spring 220 may be biasly disposed between the fixed end 225 and a lever member 235 . In one embodiment the lever member 235 may have a contact portion 240 , which a boater's finger may contact to move the locking member 160 . The lever member 235 may have a horizontal portion 245 that extends inwardly from the contact portion 240 , and the horizontal portion 245 may be immediately adjacent and above the floor 170 . The lever member 235 may have a hook portion 250 that extends downwardly from the horizontal portion 245 . The hook portion 250 may be able to contact the bottom side of floor 110 . For example the spring 220 may force the hook portion 250 against the floor 170 to secure the locking member 160 in place, which also secures the component or seat 10 in place. The seat 10 may be removed by forcing the lever portion 240 upwardly, which displaces the hook portion 250 away from contact with the bottom side of floor 110 , so that the lever member 235 may be lifted upwardly through the finger slot 150 .
[0060] FIG. 11 illustrates another embodiment of a locking member 160 , where the finger 40 terminates in an enlarged portion 260 , which can be displaced through a finger slot keyhole 265 of the finger slot 150 . For example, the enlarged portion 260 may have a diameter smaller then the finger slot keyhole 265 , but larger than the width or diameter of the finger slot 150 .
[0061] FIG. 12 illustrates an embodiment of a seat 10 secured to a floor 170 via the locking member 160 with the enlarged portion 260 .
[0062] FIG. 13 illustrates one embodiment with a plurality of combined first extension 30 and second extensions 80 , whereby either the first extension 30 or second extension 80 , or the interface of where the first extension 30 meets the second extension 80 , may be disposed through the second extension slot 20 .
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Relocateable boat accessories, such as seats having a second extension that can be positioned through a second extension slot, and then pivoted to position a locking member through a finger slot. The locking member can have a tip that is positioned under a floor so secure the seat to the floor. The floor may have several second extension slots and several finger slots to accommodate various accessory or seat position possibilities.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Provisional Patent Application Ser. No. 60/654,669 filed Feb. 17, 2005, herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention disclosed here is an article restraint device that attaches to an article such as a children's spill proof drinking cup, a baby bottle, a toy item, or the like. It can be used to tether any item that fits within the confines of the article holding sleeve. For instance, it can be used to hold a beverage container, a water bottle, a cell phone, an “iPod,” or any device that can fit in and be snugly surrounded by the article holding sleeve.
SUMMARY OF THE INVENTION
[0003] In many situations there is a need to have an article remain within reach of an individual.
[0004] One expected use of the invention presented herein is for use with bottles being held or used by small children. In this situation a cup or bottle is held in the restraint device which is attached to a stroller, car seat, high chair, or the like while also within reach of the child or having a portion of the device within reach of the child.
[0005] In another situation it is helpful to have a beverage container on a tether attached to the individual so that the beverage container can be easily retrieved by the individual. For instance, a hiker may be carrying a water bottle and will find situations where it is convenient to release his/her hold on the bottle and yet have the bottle still accessible and retrievable. Another example is when a person is riding a bicycle. In many cases the bicycle will have a water bottle cage however grasping, retrieving and returning the water bottle to the cage is tricky and the water bottle may be dropped.
[0006] Parents with preschool age children will understand that this device is a solution to the frustrating situation where a drink cup, such as a spill proof “sippy-cup,” is handed to a child only to be dropped from the grasp of the child. Often the dropped item is dropped beyond the reach of the child and there is no one to pick up and hand the dropped cup back to the child. A dropped bottle or “sippy-cup” is especially a problem in a car where the child is in a car seat and the cup is dropped to the seat or floor of the car. The driver, if there is no other help in the car, will have to reach back and “feel around” to locate the cup or article. This could be distracting to the driver.
[0007] Another situation where the invention is helpful is where a child is in a baby stroller and drops the cup or bottle on the ground. Perhaps the parent or guardian will notice the dropped cup and pick it up. Or perhaps the dropped cup will not be noticed and lost in a parking lot, along a sidewalk, or in a mall.
[0008] Similar scenarios involve such things a cell phones, water bottles, iPods, tools, articles of clothing, and the like (any item that can be secured in the article holding sleeve) carried by persons that may drop or dislodge them and not even realize that the item has been dropped.
[0009] Thus it is an object of this invention to provide a device that can be attached to an apparatus or secure anchor or host element, the device having an apparatus restraint and a tether to allow the device to be attached a host element.
[0010] Another object of the invention is to make the device out of a single piece of material. One aspect of this object is that the device can be made inexpensively as it will not require significant assemble, construction or sewing.
[0011] One more object of the invention is to provide a device that is flexible so that items of different shapes, sizes and uses are accommodated by the device. Thus unique configurations for similar items of varying shapes are not needed as various shapes can be accommodated by one configuration of the device.
[0012] It is also an object of the invention to provide a device that is constructed of pliable material, such as a rubber-like material, rather than unyielding material such as a metallic leash for a similar purpose.
[0013] Another object of the invention is to provide a device that can be attached to a host apparatus, such as but not limited to, a stroller, highchair, car seat, wheelchair, riding toy or machine, or the like; to restrain an article attached to the device proximate to a person secure on the host apparatus.
[0014] One further object of the invention is to make the device in that is washable, colorful and inexpensive to manufacture.
[0015] The preferred embodiments of the invention presented here are described below in the specification and shown in the drawing figures. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given the ordinary and accustomed meaning to those of ordinary skill in the applicable arts. If any other special meaning is intended for any word or phrase, the specification will clearly state and define the special meaning. In particular, most words commonly have a generic meaning. If I intend to limit or otherwise narrow the generic meaning, I will use specific descriptive adjectives to do so. Absent the use of special adjectives, it is my intent that the terms in this specification and claims be given their broadest possible, generic meaning.
[0016] Likewise, the use of the words “function,” “means,” or “step” in the specification or claims is not intended to indicate a desire to invoke the special provisions of 35 U.S.C. 112, Paragraph 6, to define the invention. To the contrary, if the provisions of 35 U.S.C. 112, Paragraph 6 are sought to be invoked to define the inventions, the claims will specifically state the phrases “means for” or “step for” and a function, without also reciting in such phrases any structure, material or act in support of the function. Even when the claims recite a “means for” or “step for” performing a function, if they also recite any structure, material or acts in support of that means or step, then the intention is not to invoke the provisions of 35 U.S.C. 112, Paragraph 6. Moreover, even if the provisions of 35 U.S.C. 112, Paragraph 6 are invoked to define the inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function, along with any and all known or later-developed equivalent structures, material or acts for performing the claimed function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention is shown in the accompanying drawings in which:
[0018] FIG. 1 is a view of the article restraint device without an article in place;
[0019] FIG. 2 is a view of the article shown in FIG. 1 with a container located in the device;
[0020] FIG. 3 is the invention as shown in FIGS. 1 and 2 and having a loop formed integral with the tether of the article restraint device;
[0021] FIG. 4 is a portion of the tether with a slit that will allow attachment to a secure mounting location;
[0022] FIG. 5 is a view of the device formed from a single tube of flexible-foam material.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 shows one embodiment of the device. In this figure the device includes a article restraint, generally 10 , having three main elements. An article holding sleeve 12 is formed as a continuous web of material into a short, pliable, elastic tube-like structure. It can be a seamless or seamed tube generally of round cross-section in one embodiment. It can also be a non-round tubular structure, such as a square cross-section tube, a triangular cross-section tube, an oval cross-section tube, a flattened tubular cross-sectioned structure, or the like. The concept is that it will be an elastic structure, in one embodiment it is a flexible-foam like material, such as neoprene, that will surround and grasp an article placed inside the structure.
[0024] A tether 14 or strap is attached or is integrally formed at one end to the article holding sleeve. In one embodiment the tether or strap is integral with, that is, it is one piece with the sleeve 12 . This could be easily done if the article is cut from a tube of material or if the article restraint is molded as a one-piece item. This embodiment, shown in FIG. 5 , would be similar to FIGS. 1 and 2 except there would be no stitching attaching the tether to the sleeve, as it would be a one-piece structure.
[0025] In another embodiment the attachment of the tether to the sleeve may be an adhesive attachment, a sewn attachment, a fused attachment or a mechanical tab and slot attachment, or the like.
[0026] FIG. 1 shows one embodiment of the invention. In this figure the tether is attached to the article holding sleeve by locating the first end of the tether adjacent an inside wall of the article holding sleeve and stitching it in place as shown by the stitch lines such as 16 . Stitching would be optional if the first end of the tether was adhesively affixed to the sleeve. Of course the first end of the tether could just as easily be stitched, or otherwise attached, to the outside of the article holding sleeve.
[0027] In one embodiment of the invention there is a loop 18 formed at the end of the tether. It can be a continuous loop of material integral with the tether such that there is no stitching, snap, hook and loop attachment, or the like used in forming the loop. One embodiment of such a design is shown in FIG. 3 .
[0028] In an alternative embodiment, as shown in FIG. 2 , the loop 18 is formed in the second end of the tether. It is the bitter end of the tether folded back over itself and stitched, such as at junction 20 , or otherwise fastened to an intermediate section 22 of the tether. Any type of fastener, as an alternative to stitching shown at junction 20 , such as a loop and hook fastener, a snap fastener, a buckle fastener, or the like, may be used to form and maintain the loop in the second end, generally 24 , of the tether.
[0029] The tether may be tapered along its length as shown in FIGS. 1 and 2 or, alternatively the tether can be of a constant or an undulating width.
[0030] The fabric of the invention, in one embodiment, is a thin neoprene or neoprene-like web, similar to wetsuit material. In one embodiment the neoprene is 2 mm thick, but may be thicker or thinner depending on the color, pattern, or salient design considerations. Neoprene fabric is strong, flexible, returns to shape readily and is easy to work with, fabricate, sew, and glue if desired. It is expected that the article holding sleeve is neoprene and the tether and loop is the same material, perhaps even being cut from the same piece of flat or tubular shaped material. This allows the tether to stretch and flex in a user friendly and familiar way. However, the tether can be made of a material different from the article holding sleeve and still function extremely well in fulfilling one of the objectives of the invention.
[0031] The operation and function of the device is apparent from looking at FIG. 2 . Here an article, in this case a sippy-cup 22 , “sippy-cup” being a moniker for a cup used by infants that is generally spill-proof, is inserted into the article holding sleeve, which has flexed or stretched to conform to the contour of the sippy-cup. The tether 14 , through the loop 18 is attached to an anchor, such as, but not limited to, a safety strap or lap belts on a car seat, a strap on a baby carrier, a wheel chair, a hook or attachment point on a grocery cart, or onto any point that will enable the restrained article to remain in proximity to the child, person or location desired by the custodian. The loop could even pass over the hand or foot of the child and encircle the child's wrist or ankle. If a snap, loop and hook, or other type of removable fastener is used to form the loop, the second or bitter end of the tether could be treaded through an aperture or around an object and be refastened to secure the tether to the anchor object. Furthermore, if the tether is neoprene, it is flexible enough to allow the article holding sleeve portion to pass through the loop after positioning the tether around an anchor object to make a secure connection.
[0032] FIG. 3 is an embodiment of the invention wherein the loop at the second end of the tether is formed in the tether itself by cutting a hole 26 in the tether. This enables the article restraint device to be hooked on or over a secure element or, alternatively, allows the sleeve 12 to be threaded through the hole 26 after the tether is directed around an anchoring element such as a strut or frame member of a chair, carriage, seat belt or similar anchor providing elements.
[0033] FIG. 4 provides another embodiment. In this embodiment a slit 30 is cut through the second end of the tether and this slit can be used as the opening through which a hook or other projection passes to anchor the article restraint device. As discussed with respect to FIG. 3 , the sleeve 12 can be threaded through the slit 28 after the tether is directed around an anchoring element such as a strut or frame member of a chair, carriage, seat belt or similar anchor providing element.
[0034] FIG. 5 is presented to show that the device can be formed without stitching or fasteners. In this embodiment the device would be cut out of a tube of flexible-foam material such that the article holding sleeve remains a section of the tube. The tether and second end of the tether is from the same piece of tube as the sleeve. This configuration is effective in minimizing hand work to complete the device. In order to conserve materials the layout of devices on the tube before they are cut out would be studied to minimize the amount of selvage generated by cutting the device out from a tube in one piece. It may be more efficient to have more than one component making up the device. This could be a section of a tube for the sleeve and a second element making up the tether and loop as is shown in FIGS. 1 and 2 .
[0035] In summary one embodiment of the invention is a device providing restraint of an article such as, but not limited to, an infant bottle or drink cup for infants. The device comprises a tether of flexible-foam type material, such as, but not limited to, neoprene, the tether having a first end and a second end. An article holding sleeve of flexible-foam type material is in communication with the tether at the first end of the tether while a loop is in communication with the second end of the tether.
[0036] In another embodiment of the invention a device for accomplishing the restraint of an article comprises a flexible-foam type material article holding sleeve; a tether extending from the article holding sleeve, the tether of flexible-foam type material having a first end and a second end; a loop in communication with the tether, the loop positioned at the second end of the tether. In this embodiment the flexible-foam type material of the tether is similar to, or could be of, the same material as the flexible-foam type material of the article holding sleeve. Likewise the loop can be made of flexible-foam type material similar to, or identical to, the flexible-foam type material of the tether. It is known that so called “neoprene” is a good flexible-foam type material and thus the article holding sleeve, the tether and the loop can be of neoprene material.
[0037] On further embodiment of the article restraint is cut out from a single tubular piece of flexible-foam type material. That is, the device comprises the holding sleeve, the tether and the loop all formed from a single tubular shaped piece of flexible-foam like material such as neoprene.
[0038] The inventors believe there are many nuances of the design that can make the basic invention even more desirable, for instance, text can be printed on the fabric to inform readers of various information and designs can be printed on the fabric for appearances, just to mention several nuances of the invention contemplated by the inventor. Since one of the preferred fabrics is neoprene flexible-foam type material, this material will provide some degree of flotation and thus may slow down the sinking of a contained object. This material is also somewhat easy to cut, as contrasted to nylon webbing or a leather strap, for instance.
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An article restraint device for use in restraining an article such as a baby bottle proximate a given location. The device can be used to tether items that fit into an article holding sleeve to adjacent structure or to an individual. The device is made of flexible-foam type material that will stretch to accommodate items of various dimensions.
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This application is a file wrapper continuation of U.S. application Ser. No. 08/114,183, filed Sep. 1, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a nonvolatile memory, and more particularly to an electrically erasable read only memory (EEPROM).
2. Description of the Related Art
In various kinds of recent electronic equipments, EEPROMs are used as initialization memories. Occasionally, in consumer market appliances such as televisions and cameras, data which needs to be frequently updated and initialization data which only occasionally reloaded after being once written are stored in a mixed fashion in a nonvolatile memory. For example, in a television, if the power supply is switched off, data of the last channel being viewed immediately before the switch off, i.e. channel information such as a receiving frequency, volume and degree of screen brightness, is stored in the memory so that the television will start operating in the same conditions as before when it is switched on the next time. Since such data (hereinafter called "last channel memory data") is stored whenever the power supply is switched off, the memory is reloaded repeatedly. On the contrary, initialization data for presetting to match a channel button with a frequency rarely needs to change after having been set up once, and the memory must be reloaded only several times at most.
FIG. 7 shows a U-shaped curve representing the reloading characteristic of an EEPROM. Initial failure, which results from various causes in the manufacturing process, can be screened by conducting tests; but random failure and wear-out failure would still be problems. In a random failure region, though its failure frequency is very approximately zero, a much better idea is needed to get it to be absolutely zero. In a wear-out region, since the frequency of reloading and failure frequency increase, measures would be required to increase the frequency of reloading as high as possible until it enters the wear-out region.
One of the conventional measures employs a so-called ECC (error correction code) system.
In the ECC system, when correcting a 1-bit error, for example, 4-bit parity data is needed for 1-word-8-bit data. If this method is applied to every word address, the chip size would be large to increase the cost of production. Similarlly to a television receiver, in the case where last channel memory data which need to be reloaded frequently and preset memory data which rarely need to be reloaded are stored in the memory in a mixed fashion, wear-out failure as shown in FIG. 7 need scarcely be considered for the latter, i.e., preset memory data, but only for last channel memory data. However, according to this conventional method, since the ECC system is used to add parity bits to every word address of EEPROM even if the last channel memory data occupies only several bytes, it requires many more memory bits than necessary, which thereby increases the cost of production.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide an electrically erasable read only memory which is inexpensive and is highly reliable when used in storing, in a mixed fashion, data to be reloaded frequently and data to be rarely reloaded.
According to a first aspect of the invention, there is provided an electrically erasable read only memory for storing, in a mixed form, data to be reloaded at high frequency and data to be reloaded at low frequency, comprising: data identifying means for identifying whether object data to be written is the high-frequency reload data or the low-frequency reload data; and data reloadable control means for writing in memory cells said object data by a predetermined highly reliable method if said object data is the high-frequency reload data as the result of identification of said data identifying means and for writing in memory cells said object data by an ordinary method if said object data is the low-frequency reload data.
In the first arrangement, discrimination is made as to whether the object data to be written is high-frequency reload data or low-frequency reload data, and writing is performed in conformity with the result of discrimination.
According to a second aspect of the invention, there is provided an electrically erasable read only memory for storing, in a mixed form, data to be reloaded at high frequency and data to be reloaded at low frequency, comprising: write address detecting means for detecting whether or not designated write addresses are within a predetermined range; data writing means for discriminating said object data to be the high-frequency reload data only when said write addresses are within the predetermined range as the result of detection by said write address detecting means and then overwriting said object data in a plurality of memory cells; and read data deciding means for reading said data written in said plural memory cells by said data writing means when said predetermined range of addresses are designated during reading and for deciding one of the read data.
In the second arrangement, detection is made of whether or not the designated write addresses are within a predetermined range, and as a result, if they are within the predetermined range, the object data to be written is judged to be the high-frequency reload data and is overwritten ill plural memory cells. For reading, one of the read data is decided for output, based on the written data.
According to a third aspect of the invention, there is provided an electrically erasable read only memory for storing, in a mixed form, data to be reloaded at high frequency and data to be reloaded at low frequency, comprising: write address detecting means for detecting whether or not designated write addresses are within a predetermined range; data writing means for discriminating that said object data is the high-frequency reload data only when said write addresses are within said predetermined range as the result of detection by said write address detecting means and writing in memory cells said object data with an error correction code added; and error correcting means for reading said data, which is written by said data writing means, when said predetermined range of addresses are designated during reading and for making an error correction based on said error correction code.
In the third arrangement, detection is made whether or not the designated write addresses are within a predetermined range, and as a result, if they are within the predetermined range, the object data to be written is judged to be the high-frequency data and is written in memory cells after an error correction code is added. For reading, error correction is made using the error correction code.
According to a fourth aspect of the invention, there is provided an electrically erasable read only memory for storing, in a mixed form, data to be reloaded at high frequency and data to be reloaded at low frequency, comprising: write address detecting means for detecting whether or not designated write addresses are within a predetermined range; data writing means for discriminating said object data to be the high-frequency reload data only when said write addresses are said predetermined range as the result of detection by said write address detecting means and for writing said object data and reverse data thereof respectively in different memory cells; and differential data creating means for reading both said object data and said reverse data, which are written by said data writing means, when said predetermined range of addresses are designated during reading and for creating read data according to the difference between said object data and said reverse data.
In the fourth arrangement, detection is made of whether or not the designated write addresses are within a predetermined range, and as a result, if they are within the predetermined range, the object data to be written is the high-frequency reload data, and the object data to be written and its reverse data are written in the respective memory cells. For reading, the difference between the original data and the reverse data is outputted as read data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an EEPROM according to a first embodiment of this invention;
FIG. 2 is a block diagram showing an EEPROM according to a second embodiment of the invention;
FIG. 3 is a block diagram showing an EEPROM according to a third embodiment of the invention;
FIG. 4 is a block diagram showing an EEPROM according to a fourth embodiment of the invention;
FIG. 5 is a characteristic graph showing the relationship between the memory transistor's threshold voltage and the frequency of rewriting to the EEPROM;
FIG. 6 is a diagram illustrating the principle of reading data from the EEPROM; and
FIG. 7 is a characteristic graph showing the relationship between the error rate and the frequency of reloading in a conventional EEPROM.
DETAILED DESCRIPTION
Embodiments of this invention will now be described in detail with reference to the accompanying drawings.
FIG. 1 shows an EEPROM according to a first embodiment of this invention. In the EEPROM, 1 word consists of 8 bits. As shown in FIG. 1, this circuit is equipped with a data creating circuit 11 connected to an address detecting circuit 12. When D 7 -D 0 as 8-bit wide write data 17 are inputted to the data creating circuit 11, the address detecting circuit 12 checks address data 18 and outputs a detection signal 20 to the data creating circuit 11 if designated addresses are within a predetermined range. Upon receipt of the detection signal 20, the data creating circuit 11 writes the write data D 7 -D 0 into registers 16-1-16-3, respectively. The predetermined range of addresses are four addresses of "0"-"3", in which high-frequency reload data is to be written. In other word addresses at which low-frequency reload data is to be written.
The data of the registers 16-1-16-3 are written into memory cells of the corresponding word address of a memory 14 in parallel via read/write amplifiers 13-1-13-3, respectively. In the illustrated example, the data is written into three memory cells A 0 , A 0 ', A 0 ", respectively, of the word address "0".
If the address detected by the address detecting circuit 12 is other than four addresses of "0-"3", the data creating circuit 11 sets the data only in the register 16-1 and then writes it only into the memory cell A 0 of the corresponding word address.
For reading this data, data is read from the respective memory cells A 0 , A 0 ', A 0 " of the address "0", for example, and is inputted to a majority logical circuit 15 via the read/write amplifiers 13-1-13-3. The majority logical circuit 15 takes two or more pieces of data out of three pieces of data having been read and outputs them as read data 19.
Thus, in this embodiment, data to be frequently reloaded is written trebly, while data to be scarcely reloaded is written singly. Regarding the threefold data, since reading is done by majority logic, occurrence of data error is reduced to a minimum to secure reliability.
FIG. 2 shows an EEPROM according to a second embodiment of the invention. In FIG. 2, parts or elements similar to those of the first embodiment (FIG. 1) are designated by the same reference numerals, and repetition of their description is omitted. In this embodiment, if the write address detected by the address detecting circuit 12 is any of "0"-"3", the write data D 7 -D 0 are written in different word addresses of a memory 20 via a read/write amplifier 22 trebly and serially. For reading, when the address detecting circuit 12 has detected the read address of the high-frequency reload data, a timing signal is outputted from a timing generating circuit 21 to control the switching operation of a switch 23. Thereby data is read from the respective memory cells A 0 , A 0 ', A 0 " corresponding to the three different word addresses and is stored, as data D 7 -D 0 , D 7 '-D 0 ', D 7 "-D 0 ", in a register 24 via the switch 23. These values of the register 24 are read to the majority logical circuit 15 where read data are decided and outputted as the read data 19. On the other hand, if the written address is other than "0" to "3", the data is written into a single word address.
Thus, in this embodiment, since data to be frequently reloaded is written trebly and is read by majority logic, data errors are reduced to secure reliability.
FIG. 3 shows an EEPROM according to a third embodiment of the invention. The circuit of this embodiment, as shown in FIG. 3, is equipped with a parity bit adding circuit 31 for adding 4-bit parity data to 8-bit data and writing them into a memory 34 via a read/write amplifier 33. For example, if the address is "0", the data is written into the memory cell A 0 and the memory cell P 0 . For reading, 8-bit data and 4-bit parity data, 12 bits in total, are read to an ECC circuit 32 where error correction is carried and the corrected data is output as 8-bit read data 19.
If the detected write address is other than "0"-"3", only data D 7 -D 0 are written with no parity bit added.
Thus, in this embodiment, since error correction is done by adding parity bits only to high-frequency reload data, data errors can be minimized to secure reliability.
FIG. 4 shows an EEPROM according to a fourth embodiment of the invention. The circuit of this embodiment is equipped with a reverse data creating circuit 41 for creating data D', which is reverse to the value of the write data, if the address detecting circuit 12 detects a high-frequency reload data address from the address data 18. Upon receipt of a detection signal from the address detecting circuit 12, a timing generating circuit 21 outputs a predetermined timing signal. As switches 44, 45 are actuated at the timing of this timing signal, data D and D' are written into the respective memory cells A 0 , A 0 ' of a memory 46 via the switch 44, a write amplifier 43 and the switch 45. These two pieces of data are inputted to a differential read amplifier 47 when reading, and the differential output is outputted as read data 19.
The operation of this embodiment will now be described in detail. Generally, in an EEPROM, as shown in FIG. 5, -2 V, for example, is taken as the transistor's threshold voltage V TH in correspondence with the write data "0", and +7 V is taken as V TH in correspondence with the data "1". For reading, as shown in FIG. 6, 2 V is applied as the read voltage to the base of a transistor 51. For example, if the threshold voltage V TH of the transistor 51 is set to +7, the transistor 51 will not be in the ON state so that the potential at a point (a) will be "H" level. As a result, "L" level is outputted as reverse output by an inverter 53. If the threshold voltage V TH of the transistor 51 is set to -2 V, the transistor 51 will be in the ON state, a voltage drop is caused due to a current flowing in a resistive load 52 so that the potential of the point (a) will be "L" level. As a result, the output voltage will be "H" by the inverter 53. In short, when the threshold voltage V TH of the transistor 51 is set to +7 or -2 V, "0" or "1" will be respectively outputted as read data.
However, as shown in FIG. 5, since the higher the frequency of reloading, the closer the respective threshold voltage V TH will become to 0 V, and a read error will definitely occur at a point X after the threshold voltage V TH has become 2 V. But as shown in FIG. 4, the difference between data D and its reverse data D', which are both previously written, is taken when reading; therefore, as shown in FIG. 5, even when the frequency of reloading is X or more, either 7 V level or -2 V level is not inverted so that correct data will be outputted from the differential read amplifier 47, thus extending the life of the memory.
If the detected write address is other than "0"-"3", only the data D is written while the reverse data D' is not written.
In the foregoing embodiments, the memory is of the type in which 1 word is 8 bits. Alternatively, 1 word may be 16 bits or more bits.
Further, in the foregoing embodiments, four addresses "0"-"3" of the memory addresses are set to those for writing data to be reloaded at high frequency. However, this invention should by no means be limited to this illustrated example; such a specified address region may be varied according to need.
As mentioned above, according to this invention, in storing high-frequency reload data and low-frequency reload data in a mixed fashion in the electrically erasable read only memory, since writing is done in a manner depending upon the frequency of reloading of the data, it is not necessary to do write/read processes with reliability more than necessary for the low-frequency reload data on account of the existence of high-frequency reload data in very limited parts, thus saving the memory capacity.
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In an electrically erasable programmable ROM in which written data contains in a very limited part high-frequency reload data, the memory capacity is reduced in the following new way. An address detecting circuit (12) detects whether or not designated write addresses are within a predetermined range and discriminates the write object data, which is to be high-frequency reload data, if the designated write addresses are within the predetermined range as the result of detection. Then, three sets of identical data (D 7 to D 0 ) prepared by a data creating circuit (11) are overwritten respectively in three different memory cells (A 0 , A 0 ', A 0 "). In data reading, the individual data are read from the respective memory cells, and one of the data decided by a majority logical circuit (15) is outputted as read data.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 10/455,294, filed Jun. 4, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to the areas of information systems and computer software. In particular, the present invention provides a database access system and a development environment for developing a database access system for business applications.
BACKGROUND INFORMATION
[0003] Information and computer technology are an essential component of modern business operations. The utility of computer technology has been enhanced by the coupling of computers with information networks such as the Internet and the World Wide Web (“WWW”). Successful business operations in the global marketplace may require a synergetic relationship between local and distributed operations. For example, localized operations may include research and development, inventory management, customer service, strategic planning, etc. Distributed operations are conducted, for example, by sales personnel in the field who interact with customers and perform such tasks as order generation, customer relations, customer support, etc. Field personnel may utilize mobile devices such as laptop computers or personal digital assistants (“PDAs”) for accessing customer information, receiving customer orders, communicating with one or more centralized databases at the home office, etc.
[0004] Field personnel may require accurate and timely information regarding the state of business operations in order to effectively perform their jobs. For example, sales personnel may require up-to-the-minute information regarding current inventory levels, product availability and customer data. Conversely, the enterprise may operate more effectively through centralized management of information regarding the operations of field personnel and information collected in the field.
[0005] One model for providing the requisite computing environment may involve a plurality of mobile devices operating in an offline mode, in which the offline mode status is transparent to the users. That is, the mobile devices may run applications in offline mode, yet the user may interact with the mobile applications as if they were running in an online mode.
[0006] A relational database allows the definition of data structures, storage and retrieval operations and integrity constraints. In such a database, the data and relations between them are organized in tables. A table is a collection of rows or records and each row in a table contains the same fields. Certain fields may be designated as keys, which means that searches for specific values of that field will use indexing. Where fields in two different tables take values from the same set, a “join” operation can be performed to select related records in the two tables by matching values in those fields. The fields may have the same name in both tables. For example, an “orders” table might contain (customer_id, product_code) pairs and a “products” table might contain (product_code, price) pairs. Therefore, in order to calculate a given customer's bill, the prices of all products ordered by that customer would be summed by joining on the product-code fields of the two tables. This can be extended to joining multiple tables on multiple fields. Because these relationships are only specified at retrieval time, relational databases may be classed as a dynamic database management system. (See The Free On - line Dictionary of Computing, 1993-2003, by Denis Howe).
[0007] There is a need for a method of developing and downloading efficiently a database access system to a mobile application. There is also a need for managing databuffers and redundant copies of records in a mobile application. Additionally, there is a need for managing a limited number of database connections in a run-time environment.
SUMMARY OF THE INVENTION
[0008] According to an exemplary embodiment of the present invention, a method for accessing a database is provided. The method includes creating in a design environment an file that defines a metadata. The metadata relates at least one business object and at least one query. The method also includes communicating the file to a mobile device, storing the file on the mobile device, and transforming the file into a binary structure at an initial run of a computer application running on the mobile device. The binary structure is adapted to be read by the computer application. The method also includes recording the binary structure in a memory of the mobile device.
[0009] A method is provided which includes retrieving a first record from a database in response to a request from a first recordset and saving the first record on a first bufferpage of a memory. The first bufferpage is associated with the first recordset. The method also includes repeating the previously mentioned steps for a further record. When a next record requested by the first recordset is larger than a freespace on the first bufferpage, the method indicates to save the next record on a second bufferpage of the memory. The second bufferpage is associated with the first recordset.
[0010] A method of managing a memory is provided which includes dividing the memory into a plurality of blocks and recording in a first block of the memory in a first databuffer at least a first property of a first record in response to a first request of a first recordset. The method also includes recording in one of the first block and a second block of the memory in a second databuffer at least one of the first property and a second property of the first record in response to a second request of one of the first recordset and a second recordset. The method further includes storing with the first databuffer a pointer to the second databuffer.
[0011] A method for providing database access for a plurality of files with a limited number of database access channels is provided which includes receiving a first signal indicating an initiation of a new file. If a desired number of database access channels is greater than or equal to the limited number of database access channels, the method indicates to determine a respective active file corresponding to each of the database access channels. The method also includes sequentially causing each of the active files to access one of a database record and a plurality of database records. The method further includes repeating the step of sequentially causing each of the active files to access one of a database record and a plurality of database records until a second signal is received indicating a first active file has accessed all database records. The method also includes the step of reassigning a first database access channel which was assigned to the first active file to the new file.
[0012] A method for providing access to a database in a computing environment for a plurality of recordsets is provided. Each of the plurality of recordsets is associated with a database access channel for fetching records of the plurality of recordsets from the database upon occurrence of a preselected event. The method includes initiating a new recordset and, if a number of the plurality of recordsets is equal to a maximum number of database access channels, sequentially fetching at least one record for each recordset until a first recordset has fetched all records associated with the first recordset. The method further includes assigning the database access channel of the first recordset to the new recordset.
[0013] A method of fetching data for a plurality of active files from a database having a limited number of database connections is provided. The method includes assigning each database connection of the limited number of database connections to an active file until one of (i) all of the limited number of database connections have been assigned, and (ii) each active file desiring a database connection has a corresponding assigned database connection. The method also includes determining if any active file desiring the database connection does not have the corresponding assigned database connection. If any active file desiring one of the limited number of database connections does not have a corresponding assigned database connection, the method indicates to fetch a record for each file from the database on the assigned database connection sequentially until all records for at least one file are fetched. The method further includes reassigning the assigned database connection for the at least one file for which all records have been fetched to another active file that does not have a corresponding assigned database connection.
[0014] XML (extensible markup language) is a standard for exchanging structured information, and may provide flexibility to the designer by combining human readability with machine readability.
[0015] The Data Access Layer, or DAL, collapses the Business Object Layer (“BOL”) and the Transaction Layer (“TL”) into one layer, and replaces TL database access functionality with embedded, direct database access. Methods within the BOL access the local database tables directly, and the inefficiencies associated with recordset abstraction may thereby be avoided. Memory buffers may also be managed more efficiently within a single layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 shows a schematic diagram of an application that a user uses to interface with a database and the relationship between the system in the run-time environment and the design environment.
[0017] [0017]FIG. 2 shows a schematic diagram of an exemplary embodiment of the present invention that a user uses to interact with a database and the relationship between the system in the run-time environment and the design environment.
[0018] [0018]FIG. 3 shows a schematic diagram of an exemplary embodiment of the present invention showing a business object layer (BOL) having a data access layer (DAL) and interacting with a database.
[0019] [0019]FIG. 4 shows a schematic diagram of an exemplary embodiment of the present invention showing a database and multiple business object collections (b.o.collections or files) of an application accessing the database via channels.
[0020] [0020]FIG. 5 shows a schematic diagram of an exemplary embodiment of the present invention showing a database and multiple b.o.collections with buffer memories having records.
[0021] [0021]FIG. 6 shows a flowchart of an exemplary method of the present invention for managing a limited number of channels to a database in a fetch-on-demand application environment.
[0022] [0022]FIG. 7 shows a flowchart of an exemplary method of the present invention showing the relationship between an XML file created in the development environment and a binary structure of the XML file for use in a run-time environment.
[0023] [0023]FIG. 8 shows a schematic diagram illustrating the relationship between a BOManager, BOKernel and several databuffers.
[0024] [0024]FIG. 9 shows a schematic diagram illustrating the relationship between a BOCollection, BOKemels having keys, and a buffer page having several databuffers.
[0025] [0025]FIG. 10 shows a schematic diagram of an exemplary embodiment of a system of the present invention showing a mobile system and a network.
[0026] [0026]FIG. 11 shows a flowchart of an exemplary method of the present invention for storing records in a memory.
DETAILED DESCRIPTION
[0027] A mobile client application may be based on an object-oriented software approach and may be divided into three tiers, or layers: the User Interface Layer (UIL), the Business Object Layer (BOL) and the Transaction Layer (TL). The BOL provides the application's business logic, while the TL offers access to the underlying data in a database. The TL provides access to the underlying data by mapping recordsets, referenced by the BOL, to local database tables. The recordset abstraction of the TL may produce inefficiencies in the run-time environment of the mobile client due to latencies associated with data access and translation. Separate memory buffer management may also be required for each layer.
[0028] A business object type is the representation of a business entity in the system. It encompasses both the functionality (in the form of methods) and the data (in the form of attributes) of this entity. The implementation details of the business object type may be hidden from the user. The business object type may be accessed through defined functions (also referred to hereinafter as methods). This may be referred to as “encapsulation.”
[0029] Business object types are used to break a system down into smaller, disjunctive units. As a result, the system's structure is improved while its complexity is reduced. Business object types may form the point of entry for the data and the functions of the system. At the business object type level, both internal systems and various business components can communicate with each other.
[0030] An example of a business object type follows. The business object type “FlightBooking” may represent a binding seat reservation for a flight. A special flight booking is identifiable by a booking number and the airline. The business object type “FlightBooking” may be accessed by various methods. These access methods may include: FlightBooking.GetList( ), which may return a list of all flight bookings stored in a system (which may be optionally restricted according to particular search criteria); FlightBooking.CreateFromData( ), which may create a new flight booking in the system. FlightBooking.Cancel( ), which may cancel a flight booking that has already been created; and FlightBooking.Confirm( ), which may convert a flight reservation into a legally binding flight booking.
[0031] A business object type may therefore include a business concept and how to realize it in a computer system. The term “business object type” may correspond to the term “class” in object-oriented programming languages.
[0032] A specific occurrence of a business object type, for example, a flight booking that is actually stored in the system, may need to be distinguished from the business object type itself. An occurrence of a business object type may be termed an instance of a business object type or a business object (the usual term in object-oriented programming languages).
[0033] An example of an instance of a business object type may be the flight booking “LH 4711 FlightBooking.” This flight booking is identified by the airline code “LH” and the booking number “4711.” The object is described according to its attributes, for example the flight date or the customer number.
[0034] A generic business object may represent a physical or logical entity in a business scenario and may be characterized by any of: attributes; methods; events; business rules; and relations to other business objects. A business logic framework may support objects other than business objects including: business collections (short for business ‘objects’ collections); query objects (used for predefined searches); combinations (used for fetching allowed sets of values); and salient features. A general foundation for modeling business objects may provide elements that are richer and closer to the business domain than the typical elements of relational databases.
[0035] [0035]FIG. 1 shows a schematic diagram of a system level application that user 12 uses to interface with a database and the relationship between the system in run-time environment 10 and design environment 11 . User 12 interfaces with user interface layer 13 which communicates with interaction layer 14 . User interface layer 13 may be a display and interaction layer 14 may include a display driver. Interaction layer 14 communicates with business object layer 15 , which in turn communicates with transaction layer 16 . Transaction layer 16 controls access to a database. Each of the different layers 13 , 14 , 15 , 16 may require a separate memory buffer for functioning. Therefore, four separate buffer memory arrangements may be required to operate the system. The system is designed in design environment 11 . Design environment 11 may include mobile application studio 17 , which may be adapted to design and create applications, which in turn may be run on mobile devices. Mobile application studio 17 may include interaction component modeler 18 for designing interaction layer 14 and business object modeler 19 for designing business object layer 15 . Design environment 11 also may include bdoc modeler 20 , which may be adapted to design transaction layer 16 . After the system is designed in design environment 11 , each respective layer may be converted into a respective layer by converters 21 a , 21 b , 21 c . Converters 21 a , 21 b , 21 c may be a converter, translator or generator, and may output object code, machine readable code, and/or any binary structure readable by a machine. Alternatively, converters 21 a , 21 b , 21 c may simply be a communication outlet for the design components (mobile application studio 17 , interaction component modeler 18 , business object modeler 19 , and/or bdoc modeler 20 ) to communicate an unformatted system to the mobile system running in run-time environment 10 .
[0036] Design environment 11 may exist primarily on a network, though the design of the system and the creation of files (in particular XML files) may occur in a mobile device. Run-time environment 10 may exist in both a network and a mobile device.
[0037] [0037]FIG. 2 shows a schematic diagram of an exemplary embodiment of the present invention that user 12 uses to interact with a database and the relationship between the system in run-time environment 10 and design environment 11 . User 12 interfaces with user interface layer 13 . User interface layer 13 communicates with interaction layer 14 . Interaction layer 14 communicates with business object layer 15 . Business object layer 15 includes data access layer 22 . Data access layer 22 controls access to a database. Integrating data access layer 22 into business object layer 15 therefore may reduce the number of memory buffers which may be required for functioning of the system. Three or fewer separate buffer memory arrangements may only be required to operate the system.
[0038] The system shown in FIG. 2 is designed in design environment 11 . A combination of business object modeler 19 of mobile application studio 17 and bdoc modeler 20 (both operating in design environment 11 ) may determine the structure of business object layer 15 including data access layer 22 (operating in run-time environment 10 ).
[0039] Replacing transaction layer 16 with data access layer 22 integrated in business object layer 15 enables an embedded direct database access, which may be responsible for read and write access. Buffer management may be suited for business object layer 15 since it may avoid recordset abstraction. Business object layer 15 's metadata may be enhanced by information from the bdoc modeler 20 .
[0040] The buffer management as implemented by data access layer 22 may have the advantages that it acts: as a cache of database data; uses minimal memory; avoids fragmentation; avoids unnecessary copies; and supports data from multiple different sized data selections.
[0041] Converter 21 c , and optionally converters 21 a , 21 b , may communicate an XML file that is created in design environment 11 to run-time environment 10 . In run-time environment 10 , the XML file may be loaded onto a mobile device, for instance a laptop computer or PDA. When the application is run for the first time, the XML file is converted into a binary structure that is readable by the machine. This binary structure is then saved on the machine. When the application which accesses the database is subsequently run on the machine, the XML file does not need to be converted. Instead, the binary structure may be read from memory and mapped into the buffer for accessing the database.
[0042] The XML file contains metadata. Metadata, in contrast to data, resembles a system in which data can be entered. The metadata sets may be an order, and the order may have a number and may have items. Metadata describes how data itself looks. Bdoc modeler 20 may create this XML file and design the metadata. The conversion of the XML file into a binary structure may occur in run-time environment 10 .
[0043] Alternatively, the mobile system may load the unformatted files over converters 21 a , 21 b , 21 c from the design components (mobile application studio 17 , interaction component modeler 18 , business object modeler 19 , and/or bdoc modeler 20 ). The mobile system may then compile, convert, translate, and/or generate object code from the unformatted files on the first running of the application on the mobile system. On subsequent running of the application on the mobile system, the mobile system may use the previously compiled object code or may compile, convert, translate, and/or generate object code from the unformatted files again.
[0044] [0044]FIG. 3 shows a schematic diagram of an exemplary embodiment of the present invention showing business object layer (BOL) 15 having data access layer (DAL) 22 and interacting with database 29 . Data access layer 22 includes data loaders 28 a , 28 b which access database 29 . Data loaders 28 a , 28 b read records out of database 29 in response to a query or an operation of the application. Data loaders 28 a , 28 b may only load as much data as may be displayed by a user interface, or tile, within the application. Each of data loaders 28 a , 28 b may be associated with a different tile of an application. The number of records loaded by data loaders 28 a , 28 b may be controlled by b.o.collections (business object collections, which may also be referred to hereinafter as a file or an active file) 24 a , 24 b , respectively. When a complete record set is completely loaded by data loaders 28 a , 28 b , data loaders 28 a , 28 b may be terminated because they are no longer needed.
[0045] B.o.collections 24 a , 24 b determine the number of records being requested by the application and communicates those records to com.b.o.collections (communication business object collections) 23 a , 23 b , respectively, which may be part of the business object layer but which may be outside of the data access layer. Com.b.o.collections 23 a , 23 b may communicate the data that is to be displayed to a user interface. COM refers to communication technology and may be a way to expose objects to the application code.
[0046] B.o.collections 24 a , 24 b may also communicate the identity of which records are loaded by data loaders 28 a , 28 b to business object manager (BOManager) 25 . Business object manager 25 may be a shared operation that communicates with several b.o.collections 24 a , 24 b which are active in supplying records to respective tiles or windows of an application.
[0047] Business object manager 25 may determine if a particular record loaded by either of data loader 28 a or data loader 28 b has previously been loaded. If the particular record has not previously been loaded, then business object manager 25 may create a b.o.kernel (business object kernel) 26 a for the particular record. Alternatively, business object manager 25 may direct b.o.collection 24 a , 24 b to create b.o.kernel 26 a for the new record. B.o.kernel 26 a may store the record in a buffer memory using memory management 27 in a location appropriate to the other records being loaded by the respective data loader 28 a , 28 b . This location may be determined by memory management 27 .
[0048] For instance, if records for data loader 28 a (corresponding to records for b.o. collection 24 a ) are being loaded into buffer memory in blocks to allow easy reading and efficient erasing, then the new record will be loaded into the buffer memory in a similar fashion. B.o.kernel 26 a may include a key indicating the record stored and the location of the record stored.
[0049] If the same record is loaded again by either the same data loader 28 a , the other data loader 28 b , or another data loader entirely, then business object manager 25 will recognize that the record has been stored because b.o.kernel 26 a indicates that this record has been stored. B.o.kernel 26 a will store the record again in the buffer memory in a location appropriate to the other data being loaded and as indicated by memory management 27 . B.o. kernel 26 a will cause the first recording of the record to include a pointer to the second recording of the record, so that the records are linked in a buffer chain.
[0050] For example, data loader 28 a may load a record from database 29 into b.o.collection 24 a . This record may be communicated to com.b.o.collection 23 a for display to a user and the identity of this record may also be communicated to business object manager 25 . Business object manager 25 may determine if the record has been previously stored in the buffer memory by checking a look-up table. If the record has not been previously loaded into buffer memory, then business object manager 25 may create b.o.kernel 26 a or may direct b.o.collection 24 a to create b.o.kernel 26 a . B.o.kernel 26 a may include a pointer, which will point to the address at which memory management 27 records the record in the buffer memory. B.o.kernel 26 a may also include a key which identifies the record assigned to b.o.kernel 26 a and may also include a counter indicating the number of times which the record is stored for different recordsets which are currently open in the application. A recordset may correspond to a group of records that satisfy a query or are properly displayed in a window or tile. The recordset may be referred to hereinafter interchangeably with the query, window, and/or tile that creates and/or defines the recordset. Data loader 28 b may later load the same record from database 29 and may communicate the record to b.o.collection 24 b . B.o.collection 24 b may communicate the record to com.b.o.collection 23 b for display to the user, and may also communicate the identity of the record to business object manager 25 . Business object manager 25 may determine that the record has already been stored in the buffer memory by evaluating b.o.kernel 26 a and other b.o.kernels which are included in a look-up table in business object manager 25 . Business object manager 25 will recognize that the record has been stored since b.o.kernel 26 a includes a key identifying the record stored in the buffer memory. The record will be communicated to b.o.kernel 26 a by b.o.collection 24 b , which will then communicate the record to memory management 27 . Memory management 27 will store the record with other records accessed by data loader 28 b in the appropriate memory buffer block. Memory management 27 will communicate the location of the record to b.o.kernel 26 a . B.o.kernel 26 a will then record this second buffer location in a pointer included in the first buffer location of the record. In this way a chain will grow in the event that additional identical records are read from database 29 and stored in the buffer memory. B.o.kernel 26 a will point to the first recording of the record in the buffer memory, and the first record will point to the next recording of the same record, and so on.
[0051] Each recording of a record may be different even if they relate to the same piece of data since the data in database 29 relating to that record may have changed between one loading of that record and the next loading of the record. Additionally, data loader 28 a , 28 b may only load some fields (also referred to hereinafter as properties) from database 29 for a particular record. For instance data loader 28 a , 28 b may load from database 29 only the first three fields, all fields, only the third, seven and ninth fields, or any other possible combination of fields of a table. Therefore, each recording of a record set might include different combinations of fields.
[0052] Inconsistencies may arise between the different data buffers containing the same record, either due to changes in database 29 between different loadings of the record, or, in a read/write scenario, due to changes in the record originating in the application. These inconsistencies may be dealt with in various manners. In one method, the first data buffer may have all the fields. Subsequent loadings may be done from this first buffer, thereby avoiding inconsistencies due to database 29 changing between different loadings by data loader 28 a , 28 b . In this situation, this first databuffer may not be assigned to any b.o.collection, and may remain open until all b.o.collections referencing that record (by that b.o.kernel) have closed. Alternatively, different versions of the same record may exist within the chain of databuffers. Since the last appended record is the most recent (in the “read only” situation), then simply reading the property from the first record starting from the end of the databuffer chain to include that property would ensure that the property is the most recent version loaded from database 29 .
[0053] [0053]FIG. 4 shows a schematic diagram of an exemplary embodiment of the present invention showing database 29 and multiple b.o.collections 24 a - e accessing database 29 via channels 43 a - e , respectively. Database 29 may operate with a maximum number of channels 43 a - e , which may be determined by software or hardware, and which may be absolute or flexible. Channels 43 a - e may each access database 29 for a respective b.o.collection 24 a - e . B.o.collections 24 a - e may respond to a query or may require other data from database 29 . B.o.collections 24 a - e may not load all records from the recordset which satisfy the query in order to avoid filling up a buffer memory, from which associated buffer memory 42 a - e are divided or partitioned. This fetch-on-demand system may also allow the system to be more responsive to the user's requests by avoiding the situation in which a single query completely fills all of the buffer memory associated with buffer memories 42 a - e . Therefore, the system may avoid the situation where it would need to communicate to the user that all records could not be loaded because the query was too broad. However, the fetch-on-demand method may require that each of b.o.collections 24 a - e have a dedicated channel 43 a - e . These channels 43 a - e may each access database 29 sequentially and thereby provide a pointer to database 29 where the next record is located which satisfies the query or other operation accessing database 29 . Therefore, when the user scrolls down in the window or tile to reveal more records, each of channels 43 a - e would access database 29 for the respective b.o.collections 24 a - e . Channels 43 a -e may operate simultaneously to load records for the respective b.o.collections 24 a - e.
[0054] In the event that all of channels 43 a - e are occupied accessing database 29 and another b.o.collection 24 f may require access to database 29 , the system would begin a process to free a channel to database 29 for b.o.collection 24 f . The process may involve sequentially accessing database 29 for each b.o.collection 24 a - e , and storing the record for each b.o.collection 24 a - e in associated buffer memory 42 a - e . Alternatively, blocks of records for each b.o.collections 24 a - e may be accessed and stored in associated buffer memory 42 a - e . The blocks of records may be of an equal size for each b.o.collection 24 a - e , and may be blocks of 2 records, 3 records, or more. The sequential accessing of database 29 for each b.o.collection 24 a - e continues until all the records in a recordset for one of b.o.collections 24 a - e has been loaded and stored in associated buffer memory 42 a - e . After all the records for one application have been loaded and stored, that application may no longer require a channel to database 29 , and therefore the open channel may be dedicated to b.o.collection 24 f which may require a channel.
[0055] [0055]FIG. 5 shows a schematic diagram of an exemplary embodiment of the present invention showing database 29 and b.o.collections 24 a , 24 b with buffer memories 42 a , 42 b having records 51 a - i . B.o.collections 24 a , 24 b are both part of application 40 , and may represent queries, tiles or windows open in the user interface. Application 40 may alternatively have more or fewer b.o.collections. Each of b.o.collection 24 a , 24 b has an associated buffer memory 42 a , 42 b . B.o.collection 24 a includes buffer memory 42 a , which in turn stores records 51 a - f . B.o.collection 24 b includes buffer memory 42 b , which in turn stores records 51 d - i . B.o.collections 24 a , 24 b may include redundant records in respective buffer memories 42 a , 42 b (for instance, records 51 d - f ). Keeping redundant records 51 d - f stored in two (or more) separate buffer memories 42 a , 42 b may cause some inefficiency due to a short-term increase in memory requirements. However, keeping related records necessary for b.o.collections 24 a , 24 b in adjacent memory in buffer memories 42 a , 42 b , for instance in buffer pages or buffer blocks, may increase long term memory efficiency by eliminating holes and other unusable memory areas by allowing complete pages or blocks of memory to be freed when b.o.collections 24 a , 24 b are shut down. Redundant records 52 d - f recorded in different buffer memories 42 a , 42 b are related by pointers and b.o.kernels as described above and hereinafter.
[0056] [0056]FIG. 6 shows a flowchart of an exemplary method of the present invention for managing a limited number of channels to a database in a fetch-on-demand application environment. The flow proceeds from start circle 60 to question 62 , which asks whether any unfilled record sets do not have an assigned channel. An unfilled recordset in this context represents a query, window, and/or tile which has not loaded into the buffer memory all the records which satisfy the query or belong in the window or tile. In the fetch-on-demand situation, a window or tile may only load from a database a sufficient number of records satisfying a query to fill a window or tile. Therefore, queries that determine a very large recordset would not completely fill the databuffer in a fetch-on-demand system. As a user scrolls through the recordset via the window or tile, new records would be accessed from the database into memory for display in the window or tile. Each query, tile, and/or window which includes a recordset which has not been completely loaded into buffer memory may require a channel to the database for accessing the remaining records to complete the recordset. The channel may include a pointer which would indicate at which point in the database to begin reviewing for additional records that satisfy the query and/or should properly be displayed in the tile and/or window. The number of channels to the database for an application may be limited by hardware, software, and/or design considerations. For instance, the number of database access channels for an application may be limited to five. Therefore, if a sixth query, tile and/or window attempts to access the database, then the unfilled recordset associated with that sixth query, tile and/or window would not have an assigned channel.
[0057] If the answer to question 62 is yes, the flow proceeds to question 63 , which asks whether there are any channels available. If the answer is yes, the flow proceeds to action 64 , which indicates to assign an unassigned channel to the unfilled record set. From action 64 , the flow proceeds again to question 62 . If the answer to question 63 is negative, the flow proceeds to action 65 , which indicates to fetch a record from a recordset. Alternatively, a block of records may be fetched from a recordset. The size of the blocks of records may correspond to the size of the buffer blocks or pages used by the system. From action 65 , the flow proceeds to action question 66 , which asks whether the recordset is completely loaded. If the answer to question 66 is negative, the flow proceeds to action 67 , which indicates to move to a next sequential record set. From action 67 , the flow proceeds to action 65 . If the answer to question 66 is affirmative, the flow proceeds to action 64 , which is described above. If the response to question 62 is negative, the flow proceeds to end 68 .
[0058] [0058]FIG. 7 shows a flowchart of an exemplary embodiment of the present invention showing the relationship between an XML file created in the development environment and a binary structure of the XML file for use in a run-time environment. The flow proceeds from start 70 to action 71 , in which an application is started. The flow then proceeds to question 72 , which asks whether the XML file that contains the metadata has a corresponding binary structure stored. If the response to question 72 is negative, the flow proceeds to action 73 , which indicates to convert the XML file into a binary structure. From action 73 , the flow proceeds to action 74 , which indicates to store the datestamp and the filesize of the XML file in the memory. From action 74 , the flow proceeds to action 75 , which indicates to save the binary structure in the memory together with the datestamp and the filesize. From action 75 , the flow proceeds to action 76 , which indicates to map the stored file of the binary structure in the memory. From action 76 , the flow proceeds to end 80 . If the response to question 72 is affirmative, the flow proceeds to action 77 , in which the filesize and datestamp are read. From action 77 , the flow proceeds to question 78 , which asks whether the datestamp and filesize recorded with the binary structure match the datestamp and filesize of the currently loaded XML file. If the response to question 78 is negative, the flow proceeds to action 79 , which indicates to delete the outdated binary structure and the included datestamp and filesize records. From action 79 , the flow proceeds to action 73 . If the response to question 78 is affirmative, the flow proceeds to action 76 .
[0059] [0059]FIG. 8 shows a schematic diagram illustrating the relationship between a business object manager (BOManager) 25 , b.o.kernels 26 a , 26 b , and databuffers 83 a , 83 b , 83 c . Business object manager 25 includes a look-up table for the records which have been loaded into a memory buffer. Each record loaded into the memory buffer has b.o.kernel 26 a , 26 b or another b.o.kernel. B.o.kernel 26 a , 26 b includes kernel pointer 84 a , 84 b , respectively. Kernel pointer 84 a , 84 b , points to a position in the buffer that hold the first recording of the unique record designated for b.o.kernel 84 a , 84 b . For example, b.o.kernel 84 a has kernel pointer 84 a which points to databuffer 83 a . Databuffer 83 a holds properties 86 a , 86 b , 86 c which represent fields in a row or record from a datatable of the database. Properties 86 a , 86 b , 86 c may include all the fields of one record, or only some of the fields of one record which may be required for a b.o.collection. Databuffer 83 a may also include a pointer 85 a which points to another databuffer 83 b which holds the next recording of the same record held in databuffer 83 a . Databuffer 83 b may also include all or only some of the properties associated with the record, and is shown as including property 86 a in common with databuffer 83 a , as well as different properties 86 d , 86 e . Databuffer 83 b also includes a pointer 85 b which points to the next recording of the record, which in particular points to databuffer 83 c . Databuffer 83 c includes property 86 a in common with databuffer 83 a , property 86 d in common with databuffer 83 b , and unique property 86 f . B.o.kernel 26 b represents another record and includes kernel pointer 84 b and key 82 b . Key 82 a of b.o.kernel 26 a may include such information as an identifier of the record assigned to b.o. kernel 26 a counter indicating the number of recordings of the record which exist in the buffer chain.
[0060] When a b.o.collection closes and therefore may no longer require a supporting databuffer, that databuffer can close. The pointer from that databuffer can be written into the next earliest recorded record, thereby overwriting the pointer that pointed to the now-erased databuffer and exchanging it with the databuffer recorded after the now-erased databuffer. In this manner, the chain of databuffers is maintained. Keys 82 a , 82 b include a counter and may therefore include information showing that no databuffers holding the record assigned to b.o.kernel 26 a , 26 b are active, and that therefore b.o.kernel 26 a , 26 b and any remaining databuffers may be erased. Databuffer 83 a , and any other databuffer that represents the first databuffer pointed to by kernel pointer 84 a or any other kernel pointer, may include more than just the particular properties which may be required by the b.o.collection that caused the creation of the databuffer and the b.o.kernel. Databuffer 83 a (or any other first recording of the record in the databuffer), may include all the properties of the record, and therefore may provide a source for loading subsequent databuffers rather than loading from the database. This method may avoid problems with changing records due to read/write applications and/or a dynamic database.
[0061] Kernel pointer 84 a points to databuffer 83 a and pointer 85 a of databuffer 83 a would now point to databuffer 83 c instead of databuffer 83 b after databuffer 83 b is closed. Pointer 85 a of databuffer 83 a is rewritten in this situation. B.o.kernel 26 a tracks the number of usages of the data from the application. When the last databuffer is erased, the corresponding b.o.kernel may be erased as well. Alternatively and equivalently, when no more b.o.collections refer to the key of that b.o.kernel, then no more databuffers for that record are in use, and therefore the b.o.kernel may be erased as well. The b.o.kernel has a counter of the number of databuffers and the number of record sets that are connected to the b.o.kernel (via b.o.collections). Business object manager 25 is a manner of searching for a given key and may include a look-up table (similar to a primary key in a database table).
[0062] Databuffers 83 a - c include tags 87 a - c , respectively, which identify the b.o.collection which created them (by the data loader). Tags 87 a - c enable b.o.kernel 26 a to determine which data buffer (in the chain) may be dropped when a b.o.collection is being deleted.
[0063] The foregoing discussion is for a read-only situation. In a read-write situation, the first buffer to which b.o. kernel 26 a points may include all properties of the record. This first buffer may be updated as records are modified and may be used as a data source when new copies of the record are requested by a b.o. collection. This first buffer may be written back into the database when b.o. kernel 26 a has no more active b.o. collections associated with it. Saving the record of this databuffer into the database may then update the database according to the modifications to the record which result from the user's interaction with the application.
[0064] [0064]FIG. 9 shows a schematic diagram illustrating the relationship between b.o.collection 24 a , b.o.kernel 26 a , 26 d , 26 e having keys 82 a , 82 d , 82 e , respectively, and bufferpage 91 having databuffers 83 a , 83 d , 83 e . Bufferpage 91 is a fixed unit of buffer memory, and may be 8 kilobytes, 4 kilobytes, or any other appropriate size. B.o.collection 24 a represents a query, window and/or tile of an application that may require a recordset. B.o.collection 24 a operates in a fetch-on-demand environment. For each record fetched, a b.o.kernel is created if no other b.o.collection has accessed that record. Otherwise, the record is attached to a chain that begins with a b.o.kernel for the record that has been previously accessed by either another b.o.collection or b.o.collection 24 a.
[0065] B.o.collection 24 a may demand that a record be loaded from the database by dataloader 28 a . Dataloader 28 a may load the record and then determine where to write the data into buffer memory by reviewing current page 90 . Current page 90 points to bufferpage 91 , which represents the current page. Bufferpage 91 includes refcount 92 and freespace 93 . Refcount 92 indicates the number of references (or databuffers) in bufferpage 91 , and freespace 93 indicates the amount of freespace remaining in bufferpage 91 . As shown in FIG. 9, refcount 92 would indicate the number 3, for databuffers 83 a , 83 d , and 83 e . Additionally, freespace 93 would indicate the size of freedatabuffer 94 .
[0066] For instance, the last record loaded in bufferpage 91 was the record in databuffer 83 e . Dataloader 28 a loaded the record into databuffer 83 e on bufferpage 91 . Dataloader 28 a compared the size of the record of databuffer 83 e with the remaining free space in bufferpage 91 , as determined by freespace 93 , and since the size of the record of databuffer 83 e was smaller than freespace 93 , dataloader 28 a loaded the data into bufferpage 91 . Dataloader 28 a did not change the designation in current page 90 . Therefore, current page 90 points to bufferpage 91 , and freespace 93 includes a number which corresponds to the size of the available memory in bufferpage 91 , which is freedatabuffer 94 .
[0067] Buffers may be sized according to the selected data and grouped into pages per selection. Each row of data may belong to one business object (BO, represented by a b.o.kernel). Different data selections might retrieve different parts of these business objects. In a typical case, 3-4 attributes may be retrieved out of a business object with up to 100 attributes. Saving into the memory buffer all 100 attributes in each row would make the row large and would fill the memory buffer quicker.
[0068] The data for one row is stored in a databuffer. Multiple databuffers may be chained to each b.o.kernel. The data selection for databuffer 83 a includes properties 86 a , 86 b , 86 c . Databuffers 83 a , 83 d , 83 e from multiple data selections (multiple records) may contain fields for the same business object. Each of databuffers 83 a , 83 d , 83 e is chained on a corresponding b.o.kernel 26 a , 26 d , 26 e . Databuffers 83 a , 83 d , 83 e which are loaded for one data selection represented by b.o.collection 24 a are kept in bufferpage 91 . Databuffers 83 a , 83 d , 83 e may also include a pointer indicating on what buffer page 91 they are stored. Bufferpage 91 may have a fixed size (for example, 8 kilobytes) and may be filled as data (records) for b.o.collection 24 a is being loaded.
[0069] In order to determine the lifetime of bufferpage 91 , each of databuffers 26 a , 26 d , 26 e includes a respective tag 87 a , 87 d , 87 e , respectively, which includes a reference to bufferpage 91 . B.o.collection 24 a includes a reference to current page 90 via dataloader 28 a that shows which bufferpage 91 is currently being filled. As long as there is enough free space on bufferpage 91 , as indicated by freespace 93 , newly loaded data buffers are put on the same bufferpage 91 . Tags 87 a , 87 d , 87 e , identify their respective databuffers 83 a , 83 d , 83 e with b.o.collection 24 a . If b.o.collection 24 a shuts down, corresponding databuffers 83 a , 83 d , 83 e may then be removed from the chain of their associated b.o.kernels 26 a , 26 d , 26 e and refcount 92 of bufferpage 91 will be set to zero. Then bufferpage 91 may be freed to be overwritten.
[0070] With respect to FIG. 9, a typical scenario might be:
[0071] Current Page gets allocated, RefCount 0, FreeSpace 8K
[0072] First DataBuffer gets filled, RefCount 1, FreeSpace 7K
[0073] 2nd DataBuffer gets filled, RefCount 2, FreeSpace 6K
[0074] . . . 8th DataBuffer gets filled, RefCount 8, FreeSpace 0K
[0075] At this point, dataloader 28 a allocates a new bufferpage if additional records need to be loaded. If b.o.collection 24 a is closed or deleted, databuffers 83 a , 83 d , 83 e may also be closed, unless any of databuffers 83 a , 83 d , 83 e is the first record in any chain from b.o.kernel 26 a , 26 d , 26 e (in other words, if kernel pointer 84 a , 84 d , 84 e , respectively, points directly to any of databuffers 83 a , 83 d , 83 e ). Any databuffer for which this is not true may be deleted. Therefore, if one databuffer must remain, then:
[0076] 7 data buffers deleted, RefCount 1, FreeSpace 0K
[0077] The space created by erasing the other databuffers is not added to freespace 93 in this situation because dataloader 28 a would not look at bufferpage 91 for loading data since current page 90 would point to another bufferpage. Additionally, since each databuffer may have a different size, attempting to load into a bufferpage which has only been partially freed would increase fragmentation within the bufferpage and therefore would decrease memory buffer efficiency. Finally, continuing the example above:
[0078] when the last data buffer is deleted, RefCount 0, FreeSpace 0K Now the whole of bufferpage 91 is freed, and therefore, when any dataloader needs a bufferpage for loading, current page 90 may choose bufferpage 91 .
[0079] There are two different kinds of data buffers, which may be distinguished by a discriminator. A compressed layout, in which all fields use the actual needed space is possible. This buffer type may be used for “read only” access, which is the case for all data read from the database. An expanded layout, in which all fields have the maximum space is also possible. This buffer type is able to store data of any allowed length. It is allocated when the business object becomes dirty or is newly created. Each row of the record set may have a key.
[0080] [0080]FIG. 10 shows a schematic diagram of an exemplary embodiment of a system of the present invention showing mobile system 109 and network 103 . Mobile system 109 may include one or more mobile clients, and may include laptops and PDAs. Connected to mobile system 109 is database 108 , which may be a user database that is synchronized with central database 110 when mobile system 109 is connected to network 103 . Mobile system 109 may connect to network 103 via connection 107 , which may be a wireless connection, bus connection, or telephone connection. Connection 107 may connect mobile system 109 and communication station 106 . Communication station 106 may connect by a hardwire connection to network 103 . Network 103 may include one or more network servers 104 and may couple to central database 110 . Network 103 may also connect to other systems 111 , which may include the internet or any other electrical device or electronic system. Network servers 104 may also connect to mobile repository server 101 , which may include a mobile repository database 102 . Mobile development workstation 100 may connect to mobile repository server 101 . Mobile repository server 101 , mobile repository database 102 , and mobile development workstation 100 may all exist in development environment 11 . A mobile system may be designed on mobile development workstation 100 and tested using a sample database on mobile repository database 102 .
[0081] Mobile development workstation 100 may be used to create an XML file that provides information on how a database access system should behave which may be running on the mobile application. The XML file, or other human readable file, may describe how business objects are mapped into a database table. The XML file may also indicate how to execute queries and may contain SQL statement and/or portions of SQL statements. For example, a user may enter a customer name but not an address (or other field). The system may then use a piece of the SQL statement that is dedicated to the field that has been input by the user. There may be two things in the SQL statements: data to be retained (i.e. attributes of the business objects); and criteria for matching and/or selecting records from the database. The XML file (or other human readable computer file) may describe both parts of the SQL statements. The XML file may have queries for SQL statements for two type queries. The first type of query may be the objects which have a field value which satisfies a query. This group of objects may constitute a list. A second type of query may load a whole business object. The record corresponding to the business object may be loaded and may not be immediately displayed for the user. For example, a user may click on a field in a list of partial records and the remaining fields in that record may be loaded. If the user clicks again on the field, all the records for that business object may be displayed. A different SQL statement may be used for this purpose. The XML file may describe how to fetch data from the database, and in particular may describe how build SQL statements for executing against the database. The XML file may also describe which field of the record is the key (for example, a unique identifier) of the record. This key may be saved in the b.o.kernel for identification by the b.o.manager of the records which have been loaded from the database into the memory of the mobile device. If an SQL statement is a query, then the data retrieved is for read-only purposes, and therefore only the fields requested may be retrieved from the database. If the data is for writing purposes also, then all fields associated with the b.o.object should be retrieved from the database. The XML file is human readable and may be modified on the mobile device, though typically this may only be done in a development situation for prototyping purposes.
[0082] [0082]FIG. 11 shows a flowchart of an exemplary method of the present invention for storing records in a memory. The flow starts in start circle 114 and proceeds to action 115 , which indicates to retrieve a record from a database in response to a request from a recordset in an application. From action 115 , the flow proceeds to question 116 , which asks whether the size of the record is smaller than the freespace on the active bufferpage. If the response question 116 is negative, the flow proceeds to action 117 , which indicates to change the active bufferpage. From action 117 , the flow proceeds to action 118 , which indicates to save the record in a databuffer on the active bufferpage of a memory associated with the recordset. If the response question 116 is affirmative, the flow proceeds to action 118 . From action 118 , the flow proceeds to question 119 , which asks whether the record been retrieved and stored previously in the application. If the response question 119 is affirmative, the flow proceeds to action 120 , which indicates to store a pointer pointing to the databuffer of the newly saved record in the databuffer of the next most recently recorded copy of the record. From action 120 , the flow proceeds to question 122 . If the response question 119 is negative, the flow proceeds to action 121 , which indicates to make a b.o.kernel including a key to the record. From action 121 , the flow proceeds to question 122 , which asks whether more records need to be loaded for the recordset. If the response question 122 is affirmative, the flow proceeds to action 115 . If the response question 122 is negative, the flow proceeds to end circle 123 .
[0083] While the present invention has been described in connection with the foregoing representative embodiment, it should be readily apparent to those of ordinary skill in the art that the representative embodiment is exemplary in nature and is not to be construed as limiting the scope of protection for the invention as set forth in the appended claims.
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A method for accessing a database is provided. The method includes creating in a design environment a file that defines a metadata. The metadata relates at least one business object and at least one query. The method also includes communicating the file to a mobile device, storing the file on the mobile device, and transforming the file into a binary structure at an initial run of a computer application running on the mobile device. The binary structure is adapted to be read by the computer application. The method also includes recording the binary structure in a memory of the mobile device. A method for providing database access for a plurality of files with a limited number of database access channels is provided. A method for is provided for accessing a database in a computing environment for a plurality of recordsets. Each of the plurality of recordsets is associated with a database access channel for fetching records of the plurality of recordsets from the database upon occurrence of a preselected event. A method of fetching data for a plurality of active file from a database having a limited number of database connections is provided. A computer readable medium is provided which stores instructions executable by a computer. The instructions include a method for providing database access for a plurality of files with a limited number of database access channels. A device for accessing a database is provided. A system for updating a database access program is provided.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to surgical fastener apparatus. More particularly, the present disclosure relates to apparatus for forming variable height surgical fasteners to body tissue in surgical procedures.
[0003] 2. Background of Related Art
[0004] Surgical devices wherein tissue is first grasped or clamped between opposing jaw structure and then joined by means of surgical fasteners are well known in the art. In some instruments, a knife is provided to cut the tissue which has been joined by the fasteners. The fasteners are typically in the form of surgical staples.
[0005] Instruments for this purpose may include two elongated members which are respectively used to capture or clamp tissue. Typically, one of the members carries a cartridge which houses a plurality of staples arranged in at least two lateral rows while the other member includes an anvil which defines a surface for forming the staple legs as the fasteners are driven from the cartridge. Generally, the stapling operation is effected by a pusher which travels longitudinally through the cartridge carrying member, with the pusher acting upon the staples for sequentially ejecting them from the cartridge. A knife may travel with the pusher between the staple rows to longitudinally cut and/or open the stapled tissue between the rows of staples.
[0006] A later stapler disclosed in U.S. Pat. No. 3,499,591 applies a double row of staples on each side of the incision. This is accomplished by providing a cartridge assembly in which a cam member moves through an elongate guide path between two sets of staggered staple carrying grooves. Staple drive members are located within the grooves and are positioned in such a manner so as to be contacted by the longitudinally moving cam to effect ejection of the staples. Other examples of staplers are disclosed in U.S. Pat. Nos. 4,429,695, 5,065,929, and 5,156,614.
SUMMARY
[0007] The present disclosure is directed towards a staple fastening assembly for use with a surgical instrument to apply surgical staples. The staple fastening assembly includes cooperative first and second jaws, a jaw operating mechanism, and a staple driving assembly. One jaw is generally elongate and includes a staple magazine. The staple magazine may be fixedly attached or releasably attached to the jaw and includes a plurality of staples arranged in at least one row. A first tissue contacting surface is defined on one face of the staple magazine and includes a plurality of retention slots corresponding to the number of staples included in the staple magazine. It is contemplated that multiple rows of staples may be provided and arranged in columns. The retention slots may be longitudinally aligned or offset from one another. Each retention slot is configured and adapted for releasably receiving its respective staple. Each staple includes first and second substantially parallel legs connected by a backspan forming substantially right angles to each of the legs.
[0008] The second jaw is generally elongate and movable throughout a plurality of positions between an open position and a closed position. An anvil member is disposed on the second jaw and includes a second tissue contacting surface. The second tissue contacting surface includes a plurality of staple pockets wherein the number and arrangement of staple pockets corresponds to the number and arrangement of retention slots in the staple magazine. The second tissue contacting surface is oriented such that it is in juxtaposition with the first tissue contacting surface and defines a tissue gap therebetween.
[0009] Each staple pocket includes a pair of staple forming grooves for capturing the legs of each staple. The staple forming grooves are substantially symmetrical about an intermediate point and have opposing inclined surfaces. A substantially lemniscate channeling surface is formed about a perimeter of each staple pocket. Each staple forming groove urges one leg of each staple towards the other leg while maintaining lateral separation of the legs during and after staple formation.
[0010] The jaw operating mechanism is disposed in a housing that is attached to a proximal portion of the staple fastening assembly. The jaw operating mechanism includes a cam rotatably mounted to the housing, a cable, and a spring that are cooperatively coupled to one another. An approximating mechanism in the surgical instrument is operatively coupled to the jaw operating mechanism to cause proximal motion of the spring. Proximal movement of the spring is coupled to the cam via the cable. In one embodiment, the cam has an eccentric outer surface for maintaining contact between at least a portion of the outer surface of the cam and an outer surface of the second jaw. The cam may include an anti-reverse assembly (i.e. self-locking) to permit counter-clockwise rotation of the cam while inhibiting clockwise rotation of the cam. Configured thusly, counter-clockwise rotation of the eccentric cam continuously urges the second jaw towards the first jaw during proximal movement of the spring. The dimensions of the cam and the cable, as well as the dimensions and material selected for the spring, contribute towards the tissue capturing characteristics of the jaw operating mechanism. It is desirable for the jaws to capture and hold tissue in position while minimizing trauma to the tissue. Advantageously, the combination of the cam, the cable, and the spring allows for automatic adjustment of the tissue gap to accommodate different thicknesses of tissue during stapling operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the presently disclosed surgical instrument are described herein with reference to the drawings, wherein:
[0012] FIG. 1 is a side cross-sectional view of a staple fastening assembly in accordance with an embodiment of the present disclosure in an open position;
[0013] FIG. 2 is a side cross-sectional view of the staple fastening assembly of FIG. 1 in an intermediate position;
[0014] FIG. 3 is a side cross-sectional view of the staple fastening assembly of FIG. 1 in a closed position;
[0015] FIG. 4 is a top plan view of a staple magazine of the staple fastening assembly of FIG. 1 ;
[0016] FIG. 5 is an exploded perspective view of a staple driving assembly showing the relationship among the several components;
[0017] FIG. 6 is a bottom plan view of an anvil member;
[0018] FIG. 6A is a top plan view of a staple pocket;
[0019] FIG. 7A is a side view of an unformed staple;
[0020] FIG. 7B is a side view of the staple of FIG. 7A formed to a first configuration in accordance with the present disclosure;
[0021] FIG. 7C is a side view of the staple of FIG. 7A formed to a second configuration in accordance with the present disclosure;
[0022] FIG. 7D is a side view of the staple of FIG. 7A formed to a third configuration in accordance with the present disclosure;
[0023] FIG. 7E is a side view of the staple of FIG. 7A formed to a fourth configuration in accordance with the present disclosure;
[0024] FIG. 7F is a plan view of the staple of FIG. 7B showing an overlap between first and second legs of the staple;
[0025] FIG. 8A is an enlarged side view of a staple pocket, an unformed staple, a staple sled, and a rod sled;
[0026] FIG. 8B is an enlarged side view of the components of FIG. 8A showing the staple formed into a first configuration; and
[0027] FIG. 8C is an enlarged side view of the components of FIG. 8B showing a backspan of the staple being dimpled by the dimpling rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Embodiments of the presently disclosed surgical instrument will now be described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “distal” refers to that portion of the instrument, or component thereof which is further from the user while the term “proximal” refers to that portion of the instrument or component thereof which is closer to the user.
[0029] An example of a surgical stapling apparatus is disclosed in U.S. Pat. No. 5,480,089 to Blewett, currently owned by and assigned to United States Surgical, a division of Tyco Healthcare, the contents of which are hereby incorporated by reference in their entirety. Referring to FIG. 1 , a staple fastening assembly, shown generally as 100 , includes a fixed first jaw 104 , a moveable second jaw 140 , and a jaw operating mechanism 160 . In one embodiment, staple fastening assembly 100 is adapted for use in connection with endoscopic or laparoscopic stapling instruments as are known in the art.
[0030] First jaw 104 includes a staple magazine 120 having a first tissue contacting surface 122 . A plurality of retention slots 124 is included in staple magazine 120 where they are arranged in rows 126 on first tissue contacting surface 122 (see FIG. 4 ). Each row 126 generally extends along a longitudinal axis of first jaw 104 . First tissue contacting surface 122 is generally elongate. Each retention slot 124 is configured for receiving a staple 110 and a staple ejector assembly. The staple ejector assembly includes a staple ejector 132 , a dimpling rod 138 (see FIG. 5 ), a staple sled 134 , and a rod sled 136 . It is contemplated that staple magazine 120 may be removably attached to first jaw 104 . In a configuration where staple magazine 120 is a removable structure, once its complement of staples 110 have been expended, it may be removed and a new staple magazine 120 is attached to first jaw 104 . Each staple magazine 120 includes a full complement of staples 110 and at least one staple driving assembly 130 (shown in FIG. 5 and discussed in detail below).
[0031] Staple magazine 120 includes a plurality of longitudinal channels 128 (see FIGS. 3 and 4 ) that are adapted for slidably receiving staple sled 134 and rod sled 136 . The number of channels 128 corresponds to the number of rows 126 of staples 110 included in staple magazine 120 . In one embodiment, staple magazine 120 include at least two rows 126 of staples 110 , although the procedure being performed, characteristics of the tissue to be fastened, and other considerations are factors in determining the number of rows 126 , as well as the number of staples 110 , included in each staple magazine 120 . Each row 126 in the plurality of rows has an identical quantity of staples 110 .
[0032] Referring now to FIGS. 5 and 8 A- 8 C, in conjunction with FIGS. 1-3 , staple driving assembly 130 is shown and it includes a staple ejector 132 , staple sled 134 , rod sled 136 , and a dimpling rod 138 . Each staple sled 134 is operatively coupled to a drive mechanism (not shown) of the surgical stapling instrument using structures that are known in the art. An example of such an instrument that includes a drive mechanism and an actuation mechanism is disclosed in U.S. Pat. No. 6,669,073 to Milliman et al., currently owned by and assigned to United States Surgical, a division of Tyco Healthcare, the contents of which are hereby incorporated by reference in their entirety. In embodiments that include a plurality of rows 126 , staple sleds 134 are operatively coupled to the drive mechanism such that their longitudinal travel is synchronized for ejecting a column 127 of staples 110 (see FIG. 4 ) substantially simultaneously during an actuation sequence. Operation of the drive mechanism results in proximal and distal movement of the respective cams in response to actuation of the actuation mechanism.
[0033] Staple sled 134 is a generally elongate structure having a pair of inclined surfaces 135 a , 135 b oriented towards the distal end of staple magazine 120 . Inclined surfaces 135 a , 135 b are laterally spaced apart to define a passage 135 c therebetween. Passage 135 c is substantially flat and dimensioned for slidably receiving rod sled 136 . Rod sled 136 is a generally inclined structure having a substantially similar incline to that of staple sled 134 . Further still, staple ejector 132 includes a pair of legs 132 a , 132 b that are laterally spaced apart and angled at their distal ends for readily engaging inclined surfaces 135 a , 135 b . A throughhole 132 c is centrally disposed in body 132 d of staple ejector 132 and is dimensioned for slidably receiving dimpling rod 138 .
[0034] Upon actuation of the actuation mechanism, staple sled 134 is driven through staple magazine 120 in a generally distal direction by the drive mechanism. As it translates through staple magazine 120 , staple sled 134 sequentially engages each staple ejector 132 . Staple sled 134 and staple ejector 132 have engaging surfaces with complementary angles such that distal horizontal motion of staple sled 134 results in vertical motion of staple ejector 132 which, in turn, drives staple 110 in a generally vertical direction towards anvil member 142 . During distal movement of staple sled 134 , rod sled 136 remains stationary in a proximal region of the magazine. In instances where a staple height of less than about 2.5 mm is desirable, as determined by tissue gap 102 , the actuation mechanism actuates the drive mechanism and drives rod sled 136 distally as will be discussed in detail hereinafter.
[0035] With reference to FIGS. 2 and 3 , a gap sensor 106 is disposed in a proximal portion of staple fastening assembly 100 . Gap sensor 106 is a generally elongate structure having a throughhole 109 disposed near one end. Further still, gap sensor 106 is fixedly attached to second jaw 140 and slidably received in an opening 105 . A dimple window 103 is disposed near a proximal portion of first jaw 104 and is configured for slidably receiving a dimpling rod driver 107 . Dimpling rod driver 107 is operatively coupled to the actuation mechanism and engages staple dimpling cam 136 when dimple window 103 is aligned with dimpling rod driver 107 . Gap sensor 106 is configured and dimensioned such that dimpling window 103 is aligned with dimpling rod driver 107 only when tissue gap 102 indicates that a staple height of less than about 2.5 mm is desired.
[0036] In an embodiment having a staple height of less than about 2.5 mm, staple sled 134 leads rod sled 136 ( FIG. 5 ) during their travel through staple magazine 120 . As staple sled 134 translates distally through staple magazine 120 , rod sled 136 follows it after a predetermined time delay. Rod sled 136 is guided along its path by passage 135 c of staple sled 134 . Therefore, staple sled 134 ejects staple 110 and drives it against anvil member 142 to form a staple having a height of about 2.5 mm as discussed above. Once staple 110 has been driven into staple pocket 150 , and before staple sled 134 passes staple ejector 132 (i.e. the delay between the sleds), sled 136 engages dimpling rod 138 . As rod sled 136 translates distally with staple sled 134 , it contacts dimpling rod 138 causing vertical motion thereof to engage backspan 116 . Rod sled 136 drives dimpling rod 138 such that it forms a depression in the center of backspan 116 and further increasing the holding strength of the formed staple 110 .
[0037] As shown in FIG. 4 , staple magazine 120 may have a plurality of rows 126 where retention slots 124 in each row 126 may be longitudinally offset from retention slots 124 in an adjacent row 126 . Since retention slots 124 are longitudinally offset, staple crimping cams 134 are operatively arranged and synchronized to eject the first staple 110 from each row 126 and advancing sequentially towards a distal end of staple magazine 120 and sequentially ejecting staples 110 from each row 126 .
[0038] As shown in FIGS. 1-3 , second jaw 140 is spaced apart from first jaw 104 defining a tissue gap 102 therebetween. Second jaw 140 is moveable through a plurality of positions between an open position and a closed position. In one embodiment, first jaw 104 and second jaw 140 are substantially parallel to one another throughout the plurality of positions. During operation, discussed in detail below, of staple fastening assembly 100 , second jaw 140 is moved towards first jaw 104 by jaw operating mechanism 160 that maintains a substantially parallel relationship between jaws 104 and 140 .
[0039] Referring to FIG. 1 , jaw operating mechanism 160 is disposed in a housing 170 and includes a cam 162 , a cable 164 , and a spring 166 . Cam 162 , cable 164 , and spring 166 are operatively connected to one another. A proximal portion of second jaw 140 is disposed within housing 170 and secured thereto. In particular, spring 166 is operatively coupled to an approximating mechanism (not shown) of the stapling instrument by structures as are known in the art. The approximating mechanism causes spring 166 to move proximally. Since cable 164 is operatively connected to spring 166 , this proximal movement of spring 166 results in proximal movement of cable 164 and counter-clockwise rotation of cam 162 .
[0040] At least a portion of cam 162 contacts an outer surface 146 of second jaw 140 and it is self-locking in the counter-clockwise direction of rotation. Cam 162 has a centrally disposed orifice 163 for rotatably attaching it to housing 170 . Although orifice 163 is substantially circular, cam 162 has a generally eccentric shape, particularly along an outside surface, such that counter-clockwise rotation of cam 162 causes at least a portion of cam 162 to maintain contact with outer surface 146 thereby urging second jaw 140 towards first jaw 104 during counter-clockwise rotation. After cam 162 has rotated a desired amount, it locks in position such that no clockwise rotation is possible (i.e. self-locking), but additional counter-clockwise rotation is possible. A release mechanism, as is known in the art, operatively couples jaw operating mechanism 160 to the surgical stapling instrument. After a complete actuation sequence, the release mechanism is actuated to unlock cam 162 and permit clockwise rotation of cam 162 . Thusly, second jaw 140 is urged away from first jaw 104 by a biasing mechanism as is known in the art to separate the jaws and allow removal of the surgical stapling instrument.
[0041] In one embodiment, cam 162 , cable 164 , and spring 166 are selected such that tissue T is captured and maintained between jaws 104 , 140 using a minimum amount of applied pressure. The advantageous combination of cam 162 , cable 164 , and spring 166 captures different thicknesses of tissue T (i.e. each tissue thickness corresponds to a particular tissue gap 102 ) while minimizing trauma to tissue T as jaws 104 , 140 capture tissue T therebetween.
[0042] Referring now to FIG. 6 , an anvil member 142 is illustrated. Anvil member 142 is generally elongate and includes a plurality of staple pockets 150 (see FIG. 6A ) disposed on an second tissue contacting surface 144 where the number and arrangement of staple pockets 150 correspond to the number and arrangement of retention slots 124 in first tissue contacting surface 122 . An example of a staple pocket is disclosed in U.S. Pat. No. 5,480,089 to Blewett. With reference now to FIG. 6A , each staple pocket 150 has a first staple leg forming groove 152 and a second staple leg forming groove 154 for forming respective legs 112 , 114 of staple 110 (see FIG. 7A ). Each staple forming groove 152 , 154 is dimensioned to accommodate legs 112 , 114 respectively.
[0043] Staple leg forming grooves 152 and 154 are symmetrical about an intermediate point 156 . A substantially lemniscate (figure-eight shaped curve) channeling surface 158 is also formed in second tissue contacting surface 144 around a perimeter of staple pocket 150 . Each channeling surface 158 forms an angle θ, with respect to a plane defined by second tissue contacting surface 144 , wherein 0°<θ<90°. Each staple forming groove 152 , 154 has a different slope than that of adjacent channeling surface 158 . More particularly, each staple forming groove 152 , 154 has a sloped end 152 a , 154 a to direct a corresponding staple leg 112 , 114 towards a backspan 116 of staple 110 . Sloped ends 152 a , 154 a are longitudinally opposed to one another.
[0044] During an actuation sequence, staple 110 is ejected from retention slot 124 and directed towards anvil member 142 thereby driving legs 112 and 114 through tissue T to enter staple forming grooves 152 , 154 respectively. As staple 110 contacts staple pocket 150 , staple forming grooves 152 , 154 direct legs 112 , 114 towards each other while maintaining lateral separation of legs 112 , 114 so that they overlap one another as shown in FIG. 7F . In particular, with reference to FIGS. 7B-7D , during formation of staple 110 , staple forming groove 152 , in cooperation with channeling surface 158 , directs leg 112 towards backspan 116 alongside and substantially parallel to an unformed portion of leg 114 . Similarly, staple forming groove 154 , in cooperation with channeling surface 158 , directs leg 114 towards backspan 116 alongside and substantially parallel to an unformed portion of leg 112 . The amount of parallel overlap between leg 112 and the unformed portion of leg 114 is a function of tissue gap 102 . Similarly, the amount of parallel overlap between leg 114 and the unformed portion of leg 112 is also a function of tissue gap 102 that is controlled by the thickness of tissue T and operation of jaw operating mechanism 160 .
[0045] Thusly, a larger tissue gap 102 results in a larger staple 110 height (e.g. about 4.8 mm as shown in FIG. 7B ) while a smaller tissue gap 102 yields a smaller staple 110 height (e.g. about 2.5 mm as shown in FIG. 7D ). In one embodiment, the actuation mechanism, in cooperation with staple magazine 120 and anvil member 142 , forms staples 110 having a height of between about 4.8 mm (i.e. the open position of second jaw 140 ) and about 2.5 mm (i.e. the closed position of second jaw 140 ) as determined by the thickness of tissue T and tissue gap 102 . It is to be understood that staples 110 may be formed having any height that is in the range of about 4.8 mm and about 2.5 mm as determined by the thickness of tissue T (an example is illustrated in FIG. 7C ). In instances where tissue T thickness indicates a need for a smaller staple 110 height (i.e. less than about 2.5 mm or the dimpling position as seen in FIG. 7E ), the actuation mechanism of the stapling instrument operates a second drive member that is operatively coupled to rod sled 136 , as discussed hereinabove.
[0046] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. For example, the staple forming structure disclosed herein can be adapted and configured for use in EEA, TA, and endoscopic staplers with similar effect. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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A surgical device for applying a plurality of surgical staples is provided. The device includes a staple fastening assembly attached to a surgical instrument. The staple fastening assembly includes a pair of cooperating jaws, a jaw operating mechanism, and a gap sensor. A staple magazine having a plurality of staples and an anvil member having a plurality of staple pockets are attached to the jaws. The staple magazine includes a staple crimping cam and a staple dimpling cam that are operatively coupled to the surgical instrument. The jaw operating mechanism is operatively connected to a drive assembly in the surgical instrument for moving the jaws for automatically setting a tissue gap between the cooperating jaws. The gap sensor cooperates with the jaw operating mechanism for controlling staple formation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from earlier filed provisional patent application No. 60/419,502, filed Oct. 18, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a system and method for creating fencing systems. More specifically, the this invention relates to a new modular configuration that is particularly suited for fabricating and assembling vinyl fencing systems that are easier to install and are tailored to the do-it-yourself marketplace.
[0003] In the prior art, the vertical post members and the horizontal rail supports used in constructing fences have typically been made of wood. However, the traditional wood construction has become less desirable for several reasons. A primary drawback is that the overall cost of installing and maintaining a wooden fence system is relatively high due to the escalation in the cost of lumber materials in recent years and the fact that wood fences require constant maintenance such as painting or staining and prevention of rot. This is particularly true when wooden posts supporting a fence are anchored in the ground. If the posts fail due to rot, the entire fence is rendered useless. Although anchoring the posts in concrete can postpone these effects, it does not eliminate them. In addressing the preservation of the wood materials, the industry has created a secondary drawback related to the use of highly toxic preservatives to prevent the wood from rotting.
[0004] Further, fences have historically been designed and erected as permanent structures, without providing for subsequent removal or alteration. These permanent structures are been built on-site from the desired fencing materials, such as chain link or raw lumber, yielding integrated structures that cannot be easily dismantled without damaging the materials. The result is that most of these prior art fences that are constructed “on site” as unitary structures, are highly labor intensive and quite expensive to have initially installed. Additionally, wood fences constructed in this manner from raw lumber can also be non-uniform in appearance, detracting from their aesthetic qualities. This problem is further amplified when the installation process is attempted by a do-it-yourself installer who has relatively little experience in working with traditional fencing systems.
[0005] As an alternative to the wood fencing systems, fences having plastic horizontal rails that snap into vertical plastic posts are known. Typically, these plastic rails have snap-in connections formed on their ends and they “snap-in” directly to the plastic posts. Problems typically encountered with this type of plastic fence construction include the fact that these constructions do not take into account the expansion and contraction of the plastic and also that the support rails may tend to rotate in response to varying thermal conditions. Further, some of these plastic fences are made of a material that has sufficient plasticity to result in sagging rails and bending posts over time.
[0006] There is therefore a need to provide an esthetically pleasing fence that overcomes the above noted drawbacks associated with wood fencing systems. Further there is a need for a fencing system that is relatively inexpensive and durable, yet can be dismantled and reassembled in sections by a do-it-yourself consumer, if desired.
BRIEF SUMMARY OF THE INVENTION
[0007] In this regard, the present invention provides for a new fencing system constructed from durable polymer components that is sufficiently rigid and durable while providing an integrated modular assembly that is easy to assembly and well suited to a do-it-yourself marketplace. In particular, the present invention provides an integrated system of interfitting vinyl components and a unique polycarbonate or ABS clip for interconnection thereof.
[0008] The present invention includes vertical post elements, top and bottom horizontal rail elements, a novel connector clip and a webbing panel that is retained therein. The vertical posts are extruded material and may be of any suitable profile for fencing posts. At least two openings are provided in the sidewall of the vertical posts. Retention clips are inserted in to each of the openings in the vertical posts. When the clips are inserted into the openings in the posts, a portion of the clips momentarily deflect and then return to their undeflected state to engage the wall of the vertical tube. Due to the shape of the clips and the manner in which they engage the wall of the vertical tube, the clips resist being withdrawn from the vertical tubes and resist deflection or rotation.
[0009] The top and bottom horizontal rails each have openings in the ends thereof, allowing these members to slide over the retention clips. Small detent openings are provided in the sidewall of these tubes that engage a mating configuration on the retention clips when the rails are snapped into place. In this manner, the top and bottom rails are also firmly retained forming a unitary structure between the vertical fence posts and the top and bottom rails. The top and bottom rails also include a continuous longitudinal groove therein for receiving fencing panels.
[0010] The present invention also anticipates the possibility of employing intermediate rail members. In this manner the intermediate rails would have longitudinal grooves provided in both their top and bottom sides for receiving the top edge of one panel and the bottom edge of another thereby allowing two or more different panels to be employed in the same section of fence.
[0011] Accordingly, one of the objects of the present invention is the provision of an integrated modular vinyl fencing system. Another object of the present invention is the provision of a durable vinyl fence system that exhibits improved structural characteristics as compared to the prior art. Yet another object of the present invention is the provision of a vinyl fencing system that is constructed of modular components that can be made to be easily interchangeable and reconfigurable. A further object of the present invention is the provision of a modular vinyl fence system that includes standardized construction components that is further capable of being easily disassembled and reused in alternate configurations.
[0012] Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
[0014] [0014]FIG. 1 is a perspective view of the assembled fence system of the present invention;
[0015] [0015]FIG. 2 is a detailed perspective view of the connection between the horizontal rail and the vertical support;
[0016] [0016]FIG. 3 is a cross-sectional view thereof taken along line 3 - 3 of FIG. 2;
[0017] [0017]FIG. 3 a is an alternative cross-sectional view thereof taken along line 3 - 3 of FIG. 2;
[0018] [0018]FIG. 4 is a perspective view of the rail connector mounted to the vertical support with the horizontal rail removed;
[0019] [0019]FIG. 5 is a side elevational view of the connector element of the present invention;
[0020] [0020]FIG. 6 is a cross-sectional view of the connector element installed in the vertical support as taken along line 6 - 6 of FIG. 2; and
[0021] [0021]FIG. 7 is a perspective view of an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to the drawings, the fencing system of the present invention is illustrated and generally indicated at 10 in FIGS. 1 - 6 . Further, an alternate embodiment of the present invention is illustrated and generally indicated at 100 in FIG. 7. As will hereinafter be more fully described, the fencing system 10 is assembled in sections wherein each section includes at least two vertical support posts 12 with at least two horizontal rails 14 extending therebetween. Each section of the fence system 10 may also include a fencing panel 16 supported between the horizontal rails 14 and caps 18 installed onto the vertical supports 12 . The present invention therefore provides a convenient and economical modular fencing system 10 that is easily assembled and installed making the system convenient for both permanent and temporary fence installations that has not been previously available in the prior art.
[0023] Turning now to FIG. 1, several adjacent sections of the fencing system 10 of the present invention are shown fully assembled. The fencing system 10 is configured to be a modular system that is equally effective when installed as a single section, two linear adjacent sections or any conceivable arrangement of any number of interconnected sections. The adjacent sections of fencing may be disposed linearly, at 90° to one another, in a “T” configuration or at any relative angle require in a particular installation. For the purposes of the detailed description the interrelationship of the various components will be described in the context of a single fencing section although the concepts and principals of this disclosure can be extrapolated to any of the configurations described above with equal success.
[0024] As stated above, the fencing system 10 includes vertical supports 12 or fence posts. The vertical supports 12 in the present invention are tubular shaped members. While in the preferred embodiment the tubular members are shown to have a square cross-sectional profile, the tubes could be formed in any desired cross-section including but not limited to rectangular, circular, elliptical, hexagonal, octagonal and combinations thereof. The vertical support members 12 are installed in a parallel spaced apart relation in the desired location where the fencing will be installed. The vertical supports 12 could be installed by directly burying a portion of the support 12 into the ground or could be installed into support member (not shown) that may or may not be fastened to the ground. By using a support member the reconfigurability and temporary installation of the fence system 10 of the present invention may be enhanced. It should be understood that the manner in which the vertical posts 12 are anchored to the environment where the fence system 10 is installed is not critical to the present invention. Additionally, if desired for aesthetic purposes or to prevent moisture from entering the vertical supports 12 , caps 18 can be installed on the top of the vertical supports 12 .
[0025] Turning now to FIG. 2, a detailed view of the connection between the horizontal rails 14 and the vertical supports 12 is shown. The ends 18 of the horizontal rail 14 contact the outer face of two of the vertical posts 12 and the horizontal rails 14 are retained and supported therebetween. Preferably, the present invention includes at least two horizontal rails 14 extending between each pair of vertical supports 12 . It should be appreciated that when the present invention is assembled in configurations of multiple adjacent sections, each section does not require two distinct and separate vertical supports 12 as the second support for a preceding section serves also as a first support for a following section. The horizontal rails 14 are supported by rail connectors 20 as will be more fully described below. As can best be seen in FIG. 3, the horizontal rails 14 are also tubular sections. While the cross-sectional profile is shown as being square, as stated above any suitable or desirable profile may be used for the horizontal rails 14 .
[0026] It can be further seen in FIG. 3 that the horizontal rails 14 include linear grooves 22 therein to receive a fencing panel 16 should one be desired in the particular fencing application. The fencing panel 16 is a flexible sheet of fabric material having pockets 24 extending along the top and bottom edges thereof. The pockets 24 have a retention member 26 placed therein to increase the overall thickness of the pocket 24 along the top and bottom edges. The retention tube 26 may be a dowel, a fiberglass rod, a piece of polymer tubing or any other suitable material for this application. To install the panel 16 into the system, the top pocket 24 including the installed retention member 26 is slid into the groove 22 in the top horizontal member 14 and the bottom pocket 24 is similarly slid into the groove 22 in the bottom horizontal rail 14 and the top and bottom rails 14 are installed between the vertical supports 12 . In this manner the panel 16 is held in a taughtly stretched manner creating a fully closed fencing section. Optionally, as illustrated in FIG. 3 a , the horizontal rail 14 may include a reinforcing wall 28 extending on its interior to maintain the dimensional stability of the cross section of the horizontal rail 14 and prevent the groove 22 from opening and releasing the panel 16 when under load. Further, in place of a continuous pocket 24 along the edge of the panels 16 , a plurality of tabs that each include retention members could extend from the top and bottom edges thereof and be retained within the groove 22 in the horizontal rails 14 .
[0027] The fencing panel 16 may be formed from a woven or knit fabric in any desired pattern of color. While the preferred material is polymer based, any other material such as canvas, laminated sheet goods or coated canvas could also be used and fall within the scope of the invention. Further the panel 16 may be formed using interwoven polymer webbing strips to form a basket weave pattern. As can be appreciated the above disclosure related to the general pattern and configuration of the panels 16 is meant to be illustrative and not limiting in any manner.
[0028] Turning now to FIGS. 4, 5 and 6 details of the rail connector 20 are shown. The rail connector 20 is installed into holes located in the sidewalls 30 of the vertical supports 12 . The rail connector 20 includes a retention member 32 that extends outwardly from the vertical support 12 when the rail connector 20 is in assembled relation with the vertical post 12 . The retention member 32 is configured to frictionally receive and retain the ends 18 of the horizontal rails 14 . As can be seen the tubular configuration of the horizontal rails 14 provide openings in the ends 18 thereof that are received onto the retention member 32 of the rail connector 20 . The rail connector 20 includes retention clips 34 that extend from the back of the retention member 32 . When the rail connector 20 is installed onto the vertical post 12 , the retention clips 34 extend into the hole in the wall 30 of the vertical support 12 and engage the wall 30 to securely hold the rail connector 20 in assembled relation with the vertical support 12 . As can best be seen in FIG. 6, the rail connector 20 includes shoulders 36 that contact the outer surface of the vertical supports 12 and cooperate with the retention clips 34 to engage the wall 30 of the vertical support 12 . The retention clips 34 are spring biased allowing them to deflect as the rail connector 20 is inserted into the hole in the vertical support 12 and return to their original, undeflected state wherein the tabs 38 at the ends of the retention clips 34 engage the wall 30 of the vertical support 12 . Additionally, the rail connector 20 may include a detent 40 on the side of the retention member 32 . The purpose of the detent 40 is to engage a hole located in the side wall of the horizontal rail 14 to prevent it from becoming dislodged from the rail connector 20 .
[0029] The materials utilized for the vertical posts 12 , horizontal rails 14 and rail connectors 20 may be either metallic or polymer based. In the preferred embodiment of the preset invention, polymer materials are utilized to reduce the cost, make the parts easier to handle and provide longer term durability and a cleaner appearance. The vertical supports 12 and the horizontal rails 14 are preferably formed from extruded vinyl and PVC, although any other suitable polymer may be employed. Further the rail connector 20 is preferably formed from a polymer material such as ABS, PVC, HDPE or polycarbonate.
[0030] Turning now to FIG. 7, an alternate embodiment 100 of the present invention is shown. This embodiment is intended to illustrate a configuration wherein three horizontal rails 102 a - c are used in conjunction with two panels 104 a - b to create a customized fence appearance. As described above, at least two vertical supports 106 are arranged is spaced parallel relationship. Three horizontal rails 102 a - c are installed between the two vertical supports 106 utilizing rail connectors 20 as described above. While the top 102 c and bottom 102 a rails each include one longitudinal groove in the walls thereof, the middle rail 102 b includes a groove in both its top and bottom surface. In this manner a top panel 104 b can extend between the top rail 102 c and the middle rail 102 b and be retained in the groove in the top of the middle rail 102 b . Further, a bottom panel 104 a extends between the bottom rail 102 a and the groove in the bottom of the middle rail 102 b . In this manner, the installed fencing system 100 can have a custom appearance and can include two panels 104 a - b having two different patterns, textures or appearances.
[0031] It can therefore be seen that the present invention provides a unique modular fencing system 10 that is inexpensive to fabricate yet is highly durable and requires little maintenance. The fencing system 10 is easy to install, reconfigure and remove as required and is well suited to a do-it yourself installer. Further, the present invention can be modified and reused as required to facilitate temporary installations. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.
[0032] While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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A new fencing system is provided in the present disclosure that is constructed from durable polymer components that are sufficiently rigid and durable while providing an integrated modular assembly that is easy to assembly and well suited to a do-it-yourself marketplace. In particular, the present invention provides an integrated system of interfitting vinyl components and a unique polycarbonate or ABS clip for interconnection thereof. The fence includes vertical posts with horizontal members extending therebetween. The horizontal members include grooves therein to support fence panels in the form of web panels. The horizontal members are connected to the vertical members utilizing a novel and uniquely configured connector element.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit, under 35 U.S.C. §119(e), of the filing date of each of U.S. provisional application Ser. No. 60/564,447 entitled “Recording of Location Event Information in RFID Tags,” filed Apr. 22, 2004, and U.S. provisional application Ser. No. 60/564,402 entitled “Pedigree and Integrity Evaluation of Packages,” filed Apr. 22, 2004. Each of the foregoing applications is hereby incorporated herein by reference in its entirety.
FIELD OF INVENTION
The present invention relates generally to methods and apparatuses that may be used to authenticate the pedigree and/or integrity of a transported package. In some embodiments, information accumulated at a source location for a package, e.g., by entering the information into a database, is compared with information accumulated at a destination location for the package, e.g., by reading the information from a radio frequency identification (RFID) tag associated with the package, so that the pedigree and/or integrity of the package can be authenticated.
BACKGROUND
An important business process is the transportation of goods through a manufacturing process or supply chain/distribution network. During transportation through such channels, which may include several links and involve significant time periods (transport via land, sea and/or air, storage in one or more warehouses, etc.), products are susceptible to many potential harms. For example, goods may be misdirected, damaged, tampered with, and/or exposed to adverse environmental conditions. For certain goods, it is often useful, and in some cases critical, to know whether goods received at a destination location have been subjected to any such harms.
Conventional methods of determining whether goods have been exposed to these harms have relied on human intervention and other potentially time consuming and/or unreliable mechanisms. A need exists for improved methods and apparatuses for evaluating the pedigree and/or integrity of goods received at a destination.
SUMMARY
The present invention is directed to novel systems and methods for authenticating the pedigree and/or confirming the integrity of a transported package.
According to one aspect of the present invention, a method of evaluating the pedigree of a package transported from a source location to a destination location, the method comprises steps of (a) receiving first information concerning the package at at least one processor, the first information identifying location event information that was expected to have been accumulated by an electronic device associated with the package while the package was being transported from the source location to the destination location, (b) receiving second information concerning the package at the at least one processor, the second information comprising location event information that was actually accumulated by the electronic device associated with the package while the package was being transported from the source location to the destination location, and (c) with the at least one processor, comparing the second information with the first information to evaluate the pedigree of the package.
According to another aspect, a method of evaluating the integrity of a package transported from a source location to a destination location comprises steps of (a) receiving first information concerning the package at at least one processor, the first information identifying acceptable parameters for a physical or environmental condition of the package while the package was being transported from the source location to the destination location, (b) receiving second information concerning the package at the at least one processor, the second information identifying a physical or environmental condition of the package that was sensed by a sensor included in an electronic device associated with the package and stored in memory of the electronic device while the package was being transported from the source location to the destination location, the second information having been retrieved from the memory of the electronic device at the destination location, and (c) with the at least one processor, comparing the first information with the second information to evaluate the integrity of the package.
According to another aspect, a system for evaluating the integrity of a package transported from a source location to a destination location comprises an authentication computer configured and arranged to receive data accumulated at the destination location from a memory of an electronic device including a sensor that had monitored a physical or environmental condition of the package while the package was being transported from the source location to the destination location, to analyze the data to determine whether it falls within acceptable parameters for the physical or environmental condition of the product while the package was being transported from the source location to the destination location, and to transmit a signal to the destination location reflecting a determination made by the authentication computer concerning the integrity of the package.
According to another aspect, a system for evaluating the pedigree of a package transported from a source location to a destination location comprises an authentication computer configured and arranged to receive location event information accumulated by an electronic device associated with a package while the package was being transported from the source location to the destination location, to analyze the data to determine whether the data sufficiently corresponds with location event information that was expected to have been accumulated by the electronic device while the package was being transported from the source location to the destination location, and to transmit a signal to the destination location reflecting a determination made by the authentication computer concerning the pedigree of the package.
According to another aspect, a method of evaluating the pedigree and/or integrity of a package transported from a source location to a destination location comprises steps of (a) receiving information from an electronic device associated with the package at an authentication appliance at the destination location, (b) transmitting at least a first portion of the information from the authentication appliance to a server, (c) receiving from the server a network address of an authentication computer to be used to evaluate the pedigree and/or integrity of the package, (d) after receiving the network address from the server, transmitting at least a second portion of the information from the authentication appliance to the authentication computer at the network address, and (e) receiving from the authentication computer a signal indicative of a determination made by the authentication computer concerning the pedigree and/or integrity of the package based upon a comparison of the at least the second portion of the information with data stored in a database.
According to another aspect, a method of evaluating the pedigree and/or integrity of a package transported from a source location to a destination location comprises steps of (a) receiving information from an electronic device associated with the package at an authentication appliance at the destination location, (b) transmitting at least a first portion of the information from the authentication appliance to a server, (c) receiving from the server a network address of an authentication computer to be used to evaluate the pedigree and/or integrity of the package, (d) after receiving the network address from the server, transmitting at least a second portion of the information from the authentication appliance to the authentication computer at the network address, and (e) with the authentication computer, comparing the at least the second portion of the information with data stored in a database to make a determination concerning the pedigree and/or integrity of the package.
According to another aspect, a method for evaluating the pedigree and/or the integrity of a package comprises steps of (a) receiving first information concerning the package at at least one processor, the first information reflecting a containment relationship amongst components of the package and having been accumulated at least in part before the package left a source location, (b) receiving second information concerning the package at the at least one processor, the second information reflecting a containment relationship amongst components of the package and having been having been accumulated after the package reached a destination location, and (c) using the at least one processor to compare the second information with the first information to evaluate the pedigree and/or confirm the integrity of the package.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an illustrative embodiment of a system for authenticating the pedigree and/or confirming the integrity of a package;
FIG. 2 shows an example of how RFID tags may be associated with various containment levels of a package; and
FIG. 3 is a flow chart illustrating a routine that may be performed by an authentication controller to authenticate the pedigree and/or confirm the integrity of the contents of a package.
DETAILED DESCRIPTION
FIG. 1 is a block diagram showing an illustrative embodiment of a system 100 for authenticating the pedigree of a package 102 (and confirming the integrity of its contents) that has been transported from a source location 104 to a destination location 106 . As used herein, the term “package” is intended to refer generically to any item or combination of items that can be transported from one location to another, and may, for instance, refer to a single item (i.e., the lowest level of product packaging such as a single vial, syringe, or bottle); a carton containing one or more items; a box containing one or more cartons; a pallet on which one or more boxes are placed; a trailer or shipping container containing one or more pallets, boxes or cartons; or a truck, airplane, train, ship, etc., carrying one or more trailers or shipping containers.
As shown, the system 100 may include a warehouse management system 108 at the source location 102 , an authentication appliance 110 at the destination location 106 , and an authentication computer 112 located somewhere in the system 100 . The authentication computer 112 may, for example, be located at the source location 102 , at the destination location 104 , or at some location remote from the source and destination locations. In some embodiments, multiple authentication computers 112 may be used, perhaps at different locations, with each computer performing a different type of evaluation (e.g., one computer may authenticate the pedigree of the package 104 and another may confirm the integrity of its contents). In the example shown, the authentication computer 112 includes an authentication controller 114 , a program memory 116 , and a database 118 . The authentication controller 114 may, for example, execute authentication software stored in the program memory 116 , and also access data stored in the database 118 .
The warehouse management system 108 and authentication appliance 110 may each communicate with the authentication controller 114 via a network cloud 120 . The network cloud 120 may be any known system for enabling communication between electronic devices. It may, for example, comprise the Internet, one or more proprietary wide or local area networks, one or more dedicated communication channels, or some combination of the foregoing.
Before the package 102 leaves the source location 104 , the warehouse management system 108 may be provided with various pieces of data concerning the package 102 , and that data may be communicated to the authentication computer 112 (via the network cloud 120 ) and stored in the database 118 . Examples of types of data that may be provisioned into the database 118 in this manner are discussed below. In addition, data concerning the repackaging of items contained in the package 102 (“repackaging data”) may be communicated to the authentication computer 112 from computers at one or more intermediate locations (not shown) responsible for such repackaging.
As used herein, the term “warehouse management system” is intended to broadly describe any system for storing information concerning products that are to be transported within a manufacturing process or a supply chain and/or distribution network, and is thus intended to encompass systems such as order management systems, enterprise resource planning (ERP) systems, and the like, in addition to systems responsible for managing the contents of warehouses.
Additional data may also be accumulated by one or more electronic devices 122 associated with the package 102 during transport. Such data may be accumulated before, during, and after the transportation of the package from the source location 102 to the destination location 106 . The data accumulated by the electronic device(s) 122 may include, for example, data reflecting temperature, humidity, or other physical or environmental conditions to which the package 102 has been subjected. Examples of electronic device(s) 122 that may be used for this purpose are described in commonly-owned U.S. patent application Ser. No. 10/934,052, which is incorporated herein by reference in its entirety.
In some embodiments, the data accumulated by the electronic device(s) 122 may also include “location event information,” i.e., data reflecting the various fixed geographic or mobile locations at or in which the package 102 was located during its journey, and perhaps the period of time the package 102 spent at each such location. Examples of electronic device(s) 122 that may be used to accumulate such information are described in the commonly-owned U.S. Patent Application entitled “Recording of Location Event Information in RFID Tags,” filed on even date herewith under attorney docket number S1446.70022US01, and incorporated herein by reference in its entirety.
When the package 102 reaches the destination location 106 , the authentication appliance 110 may be used to collect data concerning the package 102 , and perhaps download data accumulated by the electronic device(s) 122 associated with the package 102 . After such data has been accumulated by the authentication appliance 110 , the authentication appliance 110 may communicate the accumulated data to the authentication computer 112 , and request that the authentication computer 112 authenticate the pedigree and/or confirm the integrity of the contents of the package 102 .
In response to this request, the authentication computer 112 may compare the data received from the authentication appliance 110 with the data stored in the database 118 so as to authenticate the pedigree of the package 102 . Additionally or alternatively, the authentication computer 112 may confirm that the integrity of the contents of the package 102 has not been compromised, for example, by having been subjected to adverse temperature or humidity conditions for excessive amounts of time, or having spent too much time in the distribution chain (e.g., past an expiration date). This may be accomplished, for example, by comparing data accumulated by and downloaded from the electronic device(s) 122 associated with the package 102 and/or the time the package 102 was received at the destination location 106 with data stored in the database 118 to ensure that such measurements fall within acceptable parameters.
Advantageously, some or all of the data received from the authentication appliance 110 , or from elsewhere, may also be stored in the database 118 for further authentication or tracking purposes. For example, it may be useful to access such data in the future to identify the ultimate destinations of the various components of a particular lot of a product known to potentially contain a particular defect. Indeed, one step in the authentication process employed by the authentication computer 112 may be to verify that no other packages 102 from the lot in which that package originated have been recalled for any purpose or discovered to have been compromised in any way.
One simple way that the pedigree of a package 102 can be evaluated is by associating one or more unique identifiers with the package 102 before the package 102 leaves the source location 104 , and communicating the identity of those unique identifier(s) from the warehouse management system 108 to the database 118 of the authentication computer 112 . When the package 102 reaches the destination location, the authentication computer 112 may then confirm that the received package 102 is authentic by verifying that the unique identifier(s) associated with the package 102 when it is received correspond with the unique identifier(s) stored in the database 118 . The authentication computer 112 may also verify that the package 102 has not been placed on a recall list, has not been flagged as having been stolen, misplaced, or mishandled, and/or does not represent a second instance of the same unique identifier(s) passing through the same or a parallel transportation channel.
In some embodiments, one or more radio frequency identification (RFID) tags having embedded electronic product codes (EPCs) may be associated with the package 102 , which RFID tags may be read by an RFID reader included in the authentication appliance 110 . In such embodiments, the RFID tags may optionally be included within the housing of and/or integrated functionally with other components of the electronic device(s) 122 . Alternatively, the unique identifiers for the packages 102 may comprise alphanumeric codes, bar codes, invisible ink markings, etc., which may be either automatically read by or manually input into the authentication appliance 110 . When EPC codes or other distinguishing identifiers are used, the internet protocol (IP) address of the authentication computer 112 that is to be used to authenticate the pedigree and/or confirm the integrity of the package 102 may be retrieved from an object name server (ONS) 124 , as discussed more detail below.
In some embodiments, authentication computers may be specific to one or more products and/or manufacturers and may thus include data and algorithms that correspond only to such products and/or manufacturers. In such embodiments, it may therefore be necessary for the authentication appliance to initially determine which authentication computer it should use to authenticate the pedigree and/or confirm the integrity of the contents of a particular package 102 . One possible method for selecting the proper authentication computer involves using the EPC embedded in an RFID tag, as an EPC is a unique identifier that is both product specific and manufacturer specific.
In some embodiments, the EPC or other identifier may be read by an RFID reader included in the authentication appliance 110 , and then transmitted by the authentication appliance 110 to the ONS 124 . The ONS 124 may then respond by transmitting to the authentication appliance 110 the IP address (or other network address) of the authentication computer 112 that is to be used to authenticate the pedigree and/or confirm the integrity of the package 102 . Thereafter, the authentication appliance 110 may communicate directly with the authentication computer 112 via the network cloud.
In other embodiments, the IP address of an EPC server containing EPC information for the package 102 may be retrieved from the ONS 124 . That EPC server may then be contacted to retrieve information concerning the package 102 , and such retrieved information may advantageously include the IP address of the authentication computer 112 that is to be used to authenticate the pedigree and/or confirm the integrity of the package 102 .
In some embodiments, information indicating that a package 102 having particular unique identifier(s) associated with it is being shipped to the destination location 106 , and perhaps indicating that the package 102 is expected to arrive at the location 106 within a particular time window, may also be transmitted from the warehouse management system 108 at the source location 104 to the database 118 of the authentication computer 112 . In such cases, when the package 102 reaches the destination location 106 , the authentication computer 112 may also verify, based on the information stored in the database 118 , that the package 102 having such unique identifier(s) was actually received at its intended destination, and that the package 102 was actually received within the expected time window. Thus, if the package 102 was misdirected or experienced a significant delay during transport, appropriate action may be taken to investigate the cause of the discrepancy.
In embodiments in which location event information is communicated to and written into memory of one or more electronic devices 122 as the package 102 travels between the source location 104 and the destination location 106 , that location event information can also be retrieved from the electronic device(s) 122 by the authentication appliance 110 and communicated to the authentication computer 112 . If information concerning the intended supply and/or distribution chain for the product 102 had been communicated from the warehouse management system 108 to the database 118 , then the authentication computer 112 can confirm that the package 102 traveled through the correct supply and/or distribution chain by comparing the location event information accumulated by the electronic device(s) 122 with the intended supply and/or distribution chain information contained in the database 118 . When the accumulated location event information also includes data reflecting mobile locations (e.g., cargo containers, trailers, railroad cars, airplanes, etc.) in which the package was disposed at particular times, it may also be determined whether the packages were transported through the distribution chain on the appropriate vehicles or in appropriate containers.
Another way the pedigree of a product can be authenticated is by evaluating the “containment relationship” amongst components of a package 102 received at the destination location 106 . As used herein, a “containment relationship” exists between two packages when one of the packages is contained within the other, or when one package is disposed upon another along with other like packages (e.g., a containment relationship would exist between a pallet and several boxes disposed on it). Such a containment relationship can be evaluated, for example, by associating unique identifiers, e.g., RFID tags containing EPCs, at various containment “levels” of the package 102 .
FIG. 2 shows an illustrative example of how this may be accomplished at three levels of packaging. The package 102 shown in FIG. 2 may, for example, represent a pallet which has four boxes 102 A-D disposed on it. Each of the four boxes 102 A-D, in turn, may contain four cartons 102 A 1 - 4 , 102 B 1 - 4 , 102 C 1 - 4 and 102 D 1 - 4 of some product (e.g., vials of vaccine). As shown, the package (e.g., pallet) 102 may itself have an RFID tag 202 associated with it. In addition, each of the packages (e.g., boxes) 102 A-D may have an RFID tag 202 A-D associated with it, and each of the packages (e.g., cartons) 102 A 1 - 4 , 102 B 1 - 4 , 102 C 1 - 4 and 102 D 1 - 4 may also have an RFID tag 202 A 1 - 4 , 202 B 1 - 4 , 202 C 1 - 4 and 202 D 1 - 4 associated with it.
Information concerning which RFID tags 202 are associated with which packages and sub-packages 102 may be provided from the warehouse management system 108 to the database 118 . As noted above, information concerning how items are repackaged at intermediate locations may also be communicated to the database 118 from the locations at which such repackaging took place. Thus, when the authentication appliance 110 reads the RFID tags 202 from the incoming package(s) 102 , and transmits such information to the authentication computer 112 , the authentication computer 112 can verify that the actual containment relationship amongst the components of the package 102 corresponds to the containment relationship data stored in the database 118 .
Examples of electronic devices 122 comprising RFID tags that may be associated with a package 102 and that may be used to store and accumulate data concerning (1) the unique identity of the package, (2) the physical configuration and intended transportation route and destination of the package, (3) physical and environmental condition(s) of the package as a function of time during its transport, and (4) the physical location (geographic and mobile) of the package as a function of time during its transport, are described in the commonly-owned application entitled “Recording of Location Event Information in RFID Tags,” filed on even date herewith and incorporated by reference above.
FIG. 3 is a flow chart of a routine 300 that may be performed by the authentication controller 114 to authenticate the pedigree and/or confirm the integrity of the contents of a package 102 received at the destination location 106 . Instructions to be executed by the controller 114 (“authentication software”) may be stored, for example, in the program memory 116 , or in any other computer-readable medium accessible by the authentication controller 114 .
As reflected in step 302 , when a request is received from the authentication appliance 110 to authenticate the pedigree and/or confirm the integrity of the contents of a package 102 , data to be used for such purposes may be initially retrieved by the authentication controller 114 from the authentication appliance 110 . That data may comprise, for example, data that has been accumulated from RFID-enabled electronic devices(s) 122 associated with the package 102 , including information such as EPCs, data from sensors used to monitor physical or environmental conditions of the package, tracking data accumulated by electronic device(s) 122 , manifest data, etc. Information concerning the authentication appliance 110 itself, such as its identity and location, and the times at which it received data from the electronic device(s) 122 and transmitted the authentication request to the authentication computer 112 , may also be communicated from the authentication appliance 110 to the authentication computer 112 .
At the step 304 , the actual contents of the package 102 are evaluated and compared with information stored in the database 118 , so as to make a determination as to whether the package 102 includes the correct contents. As discussed above, one way this can be done is by comparing the unique identifiers (e.g., EPCs) received from the authentication appliance 110 with the unique identifiers supplied by the warehouse management system 108 , as modified by repackaging data received from intermediate locations authorized to perform repackaging. In this manner, it can be confirmed that the actual containment relationship between the package 102 and its sub-packages corresponds to the expected containment relationship, as reflected by the data stored in the database 118 .
In some embodiments, manifest data may additionally or alternatively be retrieved by the authentication appliance 110 from one or more electronic devices 122 associated with the package 102 (e.g., manifest data stored in the electronic devices 122 associated with various pallets in the package). That manifest data may then be compared with the actual contents of the package 104 (as determined by the authentication appliance 110 ) to confirm that the actual contents of the package 102 match those listed in the manifest. This comparison may be done either by the authentication appliance 110 itself, or by the authentication computer 112 , provided the manifest data retrieved from the electronic devices 122 has been communicated from the authentication appliance 110 to the authentication computer 112 . The manifest data retrieved from such electronic devices 122 by the authentication appliance 110 may also be compared with manifest data that was sent to the database 118 by the warehouse management system 108 , thereby obtaining an added level of confirmation that the package 102 that was actually received at the destination location 106 corresponds to that which was dispatched from the source location 104 .
In addition, when the manifest data retrieved from the electronic device(s) 122 is transmitted from the authentication appliance 110 to the authentication computer 112 , it may also be used to “fill in” certain gaps in other information retrieved by the authentication appliance 110 . For example, there may be occasions on which a handful of RFID tags are unreadable by the authentication appliance 110 because of the manner in which the package 102 is oriented or arranged. In such circumstances, it may be deemed acceptable to assume that a few of the tags will be missed and to fill in the gaps in accordance with the manifest data read from one or more other tags.
At the step 306 , the current location of the package 102 , the route by which the package 102 arrived at its current location, and the identity of the vehicles or containers that were used to transport the package, may be evaluated and compared with information stored in the database 118 , so as make a determination as to one or more of (a) whether the package 106 has arrived at its expected destination, (b) whether the package arrived at the destination location 106 via the correct route, (c) whether the package 104 was transported in the proper vehicles or containers, and (d) whether the package was transported in accordance with an expected time schedule. As noted above, one way this can be accomplished is by using the authentication computer 112 to compare location event information accumulated by the electronic device(s) 122 (read by the authentication appliance 110 and transmitted to the authentication computer 112 ) with information stored in the database 118 that reflects the intended destination, route, transportation mode, and schedule for the package 102 .
At the step 308 , the condition of the product may be evaluated, for example, by determining whether any products have been subjected to excessive temperatures, humidity conditions, etc., for excessive periods of time, determining whether any products have expiration dates that make them un-saleable, determining whether any products have been recalled, determining whether any products are samples that have been misdirected to a distributor and should not be sold, etc.
At the steps 310 - 314 , one or more messages may be communicated to the authentication appliance 110 , informing it whether the pedigree of the package 102 could be authenticated and/or the integrity of the contents of the package 102 could be confirmed. In the event pedigree and/or integrity of the package 102 or its contents could not be authenticated or confirmed, information concerning the reason(s) for the failure may be communicated to the authentication appliance 110 and perhaps elsewhere (e.g., the supply chain management system), so that the appropriate investigative or corrective action can be taken. In some embodiments, the authentication appliance 110 may generate an immediate response, e.g., an alarm, at least under certain circumstances to signify that some failure has occurred in the authentication process. Alternatively, messages may be transmitted to a computer at the destination location 106 , or elsewhere, indicating the nature of the failure and suggesting that investigative or corrective action be taken before the package 102 responsible for the failure leaves the destination location 106 .
It should be appreciated that, in some embodiments, the entire authentication process discussed herein may be fully automated, i.e., could function normally without human interaction. Thus, at any destination location 106 (which may be an intermediate location in a larger supply or distribution chain) equipped with an authentication appliance 110 , the pedigree and/or integrity of received packages and their contents could be evaluated automatically as a matter of course. In embodiments in which RFID technology is employed, for example, such authentication could occur automatically whenever a package 102 enters the RF range of an authentication appliance 110 . Alternatively, authentication could occur automatically by the authentication computer 112 in response to a user transmitting an authentication request to it after the authentication appliance 110 has been provided with the necessary data, or after the package 102 has been located in a position with respect to the authentication appliance 110 that it can accumulate the required data when such a request is made.
Although the routine 300 discussed in connection with FIG. 3 is described as being performed by an authentication controller 114 that is separate from the warehouse management system 108 and the authentication appliance 110 , the invention is not limited in this respect. For example, the routine 300 may additionally or alternatively be performed partially or entirely by one or more processors included in the authentication appliance 110 and/or the warehouse management system 108 .
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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The present invention is directed to novel systems and methods for authenticating the pedigree and/or confirming the integrity of a transported package. Among other things, a method is disclosed that involves receiving information from an electronic device associated with the package at an authentication appliance at a destination location, transmitting at least a first portion of the information from the authentication appliance to a server, receiving from the server a network address of an authentication computer to be used to evaluate the pedigree and/or integrity of the package, after receiving the network address from the server, transmitting at least a second portion of the information from the authentication appliance to the authentication computer at the network address, and receiving from the authentication computer a signal indicative of a determination made by the authentication computer concerning the pedigree and/or integrity of the package based upon a comparison of the at least the second portion of the information with data stored in a database.
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INDEX TO RELATED APPLICATIONS
This application claims the benefit of U.S. patent application Ser. No. 61/096,881, filed, Sep. 15, 2008 and U.S. patent application Ser. No. 61/219,159, filed, Jun. 22, 2009, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF INVENTION
The present invention relates to a convenient home, or other structure, water supply control apparatus and a method for using same.
BACKGROUND OF THE INVENTION
Virtually all owners of improved property recognize the threat to their structures posed by water damage caused by plumbing leakage. Investigation of this problem reveals that cleanup and repair costs attributable to water damage exceed one billion dollars annually. It destroys wallboard, wallpaper and paint, electrical fixtures and wiring, carpeting and padding, vinyl flooring, subflooring, and all manner of furniture and decorative items. Irreplaceable items such as financial records, photos, and mementos are destroyed beyond retrieval. Additionally, the occupants of the damaged property can expect to be driven from their structures during cleanup and repairs. Following such repairs, the structure will likely be permanently subject to mildew and related odors.
Structural water damage due to plumbing leakage occurs most often while the occupants are not present. Causes of such leakage range from frozen pipes that break resulting in water flow when thawing occurs, broken lines connected to shut-off valves attached to toilet tanks, refrigerator ice-makers, dishwashers, or a broken hose connected to a washing machine. The breaks in these lines are often caused by the nearly instantaneous closing of associated valves. Such closing causes a hammering effect on the line, in turn causing breakage in any weak areas.
Many people do not know the location of the main water shut-off valve in their structure. In addition, it is often the case that water leakage occurs due to a natural catastrophe, which is typically accompanied by an electrical power outage. Because water damage can be severe in a relatively short amount of time, a search throughout a structure, particularly a darkened one, for the water shut-off valve can result in disaster.
What is needed in the art is an apparatus allowing a structure's occupant to conveniently turn off the water supply to his or her structure each time they leave. Additionally, in the event of a power outage, the apparatus should enable automatic shutoff of the structure's water supply, thereby alleviating the necessity of manual shut-off. The present invention accomplishes these objectives by utilizing a battery-operated radio frequency wall switch transmitter and an electrical plug-in receiver controlling an electrical solenoid valve or electrically-actuated ball valve in fluid communication with a structure's water supply. When plugged in to an energized electrical wall outlet, the default setting of the solenoid valve is open, thus allowing water flow through the valve and into the structure. In the event of a power outage with concomitant loss of power to the wall outlet, the solenoid valve closes thereby preventing water flow into the structure. The solenoid valve incorporates a by-pass switch allowing, if desired, water flow through the line into the structure during a power outage. When activated, the wall switch transmitter broadcasts a radio frequency pulse to the receiver which in turn shuts the solenoid valve off, thereby preventing water flow into the structure. Upon deactivation, the wall switch transmitter broadcasts a second radio frequency pulse to the receiver which in turn opens the solenoid valve, thereby allowing water flow into the structure.
SUMMARY OF THE INVENTION
The primary aspect of the present invention is to provide an apparatus allowing a structure's occupant to conveniently turn off the water supply to his or her structure each time they leave.
Another aspect of the present invention is to provide an apparatus that enables automatic shut-off of the structure's water supply in the event of a power outage, thereby alleviating the necessity of manual shut-off.
Another aspect of the present invention is to provide an automatic water supply shut-off apparatus incorporating a by-pass switch allowing, if desired, water flow through the line into the structure during a power outage.
Another aspect of the present invention is to provide a method of conveniently controlling the ingress of water flow into a structure.
Additional aspects, 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 aspects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
The present invention provides an apparatus allowing a structure's occupant to conveniently turn off the water supply to his or her structure each time they leave. Additionally, in the event of a power outage, the apparatus enables automatic shut-off of the structure's water supply, thereby alleviating the necessity of manual shut-off. The present invention accomplishes these objectives by utilizing a battery-operated radio frequency wall switch transmitter and an electrical plug-in receiver controlling an electrical solenoid-valve or electrically-actuated ball valve in fluid communication with a structure's water supply. When plugged in to an energized electrical wall outlet, the default setting of the solenoid valve is open, thus allowing water flow through the valve and into the structure. In the event of a power outage with concomitant loss of power to the wall outlet, the solenoid valve closes thereby preventing water flow into the structure. The solenoid valve incorporates a by-pass switch allowing, if desired, water flow through the line into the structure during a power outage. When activated, the wall switch transmitter broadcasts a radio frequency pulse to the receiver which in turn shuts the solenoid valve off, thereby preventing water flow into the structure. Upon deactivation, the wall switch transmitter broadcasts a second radio frequency pulse to the receiver which in turn opens the solenoid valve, thereby allowing water flow into the structure.
In one embodiment, the solenoid is actuated or switched off by a water sensor that transmits a signal. Water sensors may be placed on the floor near sinks, toilets, bathtubs, water heaters and the like. If water is detected, the sensor can transmit a signal to the solenoid to shut off and prevent additional water from entering through the main water line.
In one embodiment, in the event of a power failure, the valve will remain in the position it was in at the time the power failed. For example, if the system had detected a leak and shut the valve off, and there was a subsequent power failure, the valve would remain in the closed position and therefore prevent continued leak or flooding. When the power resumed, it would again retain its position. If the valve was open, it will stay open. If it was closed, it will stay closed. The system may provide optimal protection during a power failure, by using an Uninterruptible Power Supply (UPS) back-up power system.
The present invention further relates to a method of controlling the flow of water supplied to a structure through main water supply plumbing of the structure comprising the steps of:
energizing a receiver; providing a transmitter actuated by a water sensor in close proximity to said receiver; placing a fluid flow regulator in fluid communication with the main water supply plumbing of the structure; serially electrically connecting said receiver to said fluid flow regulator; broadcasting a first radio frequency pulse selected from a plurality of frequencies from said transmitter to said receiver thereby setting said fluid flow regulator to a closed state; and broadcasting a second radio frequency pulse selected from a plurality of frequencies from said transmitter to said receiver thereby setting said fluid flow regulator to an open state.
The transmitter and receiver are each constructed and arranged to select from 256 possible frequencies. The selection of a single unique frequency in which the receiver is configured to only turn on and off power based on a reception of a signal on the single frequency eliminates the possibility of an undesired shut off of power in the system.
In one embodiment, the receiver is a radio frequency receiver and the transmitter is a radio frequency transmitter.
The said fluid flow regulator is a solenoid valve that is an electrically-actuated ball valve.
The present invention also includes a method of controlling the flow of water supplied to a plurality of sinks in a single room through water supply plumbing of the system comprising the steps of:
energizing a receiver; providing a transmitter actuated by remote control with said receiver; placing at least one fluid flow regulator in fluid communication with any of the main water supply, water supply to specific groups, water supply to individual sink fixtures, or combinations thereof; electrically connecting said receiver to said fluid flow regulator; broadcasting a first radio frequency pulse from said transmitter to said receiver thereby setting said fluid flow regulator to a closed state; and broadcasting a second radio frequency pulse from said transmitter to said receiver thereby setting said fluid flow regulator to an open state.
The system of the present invention wirelessly controls water flow in a building potable water heater with components comprising:
a. a relay switch attached to an electric supply of a water heater; b. a radio frequency on-off relay switch;
wherein said relay switch attached to an electric supply of a water heater is operatively connected to a radio frequency on-off relay switch and said radio frequency on-off relay switch is actuated from a remote wireless actuator.
The system has a solenoid valve connected to a main water supply line such that when said solenoid is actuated, said system ceases water delivery through said main water supply line and ceases electric supply to said water heater.
The present invention also includes a system for wirelessly controlling water flow in a building comprising:
a. an electronic solenoid valve connected to a water supply; b. a water sensor with wireless transmitter and alarm siren; c. a radio frequency on-off relay switch; wherein said water sensor is operatively connected to said radio frequency on-off relay switch and said radio frequency on-off relay switch is actuated from a signal when said water sensor detects water, the detection of water being an event that turns off the electronic solenoid valve connected to a water supply that subsequently stops water flow in said water supply.
The system event turns off said radio frequency on-off relay switch that turns off the electronic solenoid valve connected to a water supply also turns off electric to a potable water heater.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a transmittal unit configurable for 256 separate transmission codes.
FIG. 2 are components of a home water supply shut-off apparatus actuated by a transmittal unit of FIG. 1 .
FIG. 3 are components of a home water supply shut-off apparatus actuated by either a transmittal unit of FIG. 1 or a water sensor.
FIG. 4 are components of a home water supply shut-off apparatus connected to electrical input of a water heater.
FIG. 5 are components of a water supply shut-off apparatus connected to the inlet of a water heater and controlled by a wireless actuator or a water sensor.
FIG. 6 is a schematic showing components of an electronic solenoid valve with manual override.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Transmitter 10 is controlled by an incorporated electrical switch 20 and 22 . In the embodiment shown in FIGS. 1-5 , switch 20 sends a wireless signal to receiver 70 and receiver 70 turns on electricity to solenoid-valve assembly 30 and switch 22 sends a wireless signal to receiver 70 and interrupts or turns off electricity to solenoid valve assembly 30 . Solenoid valve assembly 30 has valve body 40 with attached solenoid 50 and by-pass switch 60 . Solenoid 50 is in serial electrical connection with plug-in receiver 70 .
Solenoid-valve assembly 30 is serially connected to water supply piping 80 by compression nuts 90 . Plug-in receiver 70 is connected to wall electrical outlet 100 . Transmitter 10 is attached to wall 110 in close proximity to, that is, in operative range of, plug-in receiver 70 . When wall electrical outlet 100 supplies electrical power, solenoid 50 is in an open state, thereby allowing water to flow through valve body 40 and into the structure. When electrical power to electrical outlet 100 is interrupted, solenoid 50 changes to a closed state, thereby preventing water from flowing through valve body 40 and into the structure. By-pass switch 60 may be pressed in and rotated clockwise in order to open solenoid 50 , thereby allowing water flow through valve body 40 . By-pass switch 60 may be rotated counter-clockwise in order to close solenoid 50 , thereby preventing water flow through valve body 40 . When electrical switch 20 is activated, transmitter 10 broadcasts a radio frequency pulse to plug-in receiver 70 which in turn sets solenoid 50 to a closed state, thereby preventing water from flowing through valve body 40 and into the structure. When electrical switch 20 is deactivated, transmitter 10 broadcasts a second radio frequency pulse to plug-in receiver 70 which in turn sets solenoid 50 to an open state, thereby allowing water flow through valve body 40 and into the structure.
Valve body 40 is serially connected to water supply piping 80 . Water flow through valve body 40 is controllably prevented or allowed by either solenoid 50 or by-pass switch 60 .
As shown in FIG. 1 , transmitter 10 has an accompanying faceplate 140 . Faceplate 140 has a plurality of perforated orifices that correspond with buttons 120 on transmitter 10 . Toggle switch position 125 selects a first transmission mode and toggle switch position 130 selects a second transmission mode. Transmitter 10 has a rotatable dial selecter 28 with a central rotatable select switch 23 that moves and corresponds to indicia for varying transmission from transmitter 10 . FIG. 1 includes examples of selecting openings in faceplate 140 . Configuration 151 selects buttons 120 in the first position of each column. By the term “selects, it is meant that the openings in faceplate 140 correspond to the first switch 120 in the first column of transmitter 10 and the first switch 120 of the second column of switches 120 on transmitter 10 . Configuration 152 selects buttons 120 in the second position of each column. Configuration 153 selects buttons 120 in the third position of each column. Configuration 154 selects buttons 120 in the fourth position of each column. Configuration 155 selects buttons 120 in the fifth position of each column. Configuration 156 selects buttons 120 in the sixth position of each column. Configuration 157 selects buttons 120 in the seventh position of each column. Configuration 158 selects buttons 120 in the eighth position of each column. Using combinations of two of switches 120 and sixteen positions on rotatable selecter switch 23 , transmitter 10 has 256 separate possible combinations of signal transmission. Receiver 75 is configured with first code selector 24 and second code selector 28 that are configured to receive a signal from transmitter 10 . The configuration of transmitter 10 with a receiver 75 using a single code selected from 256 possible codes allows the system of the invention to be used in an environment, such as an apartment or office building, without having a transmitter interrupt power to a solenoid apparatus 30 other than the particular solenoid apparatus 30 designated.
Solenoid apparatus 30 has electric valve actuator 50 connected to power line junction box 79 . Power line junction box 79 has a power supply cord 77 connected to receiver 75 and receiver 75 is connected to a source of power. A standard household receptacle 100 is one source of power, however, the present invention is not limited to power from household receptacle 100 .
In the embodiment of FIG. 3 , floor sensor 35 has water sensory probes 37 . When water is detected by probes 37 a wireless signal 15 is transmitted to receiver 70 and electricity is turned off to valve actuator 50 . Valve assembly 30 then prevents flow of water from water supply 80 . Floor sensor 35 has manual switches 20 and 22 as found on transmitter 10 . Floor sensor 35 further has a manual sensor test 25 and a sensor reset button 26 incorporated thereon. Floor sensor 35 has first code selector 24 a and second code selector 28 b corresponding to first code selector 24 and second code selector 28 of receiver 75 such that transmission of an actuated signal from floor sensor 35 only sends a signal that is received by a receiver 70 similarly configured. Configuration of receiver 70 and floor sensor 35 to one of 256 possible transmission signals prevents floor sensor from actuation a system other than the one for which it is configured and positioned nearby.
Another aspect of the invention relates to an apparatus and method to wirelessly control electric potable water heaters.
As shown in FIG. 4 a conventional electric water heater 230 has power line 215 connected to component box 202 . Box 202 has an internal power line 205 operatively connected to Single Pole Double Throw (SPDT) switch 220 . Second internal power line 210 from circuit breaker box connects to SPDT relay switch 220 . Transmitter 10 wirelessly actuated receiver 70 and interrupts electricity to water heater 230 .
In another embodiment, as shown in FIG. 5 , floor sensor 35 is configured to actuate receiver 70 and said actuation interrupts and ceases electricity supply to solenoid assembly 30 . The lack of electricity to solenoid assembly 30 prevents water from entering from supply line 80 .
FIG. 6 is a schematic showing water supply pipe 80 in which solenoid apparatus 30 has been inserted. Solenoid apparatus 30 has a valve 40 that is open when supplied with electricity and closes upon the cessation of electricity by valve actuator 50 . In the event of a power failure, solenoid apparatus 30 is equipped with a manual override 60 which opens valve 40 and permits water in supply pipe to flow therethrough.
In one embodiment, an electric supply control apparatus for use in homes or other structures is provided that incorporates a battery-operated radio frequency transmitter 10 and an electrical plug-in receiver 70 regulating the open or closed state of a 120VAC electrical relay switch 220 that opens or closes the contacts of a 240VAC switch connected between the electrical circuit breaker 210 and the potable electric hot water heater 230 . Also provided is a method of controlling the receiver 70 utilizing radio frequency pulse broadcasts to regulate the open or closed state of the relay switch 220 .
The present invention also relates to a novel apparatus and method which allows for an easy and convenient system for shutting off and turning on an electric water heater 230 in order to save the homeowner money and conserve electric energy. Prior to the art of this invention the dwelling potable water heater 230 can only be controlled at the dwelling circuit breaker box. Presently it is not convenient for the homeowner to turn off the power to the potable water heater 230 when leaving the dwelling for any length of time.
Improving energy efficiency is a first and most important step toward achieving sustainability in buildings and organizations. Energy efficiency helps control rising energy costs, reduces environmental footprints, and saves money for the homeowner. The current invention provides for a simple apparatus and method, conveniently located at an exit/entry to the dwelling to easily turn off the electric to the potable electric water heater 230 when the dwelling is unoccupied. Upon returning to the dwelling the electric power to the electric water heater 230 is quickly and easily restored at the entry to the dwelling. Most residential dwellings are unoccupied during the hours of 9 AM thru 5 PM. And during the hours of 10 PM thru and 6 AM the demand for potable hot water is not as great as between 5 PM and 10 PM. Electrical energy conservation is an important element of energy policy. Energy conservation reduces the energy consumption and energy demand per capita and thus offsets some of the growth in energy supply needed to keep up with population growth. This reduces the rise in energy costs, and can reduce the need for new power plants, and energy imports. The reduced energy demand can provide more flexibility in choosing the most preferred methods of energy production. By reducing emissions, energy conservation is an important part of lessening climate change. Energy conservation facilitates the replacement of non-renewable resources with renewable energy. Energy conservation is often the most economical solution to energy shortages, and is a more environmentally benign alternative to increased energy production.
The present invention further relates to a novel apparatus and method which allows for an easy, convenient and automatic system for shutting off the main water supply to a dwelling or structure when uncontrolled water is detected on the floor. A battery operated water sensor apparatus 35 sounds a 102 db alarm siren while simultaneously transmitting a radio frequency signal 15 to the plugged in receiver relay switch 70 that activates the closure of the solenoid valve 40 in main water supply line 80 to the dwelling or structure.
The area of flood control is one that has received considerable attention from engineers, inventors, property owners and insurance companies. As anyone who has experienced a flood can readily attest, the damage caused by an interior flood can be quite severe.
The worst interior flooding occurs when there is no one at home or when the entire household is sleeping.
The current invention provides for a simple apparatus and method, conveniently located on the floor at the base of all water appliances in a dwelling. The current floor sensor apparatus 35 detects uncontrolled water on the floor reaching a height of 1/32″ in a given area due to leaking or broken pipes, leaking of or pressure deteriorated water controlled fixtures, bursting of or damaged hoses, at any time of the day or night.
The apparatus is particularly well suited for offices, apartments and condominiums, or any facility where units are individually secured and share a common radio frequency controlled solenoid activated main water shut-off valve system. In such a setting when the floor sensor apparatus 35 detects uncontrolled water, a radio frequency signal 15 is transmitted to receiver 70 . Receiver 70 shuts off of the main water solenoid valve 40 in solenoid assembly 30 and sounds an alarm siren to identify the location where uncontrolled water is detected. The unit owner, facility manager or maintenance person can then easily and quickly determine the location of the water detected and affect a shut off of the appliance causing the uncontrolled water on the floor with minimal damage or loss to the property.
Once the cause of the uncontrolled water has been determined and rectified the main water supply is once again restored to the on position.
The present invention relates to a novel apparatus and method which allows for an easy, convenient method to turn off both the main water supply line and the electric power to the electric potable hot water heater simultaneously at will, or when leaving a dwelling or other structure unoccupied, and restore both water and electric power simultaneously at will, or when returning to the dwelling.
While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.
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A water supply control apparatus for use in homes or other structures is provided that incorporates a radio frequency transmitter and a receiver regulating the open or closed state of an electrical solenoid valve in fluid communication with a structure's water supply. A by-pass switch enabling manual regulation of the solenoid valve is mounted on the valve itself. Also provided is a method of controlling the flow of water supplied to a structure utilizing radio frequency pulse broadcasts to regulate the open or closed state of the solenoid valve.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to shape memory polymers and, more specifically, to a self-folding polymer web.
2. Description of the Related Art
Advances in technology aim to reduce the degree of manual labor in construction and use. Devices that self-assemble are of particular interest for various applications. Origami is among the usable techniques to fabricate self-folding or self-assembling three-dimensional (3D) structures for applications in the aerospace and biomedical fields. As an example, aerospace structures require effective deployment of self-assembled space structures. Another example of using self-folding structures is the field of drug delivery where such structures may be used for delivering therapeutic drugs to targeted areas.
One focus of current research is the development of programmable self-assembling structures. For this, computer programming is required, and the program signals are sent into the material, detailing the steps of construction. An advantage of this approach is that after construction, additional programs can be sent to the structure, allowing it to reassemble into another shape. Another approach to self-assembling structures utilizes 4-dimensional (4D) printing, where the fourth dimension is time. In this case, the printed material, or one of the printed materials, responds to an environmental stimulus, resulting in a conformational change of the printed object. Drawbacks to this approach include the current size and material limitations of 3D printing and the need for a preconceived ending state; the final shape of the object must be determined prior to printing, and the shape changing mechanism must be planned to determine the geometry of the printed object.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a new design strategy for foldable products made of polymers using origami techniques. According to the present invention, new foldable designs or geometries will be possible. With origami as a source of inspiration, the present invention involves a water-triggered origami system that enables assembly of structures with minimal handling that uses electrospun poly(vinyl acetate) (PVAc) fiber mats that fold when stripes of water are drawn on the mat. As water permeates through the mat and is absorbed by the PVAc, a gradient of shrinkage forms through the thickness of the mat, causing folding. This shrinkage is mainly caused by the decrease in the glass transition temperature of PVAc fiber mat upon hydration, allowing spatially localized relaxation of processing-induced molecular orientation and associated local fiber shrinkage. The combination of strategic sample cutting and water line placement allow for the self-assembly of more intricate structures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
FIG. 1 is a series of scanning electron microscope (SEM) images of three different polymer fiber mats according to the present invention having average fiber diameters ranging from 0.5 to 1 μm.
FIG. 2 is a graph of the representative DSC traces of (a) dry and (b) hydrated PVAc fiber mats used to determine the glass transition temperatures. The second heating and cooling are shown in solid and dashed lines, respectively.
FIG. 3 is a schematic of the preparation of a polymer solution used for electrospinning PVAc fiber mats according to the present invention.
FIG. 4A is a schematic of a predetermined folding line according to the present invention, with FIG. 4B including a series of images showing the folding of a polymer mat according to FIG. 4A over time.
FIG. 5A is a schematic of a series of predetermined folding lines according to the present invention, with FIG. 5B including a series of images showing the folding of a polymer mat according to FIG. 5A over time.
FIG. 6A is a schematic of a series of predetermined folding lines to form a pyramid according to the present invention, with FIG. 6B including a series of images showing the folding of a polymer mat according to FIG. 6A over time.
FIG. 7 is a series of images of folding rates under different circumstances.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numerals refer to like parts throughout, there is seen in FIG. 1 a series of micrographs of a polymer fiber mat 10 that may be used to provide a water-triggered, self-folding structure according to the present invention. When water is applied to polymer fiber mat 10 , the water molecules plasticize the polymer in mat 10 , thereby significantly reducing the glass transition temperature. If the glass transition temperature is reduced to a temperature near that of the environment, the hydrated mat 10 will shrink as the molecular chains tend towards a lower energy state. FIG. 2 shows such a reduction in glass transition temperature. This shrinkage, along with the slow permeation of water through the thickness of hydrophobic polymer fiber mat 10 , is exploited to provide self-assembling 3D structures.
EXAMPLE
Poly(vinyl acetate) (PVAc) (weight average molecular weight MW=260,000 g/mol) was chosen as the polymer for this example of the present invention. PVAc was dissolved in a solution containing 70% methanol and 30% N,N-dimethylformamide (DMF) by volume, as seen in FIG. 3 , to obtain a 20 wt % polymer solution to be used for electrospinning Electrospinning parameters, including the flow rate of the polymer solution, the voltage applied to the syringe needle, and the electrospinning time, were varied to obtain mats with varying fiber diameters and thicknesses. Electrospinning is a technique that is commonly used to extract fibers from a polymer solution and involves a polymer solution is contained in a syringe with a metal needle. The metal needle is charged to 6-14 kV using a high voltage power supply. The polymer solution within the syringe becomes charged, and a cone forms at the tip of the syringe needle due to electrostatic repulsion. At a critical point, a charged jet of the polymer solution forms and is shot towards the grounded drum, which rotates at 400 rpm. Before reaching the drum, the solvent in the polymer solution evaporates, and fibers collect on the drum. The syringe pump ensures a constant flow of polymer solution and allows for the fabrication of a web with long, continuous nanofibers. The exact size of the fibers is affected by the flow rate of the polymer solution as well as the electrospinning voltage and the concentration of the solution.
Due to the voltage applied to the polymer solution and the ensuing elongational flow that stretches the jet on transit to the collecting drum, the polymer chains become oriented along the length of the electrospun fibers and the polymer is in a high-energy state. Raising the temperature of the fiber mat above the characteristic glass (for PVAc) or melting (for semicrystalline polymers) transition temperature of the polymer allows the chains to reconfigure to a relaxed, lower energy state. The result is a significant reduction in size of the fiber mat.
As seen in FIG. 1 scanning electron microscopy (SEM) was used to visualize the polymer fibers in the electrospun mats and includes views of three different mats with average fiber diameters ranging from 0.5 to 1 μm. Referring to FIG. 2 , representative DSC traces of an electrospun PVAc fiber mat are seen in both the dry and hydrated state. The measured glass transition temperatures of the dry and hydrated PVAc fiber mats were 44° C. and 17° C., respectively. The plasticization of the PVAc in water reduces the glass transition temperature by 27° C. to below room temperature. A fiber mat submerged in water experiences a significant reduction in size as the polymer chains relax and tend towards a lower energy state. The shrinkage of the mat is a relatively slow process, as PVAc is hydrophobic and resists water absorption. The hydrophobicity and shrinkage of the PVAc in water are used for water-triggered origami according to the present invention.
A line of water drawn on a PVAc fiber mat according to the present invention maintains its shape and does not spread or widen significantly because of the hydrophobicity of the PVAc. As the water slowly permeates through the thickness of the mat and diffuses through the fibers, a gradient of shrinkage forms through the mat thickness. This shrinkage gradient causes the mat to fold. FIG. 4B shows side-view images of a rectangular fiber mat 30×18 mm in dimension folding over time. As shown in FIG. 4A , a stripe of water was drawn on the surface of the mat in order to achieve a completely folded mat. The time needed for the mat to fold can be tuned by varying the average fiber diameter and the thickness of the mat. Smaller fiber diameters and thicker mats result in more prolonged folding.
More complex three-dimensional structures can be constructed by strategically drawing lines of water on the mat and forcing the mat to hit itself before completely folding. Two such structures are a triangle and a pyramid. A triangle can be constructed by drawing two equally spaced parallel lines on a rectangular mat as seen in FIG. 5A . Side-view images of the triangle forming over time are seen in FIG. 5B . To construct the pyramid, a four-pronged star is cut from an electrospun fiber mat and stripes of water are drawn at the base of each prong, as seen in FIG. 6A . As the prongs rise together, they hit at the top, forming a pyramid, as shown in the images in FIG. 6B .
Referring to FIG. 7 , the rate of folding can a further be controlled by varying the width of the water line applied to the fiber mat. Wider water lines amplify the shrinkage gradient and accelerate the folding. However, the faster folding rate is also accompanied by a decrease in sharpness of the fold angle. Wide lines tend to result in more of a bending of the fiber mat due to the wider area involved. Side-view images of fiber mats folding over time are seen in FIG. 7 , which illustrates the effects of water line thickness on folding rate and geometry. In FIG. 7 , water lines (a) 1, (b) 3, and (c) 5 mm wide were drawn on rectangular fiber mats. The folding speed is accelerated with wider lines and wider water lines result in a larger bending curvature.
Various three-dimensional objects can be constructed by strategically placing water lines on fiber mats that have been previously cut in predetermined shapes to achieve the desired three-dimensional object. Drawing the lines of water at the appropriate time relative to other lines of water may be necessary to ensure proper collision of the mat. The present invention may thus be used for craft projects, but are also useful in the medical and aerospace fields.
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A hydrophobic polymer fiber mat that folds in response to the application of water along a predetermined fold line, thereby allowing for the formation of three-dimensional objects strictly through the targeted application of water. The fiber mat is preferably formed by electrospinning a polymer, such as poly(vinyl acetate), to form mats with average fiber diameters ranging from 0.5 to 1 μm.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 634,823, filed July 26, 1984 and now U.S. Pat. No. 4,580,110.
BACKGROUND OF THE INVENTION
The present invention relates to frequency modulation. In particular, the present invention relates to frequency modulation using materials that carry a sliding charge density wave.
A. Modulation
The fundamental purpose of modulation is to superimpose the desired intelligence signals on a high-frequency carrier for transmission at that high frequency from one point to another.
A signal is transmitted from one point to another for a variety of purposes. The most common example is communications between geographic areas. For a communications (e.g., telephone) circuit between two points the physical equipment usually involves an enormous quantity of hardware (e.g., poles, cross-arms, insulators, and wires). When the demand on the circuit becomes large, it is necessary to add additional facilities.
One method of increasing the facility of a circuit is to use a method of modulation. For example, a voice-frequency band from 200 to 3000 cycles is required for telephone communications. If we take bands of frequencies, 0 to 3 kc, 3 to 6 kc, 6 to 9 kc, 9 to 12 kc, and 12 to 15 kc a total band of 0 to 15 kc apparently could provide five separate channels for five separate telephone circuits over one pair of wires, provided that the original band of 200 to 3000 cycles can be transferred to each of the high-frequency bands. The process of superimposing the information contained within a frequency band onto another frequency band is called modulation. The process of decoding or converting the signal back to its original form is called demodulation or detection.
The energy medium by which the signal is to be transferred is called the carrier. The signal is often termed the modulating frequency. If we consider a single-frequency carrier, ω o , we may write
e.sub.o =E.sub.m cos(ω.sub.o t+θ)
When the amplitude of the carrier E m is varied in accordance with the signal information, we have amplitude modulation (AM). When the frequency of the carrier ω o is varied in accordance with the signal, we have frequency modulation (FM). When the phase angle θ is varied in accordance with the signal, we have phase modulation.
Frequency modulation is superior to amplitude modulation for reducing the static and noise present in home reception of the standard AM broadcasts. Since most natural and manmade electrical noise is in the form of amplitude-modulated signals, a method of keeping the amplitude E m constant while incorporating the signal into variations of the carrier frequency ω o accomplishes the desired noise reduction.
The frequency ω o is modified by the signal amplitude and signal frequency. The deviation frequency, ω f from ω o contains the information on the amplitude or volume of the signal. The frequency of the signal, ω m , is the rate of change of the output frequency.
These two concepts are correlated by the index of modulation, m f , as
m.sub.f =ω.sub.f /ω.sub.m
The FM output wave can be written as an infinite series of terms (carrier plus sidebands) containing Bessel functions which depend on m f and ω m .
B. Charge Density Waves (CDW)
In most metals and semiconductors, Ohm's law and the frequency (ω)-independent conductivity σ are the well-established and well-understood consequences of the band theory of solids. Deviations from Ohmic behavior and frequency dependent response is observed only at large electrical fields E or at relatively high (optical) frequencies, where the energy provided by the dc or ac fields is comparable with the single particle energies.
In contrast to this situation, charge transport is usually field and frequency-dependent at moderate fields and frequencies in materials where the electron structure, and consequently the conduction process, is highly anisotropic.
Low dimensional conductors or linear chain conductors are materials which have a chain structure: the solid is built of chains of atoms or molecules with strongly overlapping electronic wave functions along the chain direction, while the coupling or overlap of the wave functions between the chains is weak. This chain structure leads therefore to highly anisotropic electronic band structures.
Drastic deviations from single particle transport (due to extended electron states) are expected in linear chain compounds. In addition to the modification of the single particle dispersion relation, collective modes appear where a periodic modulation of the charge density occurs.
These collective modes appear in certain low-dimensional or linear chain conductors like TaS 3 or NbSe 3 which undergo a phase transition at low temperatures to a state where the electrons condense into a spatially periodic arrangement, known as the Charge-Density-Wave state (CDW). The temperature below which the system is in the charge density wave state varies from one material to another. For example, this temperature is 220° K. for orthorhombic TaS 3 .
In these systems the CDW is pinned by the impurities present in the sample in the absence of a driving electric field. When a d.c. electric field above a certain threshold value is applied to the sample, the CDW is depinned and is able to slide through the sample, thereby providing a new mechanism of charge transport.
The sliding CDW is associated with the onset of a non-linear current-voltage characteristics and the appearance of an a.c. component in the current. The fundamental component of the a.c. current is found to be proportional to the excess current that is carried by the CDW. This a.c. component is known as the narrow-band-noise or the coherent current oscillations. The frequency spectrum of this a.c. component consists of well-defined peaks at the fundamental and its higher harmonics.
In the present invention, these characteristics of the sliding of the CDW are utilized in a method and system for the frequency modulation of a carrier frequency by a signal frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of the system according to the present invention.
FIG. 2 shows the frequency spectrum of the coherent oscillations according to the present invention. graph 1(a) shows the fundamental with no modulation; graphs (b) and (c) show two values of the modulation amplitude; the modulation frequency is 50 kHz.
FIG. 3 shows the variation of the amplitude of the fundamental and side-bands (n=0,1,2,3,4) with the modulation amplitude. The solid lines are the theoretical values of |J n |. The value of X=ω F /ω M was evaluated experimentally from the I-V characteristics. The modulation frequency is 50 kHz.
FIG. 4 shows the variation of the amplitude of the fundamental and the two side-bands (n=0,1,2 respectively). The modulation frequency is 100 kHz.
SUMMARY OF THE INVENTION
The present invention is a system and method for frequency modulation or frequency demodulation of a signal. For frequency modulation, a carrier-frequency, which is tunable, is generated. A modulation frequency then modulates the carrier. The system for the modulation of the carrier depends on the effect of a.c. - d.c. mixing in the sliding CDW which is caused by driving the system with an amplitude-modulated field. This field generates frequency modulated coherent current oscillations.
The frequency spectrum of the current of the preferred embodiment, orthorhombic TaS 3 , develops side-bands at frequencies ω o ±nω M where ω o is the material fundamental of the current oscillation in the absence of the a.c. modulation. Varying the amplitude of the modulation results in the variation of the amplitude of the side-bands and the carrier frequency. This variation is found to be in excellent agreement with the results obtained theoretically for the general case of frequency modulation (FM) with no adjustable parameters.
Thus, the sliding CDW system acts as a single crystal frequency modulator. A decided advantage of the CDW system, however, lies in the tunability of the carrier-frequency (1 kHz-1 GHz).
The steps of the method of the present invention as applied to modulation are:
(a) imposing a direct current voltage across a material which displays sliding of a charge density wave such that the voltage induces a current in the material having direct current and alternating current components wherein the alternating current has a frequency, ω o , which depends on the direct current component;
(b) applying a signal voltage having an amplitude and a signal frequency, ω M , across the material in series with the direct current voltage; and,
(c) obtaining a frequency modulated signal from the material wherein the frequency, ω o , is the carrier frequency for the modulated signal, the carrier frequency being frequency modulated in a predetermined way that depends on the signal voltage amplitude and frequency.
For frequency demodulation, the system is the same as that for frequency modulation. However, the steps of the method of the present invention as applied to demodulation are:
(a) imposing a direct current voltage across a material which displays sliding of a charge density wave such that the voltage induces a current in the material having direct current and alternating current components wherein the alternating current has a frequency, ω o , which depends on the direct current component, the frequency, ω o , being the same as the carrier frequency of the signal to be demodulated;
(b) applying the signal voltage to be demodulated across the material in series with the direct current voltage; and,
(c) obtaining a frequency demodulated signal from the material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As discussed above, many metallic layer and chain compounds show phase transitions associated with the development of charge density waves (CDW) below a particular temperature, T p .
Materials that exhibit this characteristic include:
______________________________________COMPOUND T.sub.p (K)______________________________________NbSe.sub.3 142TaS.sub.3 215NbS.sub.3 155K.sub.0.3 MoO.sub.3 183(TaSe.sub.4).sub.2 I 265(NbSe.sub.4).sub.10 I.sub.3 285______________________________________
The sliding charge density wave (CDW) conductors display intriguing electrical transport properties such as the non-linear conductivity and the coherent current oscillations--the so-called narrow-band-noise when a d.c. electric field above a certain threshold value is applied to the sample. The frequency of the oscillations is found to scale linearly with the non-linear part of the d.c. current.
The linear relationship between the d.c. CDW current and the frequency of the periodic voltage implies:
ω.sub.o =αI.sub.CDW ( 1)
where ω o is the frequency, α is a system parameter and I CDW is the nonlinear part of the current. Now if I CDW contains an a.c. component, ω o will also vary in time. In particular, by superimposing an a.c. voltage of frequency ω M upon the d.c. we obtain a signal developed across the sample that is periodic, given by ##EQU1## where J n (ω F /ω M )is the nth order Bessel function. The voltage as a function of frequency is: ##EQU2## Eq. 3 is the standard expression for frequency modulation. A comparison with experimental results measures the quality of the performance of the device.
EXAMPLE
A single crystal of orthorhombic TaS 3 , 2, was mounted in a configuration shows schematically in FIG. 1 and maintained at 130 K where it is in its CDW state. A d.c. voltage in excess of the threshold field was established. With only the dc of 60 mV across the sample the characteristic a.c. signal appeared at 830 KHz.
In FIG. 1, variable d.c. voltage 4 and a.c. signal voltage 6 are applied to the crystal 2. The resulting frequency modulated signal, V out , is then obtained from the material 2. In this example, TaS 3 is employed as a material that displays the CDW state. However, any material that displays the CDW state may be used. On superimposing an a.c. voltage at a frequency of 50 KHz, sidebands of the 830 KHz signal appeared which were multiples of 50 KHz to the high and low sides of the fundamental peak. As the amplitude of the a.c. is increased the magnitude and number of sidebands increase. Typical spectra for three values of the a.c. amplitude are shown in FIG. 2.
In FIG. 3 the amplitude of peaks are compared with the theoretical values of the Bessel functions of equation 3. Except for the fundamental, where the background provided a systematic deviation at lower values of (ω F /ω M ) the fit everywhere is excellent.
In order to complete the demonstration of the FM effect, the frequency ω M of the modulating signal was varied. In FIG. 4 the modulation frequency was 100 KHz. The fit up to the third sideband is again excellent, with the systematic background problem evident again for the fundamental.
This example shows the performance of the material orthorhombic TaS 3 as a single crystal frequency modulator. It is noted that the same system in FIG. 1 will also act as a demodulator. In this case, a variable direct current voltage 4 is applied so that the ac frequency equals the carrier frequency of the signal to be demodulated. Then the signal to be demodulated 6 is applied in series with the dc voltage. The resulting frequency demodulated signal, V out , is then obtained from the material, 2 whose amplitude and frequency spectrum varies in a predetermined way that depends on the amplitude of the carrier signal generated by the direct current voltage applied to the system. Since the basis of the operation of the system is caused by the presence of a sliding charge-density wave, all materials which have such a state will also act as frequency modulators, or demodulators.
The advantages of this device are as follows: (1) It is a single-component frequency modulator capable of replacing a complex many-component device. (2) It is a low impedance (but low power) device. (3) The carrier frequency can be tuned over a very wide range (1 KHz to 1 GHz).
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The present invention is a method and a device for the frequency modulation and/or demodulation of a signal applied to materials that carry sliding charge density waves. A particular example of such a material is orthorhombic TaS 3 that acts as a frequency modulator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the priority date of Provisional Patent Application Serial No. 60/302,209 filed Jun. 29, 2001.
FIELD OF INVENTION
[0002] This invention relates to electrographic recording apparatus such as that used in document copiers and printers, and more specifically to control of toner replenishment and monitoring of toner usage in an electrophotographic recording apparatus.
[0003] Definitions
[0004] The following terms well known in the art are defined here:
[0005] I exp —Writer current used during exposure.
[0006] V exp —Writer voltage used during exposure.
[0007] E 0 —Light produced by the print head.
[0008] E—Actual exposure of photoconductor.
[0009] V 0 —Primary voltage (relative to ground) on the photoconductor just after the charger.
[0010] This is sometimes referred to as the “initial” voltage.
[0011] V B —Development station electrode bias.
[0012] The light E 0 produced by the print head illuminates the photoconductor and causes a particular level of exposure E of the photoconductor.
[0013] In general contrast and density control are achieved by the choice of the levels of V 0 , E 0 , and V B as is well known and described in the published literature.
DISCUSSION OF PRIOR ART
[0014] Two-component development systems for electrography or electrophotography use a toner and a magnetic carrier. Other ingredients are frequently included as flow aids or charge aids for these two principal components. During normal operation of a printing system, fresh toner is added periodically to the developer mixture to replace toner that leaves the toning system as images are developed. To indicate when more toner is required, a toner concentration monitor or process control patch is frequently used, as is well known in the art. From toner concentration, the amount of toner takeout can be determined.
[0015] There are direct and indirect methods of monitoring toner concentration in multicomponent systems. See U.S. Pat. No. 5,729,787 (Resch), incorporated herein by reference, for a short summary and further references. One measurement method indirectly measures toner concentration by measuring the toner laid down on the photoconductor. Direct methods use measurements made at the development stations. In one known approach, an infrared source is directed through a window in the development sump and the reflections back are measured and used to infer toner concentration. In another approach, a planar electric coil is disposed at a suitable position in the developer container surrounded by a stream of developer. The coil inductance increases as toner concentration decreases. In yet another approach, magnetic detectors are provided at a position in a container that holds the magnetic carrier and a color toner. A coupling coefficient of the magnetic circuit changes with concentration of the toner. Still another approach sends electromagnetic energy along a probe and into the development (toner/carrier) mixture. The difference in impedance between the mixture and the probe is a measure of concentration and is used to initiate adjustment of the composition content of the development mixture.
[0016] For toner replenishment system calibration, see U.S. Pat. No. 5,649,266 (Rushing) incorporated herein by reference. For closed loop control of toner concentration for use in controlling replenishment of toner to the development station, see U.S. Pat. No. 5,678,131 (Alexandrovich, et al.), incorporated herein by reference. For a detailed explanation of the overall process control methods used in support of toner replenishment, see U.S. Pat. No. 6,121,986 (Regelsberger, et al.), incorporated herein by reference. For a detailed explanation of the toner replenishment process itself, see U.S. Pat. No. 6,181,886 (Hockey, et al.), incorporated herein by reference.
[0017] Reflectivity of image or test areas has been used to manage toner replenishment. U.S. Pat. No. 4,502,778 (Dodge, et al.) uses a sensor and a comparator for producing an output signal indicative of the reflectivity of the photoconductor using test patches on that photoconductor. U.S. Pat. No. 4,377,338 (Ernst) uses light reflectance of a maximum toned area and a minimum toned area, again using text patches on the photoconductor.
[0018] Grid and development bias voltages have also been used. U.S. Pat. No. 5,262,825 (Nordeen, et al.) shows an image density process control system for a full color electrophotographic proofing system. The system uses grid and development bias voltages combined with density measurements to create a model set of parameter values for image density control, but does not use exposure current or power. The method is defined for laser printers and copiers.
[0019] Further methods use pixel count and pixel type to manage toner replenishment. U.S. Pat. No. 5,724,627 (Okuno, et al.) uses a correction coefficient determined on the basis of the pixel frequency at each density level of a document read by image scanning, combined with tone curves and tone expression patterns (set by the emission duty ratio and emission cycle of the laser which exposes the photosensitive member) selected by an operator. The method is defined for laser printers and copiers. U.S. Pat. No. 4,847,659 (Resch) uses a toner depletion signal proportional to the number of character print signals applied to a print head, the characters preferably being pixels to be toned.
[0020] For digital printers, pixel counting provides an advance estimate of toner use before any change is observed in the image density or toner concentration. However, it has the offsetting disadvantage of requiring special electronics to be added to a standard raster image processor. Additionally, for gray-scale printing the density of each pixel also needs to be taken into account, which complicates the use of the pixel count, a second disadvantage.
[0021] Other approaches use test or reference image toner density measurements, and many further methods use direct toner density/concentration measurement, to manage toner replenishment. Each of the families of methods outlined above has its own associated cost and complexity.
SUMMARY
[0022] The invention is a system and process for measuring toner consumption and replenishing consumed toner in an electrographic printing system. In electrophotographic engines, the invention uses a photoconductor traveling along a path for receiving and developing a latent image. The path passes a plurality of processing stations including a charging station for charging the photoconductor to a desired charge level, an exposure station for exposing the photoconductor to a document to selectively discharge the photoconductor and form a latent image of the document, a toning station for applying toner to the photoconductor to develop the latent image, and a transfer station for transferring the developed latent image to a receiver sheet. At the exposure station, the invention mounts a current sensor. It calibrates the sensor by measuring quiescent current of the exposure device before exposure and storing that measurement. It uses the sensor throughout imaging by measuring the image exposure current of the exposure device. The invention compares the calibration current level with the averaged image current level using a differential amplifier and an integrator, and uses a logic and control unit for generating a toner replenishment signal proportional to the difference between the two averaged quantity signals. The invention may obtain its estimate of toner takeout by measuring currents, voltages, light intensities, power consumption, photoconductor toner densities, receiver sheet toner densities, or percent area coverage, any of which can be translated into a proportionate toner takeout measurement over time. The invention generates the replenishment signal by multiplying its measurements by a predetermined value that indicates the amount of toner required by each image. The invention then sends the replenishment signal to the toner replenishment subsystem.
[0023] Those skilled in the art understand that electrical power is the product of voltage and current. In conventional electrographic and electrophotographic machines, the voltage for the writer is usually held at a constant value and the current varies. As such, measuring only the current is sufficient to measure power. In a more general sense, one could measure both the applied voltage and the applied current, derive a product of the two over time, and then integrate the product over time to measure the total energy used to write an image. Power integrated over time is energy.
[0024] Other transducers can measure power in different ways. For example, a photocell in a densitometer measures power by converting the intensity of incident light into a current or a voltage. A portion of the incident light from the exposure system can be measured by a photodetector and is proportional to the power consumed in production of a latent image and ultimately the amount of toner used for that image. Light transmitted through a photoconductor, reflected from a photoconductor, or stray light from lenses can be used. Light reflected or transmitted from a toned photoreceptor or a copy sheet that carries the toned image can also be used to estimate the amount of toner required for replenishment of the toning system
[0025] Another way of measuring power and energy is monitoring laser current and laser shutter current to generate signals representative of energy used to form an image in a laser print engine.
[0026] In its most general form, the invention consists of estimating toner takeout by monitoring the energy required to produce a latent image and replenishing the development system with a proportional amount of toner. The measurement of energy per image can be made during the process of creating the image or estimated afterwards from characteristics of the image such as average voltage of a latent image, area coverage of a toned image, or average density.
DESCRIPTION OF DRAWINGS
[0027] [0027]FIG. 1 shows the invention as installed in a typical electrophotographic printing system.
[0028] [0028]FIG. 2 shows the invention's connections between the current sensor, the integrator, and the LCU.
DETAILED DESCRIPTION OF INVENTION
[0029] The machine 10 shown in FIG. 1, an electrophotographic printer, is typical of devices containing the invention. In machine 10 , a moving recording member such as photoconductive belt 18 is driven by a motor 20 past a series of work stations of the printer. A logic and control unit (LCU) 24 has a digital computer that operates a stored program for sequentially actuating the workstations.
[0030] A charging station 28 sensitizes belt 18 by applying a uniform electrostatic charge of predetermined primary voltage V 0 to the surface of the belt 18 . The output of the charger 28 is regulated by a programmable controller 30 , which is in turn controlled by LCU 24 to adjust primary voltage V 0 in accordance with a grid control signal, V grid that controls movement of charges from charging wires to the surface of the recording member, as is well known.
[0031] At an exposure station 34 , light projected from a write head dissipates the electrostatic charge on the photoconductive belt 18 to form a latent image of a document to be copied or printed. The write head preferably has an array of light-emitting diodes (LEDs) or some other light source such as lasers for exposing the photoconductive belt picture element (pixel) by picture element with an intensity regulated by a data source programmable controller 36 as determined by LCU 24 . Alternatively, the exposure may be by optical projection of an image of a document onto the photoconductor. A still further alternative is creating electrostatic latent images on an electrographic recording medium using needle-like electrodes or other known means for forming such latent images.
[0032] Where an LED or other electro-optical exposure source is used, image data for recording is provided by a data source 36 such as a computer, a document scanner, a memory, a data network, etc. Signals from the data source 36 and/or LCU 24 may also provide control signals to a writer network, etc. Signals from the data source 36 and/or LCU 24 may also provide control signals to a writer interface 32 for identifying and selecting exposure correction parameters for use in controlling image density. The output of the writer interface 32 contains data on line 70 for the exposure station 34 and controls the writer power supply on line 72 that generates the current for the LEDs in the exposure station 34 . In order to form calibration patches with density, the LCU 24 may be provided with ROM memory representing data for creation of a patch that is input into the data source 36 . Travel of belt 18 brings the areas bearing the latent charge images into a development station 38 . Development station 38 has magnetic brushes in juxtaposition to the travel path of the belt. Magnetic brush development stations are well known.
[0033] LCU 24 selectively activates the development station 38 in relation to the passage of the image areas containing latent images to selectively bring the magnetic brush into engagement with or a small spacing from the belt. The charged toner particles of the engaged magnetic brush are attracted imagewise to the latent image pattern to develop the pattern.
[0034] As is well understood in the art, conductive portions of the development station 38 , such as conductive applicator cylinders, act as electrodes. The electrodes are connected to a variable supply of D.C. or A.C.+D.C. potential V B regulated by a programmable controller 40 . Details regarding the development station 38 are provided as an example, but are not essential to the invention.
[0035] As is also well known, a transfer station 46 is provided for moving a receiver sheet S into engagement with the photoconductor on belt 18 , in register with the image, for transferring the image to receiver S. Alternatively, the image may be transferred to an intermediate member, and then from the intermediate member to receiver S. A cleaning station 48 is downstream from transfer station 46 and removes toner from belt 18 to allow reuse of the surface for forming additional images. A belt 18 , a drum photoconductor or other structure may be used for supporting an image. After transfer of the unfixed toner images to receiver sheet S, sheet S is transported to a fuser station 49 where the image is fixed.
[0036] LCU 24 provides overall control of the apparatus and its various subsystems as is well known. Programming commercially available microprocessors is a conventional skill well understood in the art. LCU 24 maintains and stores parametric values necessary for the operation of both the invention and the overall electrophotographic apparatus 10 . Among these parameters is the aim value for toner concentration, which determines how much stored toner must be supplied to the mixture to maintain image quality.
[0037] The invention uses a current sensor 80 to measure the current I exp used by the writer at exposure station 34 to estimate the amount of toner to be used for an image. The writer interface has two output lines, 70 and 72 . Line 70 carries the data for switching the LEDs in the writer on and off as well as conventional communication control signals. Line 72 carries power control signals for operating the writer power supply that supplies current to the LEDs of the writer 34 . In its simplest form, a current sense signal is the voltage across a resistor in series with the writer power supply. In the form shown in detail in FIG. 2, the current sensor 80 is a combination of an offset control differential amplifier 88 and a shunt resistor 89 . The shunt resistor 89 has a very low resistance on the order of 0.001 ohms. The differential amplifier has a high input impedance. It senses the voltage drop across the shunt resistor 89 and provides an output signal I exp representative of the exposure current. The current sensor 89 receives a control signal from the LCU 24 to zero the current sensor or optionally to provide automatic offset adjustment and null out standby current of the writer. Estimating toner takeout from I exp is based on the fact that the total exposure energy E 0 is proportional to V exp , the writer voltage, times I exp . For a constant voltage power supply for the writer, therefore, exposure energy E 0 is proportional to I exp alone. The exposure energy E 0 , initial voltage V 0 of the photoconductor, and the intrinsic photoconductor properties determine the voltage of the exposed image used for development.
[0038] The invention uses writer current, as just described, for systems using LEDs as writing devices. For systems that write with lasers, the lasers may be switched on and off, or they may be gated by some means of interrupting the flow of light energy to the photoconductor. In systems where the lasers are switched on and off, the invention uses the writer current to the lasers. In systems where the lasers are gated, the invention uses the controlling voltages or currents to the gating components in place of the writer current, in such a way as to calculate the total energy used in the writing of the image. With any exposure means, the system can use the intensity of light transmitted through the photoconductor or reflected from the photoconductor to calculate the total energy used in writing the image.
[0039] Calibration
[0040] In the preferred embodiment, the invention calibrates toner replenishment rate as follows. A first current measurement is made using current sensor 80 when the writer is in a quiescent or “standby” state. Other measurements are made for exposure of a process control patch. Image density measurements are likewise made and the LCU 24 determines TU, the amount of toner used per unit energy of exposure or unit current used for exposure I unit-exp . For many applications, the amount of toner used per unit of exposure is approximately constant and can be pre-determined. For extremely precise control, the toner take-out per unit of exposure can be recalculated periodically. It can also depend upon the initial photoconductor voltage, V 0 , the state of the toning station, toner charge-to-mass ratio, and aim image density. The rate of toner use per unit of exposure, TU, as determined by LCU 24 during calibration, is stored in LCU 24 for use during normal operation. LCU 24 also stores writer quiescent current level I qui and writer unit current used for exposure I unit-exp as measured at current sensor 80 . It should be noted that voltages or other signals capable of being combined arithmetically, as discussed here, may represent current levels.
[0041] Normal Operation
[0042] In normal operation, while images are being exposed onto the photoconductor, LCU 24 receives toner usage signals by monitoring the current to exposure station 34 . Refer to FIG. 2, which shows a more detailed view of the connections between current sensor 80 , integrator 84 , and LCU 24 . When writer 34 is in normal operation, integrator 84 receives current measurement signals representing I exp from current sensor 80 for exposure of an image, and current level signals representing I qui from LCU 24 for writer current during quiescence. Integrator 84 calculates the difference representing I exp -I qui using a differential amplifier 84 a , and integrates the difference over time using an amplifier 84 b with a capacitor 84 c to determine total current consumption for the entire image, I image . Integrator 84 transmits a signal representing I image to LCU 24 . Between images, LCU 24 sends integrator 84 a reset signal to prepare for the integration of current signals for the next image. The reset signal is applied to the integrator 84 b , 84 c via a zeroing switch 84 d , which is here shown as a JFET. Zeroing switch 84 d may also be a MOSFET or other switching device with similarly acceptable characteristics.
[0043] LCU 24 uses the calibrated TU with the measured I image to determine the amount of toner TI used for the image exposure. The calculation is, essentially, TI=TU×(I image /I unit-exp ). Based on the calculated value of TI, the supplied value of toner concentration TC, and the aim value for toner concentration, LCU 24 sends to the replenishment subsystem a toner replenishment signal TR, which triggers the replenisher to add toner from the toner bottle to the toning station so that toner concentration is maintained well within useful limits.
[0044] LCU 24 may initiate a calibration cycle between images in order to adjust and store any previously calibrated values. The methods of scheduling and carrying out such calibrations are numerous and well known in the art.
[0045] The use of an analog integration process to determine the amount of toner takeout is fast, simple, and inexpensive. By contrast, prior-art methods relying on pixel counts require an investment in raster image processing software and hardware for the system, to count the pixels and calculate the energy required for each pixel. The invention eliminates this investment and complexity. An image already stored on a computer as a bitmap would require pixel-by-pixel processing using these prior-art methods, but measurement of the writer current eliminates such a process entirely. Such an image can be printed directly.
[0046] In the preferred embodiment, the invention's method of toner replenishment is supplemented by algorithms based on estimates of toner concentration TC in the toning station that are activated when toner concentration deviates far from the aim value. A magnetic toner monitor in the development station usually determines toner concentration. Methods of determining toner concentration are numerous and well known in the art, as are the algorithms for their use in toner replenishment. The present invention considers their use as supplementary to the invention's own method as described above, and necessary only in exceptional cases. Such cases may occur when the toning station's concentration of toner deviates sharply from the invention's basic projections as described here.
[0047] This means of toner replenishment can be used with process control schemes for maintaining image density that, for example, adjust V 0 and exposure. The aim value of toner concentration can change depending on conditions such as toner charge or developer life, photoconductor or image voltage, and exposure. In particular, if initial photoconductor voltage or exposure intensities are near maximum values, the aim toner concentration can be increased.
[0048] The invention's method is a means of determining toner replenishment rates based on estimates of toner takeout for the actual images that are printed. Similar methods for estimating toner takeout per image include the following.
[0049] One alternative method is to estimate the actual exposure and the corresponding toner usage by measuring the intensity of light transmitted or reflected from the photoconductor adjacent to the exposure device, using a light pipe or large area photodetector. By translating the light intensity level into a voltage or current signal, and by calibrating light intensity versus toner consumption, the light intensity over time is integrated and applied using the invention's method as described above.
[0050] A second alternative method is to measure the density of the toned image with a densitometer having the width of the image. This densitometer replaces the existing densitometer, or else is situated adjacent to the post-development erase lamp(s). Again, by translating the measured image density into a voltage or current signal, and by calibrating density versus toner consumption, the image density over time is integrated and applied using the invention's method as described above.
[0051] A third alternative method is to measure the density of the toned image on the receiver. This differs from the second alternative method only in the location of measurement.
[0052] Any of these means of estimating toner takeout per image can also be used for replenishment algorithms that supplement or replace replenishment methods based on measurements of average toner concentration.
[0053] Overall, the invention uses a simple analog integration technique to produce a fast, accurate, and useful measure of toner consumption. This technique obviates the need for digital calculation and its supporting hardware, and may be used to replace other more-complex replenishment processes. The invention's simplicity and effectiveness make it less costly to build, install, and maintain. This advantage consequently renders the electrophotographic systems in which the invention operates more robust and less costly, which translates into a commercial advantage for the makers of such products.
CONCLUSION, RAMIFICATIONS, AND SCOPE OF INVENTION
[0054] From the above descriptions, figures and narratives, the invention's advantages in providing accurate and inexpensive toner replenishment should be clear.
[0055] Although the description, operation and illustrative material above contain many specificities, these specificities should not be construed as limiting the scope of the invention but as merely providing illustrations and examples of some of the preferred embodiments of this invention.
[0056] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given above.
[0057] For example, the invention may be applied to an electrographic printer or so-called direct printer. Those printers use ion beams or toner streams to directly apply toner to a copy sheet. As mentioned above, when the applied voltage of the writer is held constant, the applied current is representative of power. However, the invention can be used with variable voltage and variable currents. A signal representative of power can be derived by sampling the variable voltage and variable current, storing the sampled values, multiplying the stored values together to derive a power value and then integrating the power values over the measured time period to derive an energy signal.
[0058] The invention also contemplates variables in the electrographic or electrophotographic machine. It is possible that a user will vary the TU constant in accordance with V O , toning station state, image aim (target) density or toner charge-to-mass ratio. Those skilled in the art will recognize that corresponding changes must be made in the energy consumption estimate of toner consumption.
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A method and apparatus for replenishing toner based on the electric current used over time by the exposure subsystem. Toner take-out for each image is estimated by measuring the current used by the exposure system, subtracting the quiescent current, integrating over a page or frame, and multiplying by a predetermined value that indicates the amount of toner required by the image, based on the average current used for the exposure and other process parameters. These calculations are done either in hardware or in software. The replenishment system is used to add the correct amount of toner to the developer station to maintain the toner concentration at an approximately constant aim value.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is concerned with a wave activated power generation system using a rack and pinion mechanism, in which a plurality of rectangular power generation buoys manufactured from fiber-reinforced plastic material are activated by wave action.
2. Description of the Prior Art
It is a root demand to enjoy a safe, comfortable civilization life. Modern civilization is based on electrical energy. The demand for electrical energy never disappears as long as the human race exists.
With ocean energy, wave activated power generation is the steadiest form of power generation energy. It is characterized by the large amount available. The energy per unit area is 20-30 times of photovoltaic generation energy and is at least five times more than the force of winds. The ability of the wave activated power generation is given by natural environment in the installation location and the weather conditions. It is not uniform in all the oceans. The usage of wave activated power generation is put to practical use as a power supply of beacon buoys now. However, there is still a problem with stability and potential damage during stormy weather.
The advantages in which the wave activated power generation is adopted are as follows.
(A) Wave activated power generation is eternal energy. (B) Wave energy is clean, safe, cheap and abundant. Oil fuel and the nuclear power are unnecessary with wave activated power generation of natural energy. (C) The needed area for the wave activated power generation is smaller than that of wind power generation or photovoltaic generation. (D) It is said that the wave activated power generation can generate 30,000 kW in an area of 1K square meters. (E) As the matter of the wave activated power generation, the influence on the appearance of the surrounding area is a little compared with wind power generation. (F) The amount of power generation can be easily estimated because the conditions of the waves maybe forecast from the local wind conditions. (G) The structural mechanism is simple and the complex gearbox is unnecessary.
The system of wave activated power generation has some methods. When classified roughly, it is as follows.
(a) Method to use top and bottom of wave vibration (b) Method to use horizontal vibration of wave (c) Method to use the seawater stored to the water pond by using the wave force and to rotate the water mill. (d) Additionally, there is a method of using both of (a) and (b) together, too.
The method of (a) is being researched by a lot of research laboratories. That is the one to operate the turbine by ventilating the compressed air generated by a top and bottom of the wave vibration. This method is called the turbine method and a vibration water column type. The structure is simple and is excellent in durability. It is a main current now. There is also a simple method, such as moving the coil up and down in the magnetic field floating body vibration. Moreover, there is the one of the pendulum type that uses the horizontal vibration of the wave of (b), too.
3. Problems the Invention is Solving
This invention is directed to the application of a wave activated power generation system by rack and pinion mechanism in which pluralities of square pillars manufactured from FRP material are activated by sea wave.
With ocean energy, wave activated power generation is the steadiest form of power generation energy. It is characterized by the large amount available. The energy per unit area is 20-30 times of photovoltaic generation energy and is at least five times more than the force of winds. However, wave activated power generation is not so widespread. The usage is limited to small-scale power supply equipment, and it has a problem of being damaged by stormy weather.
As for the method called the turbine and vibration water column method, the structure used therein is simple and has excellent durability. But it is necessary to turn the turbine blades by compression air. A large amount of energy is needed to turn the turbine blades with air. The energy of the sea wave becomes large if it totals it. However, individual energy is small. It is thought that a mechanical method is preferable to take out a lot of small energy.
The corrosion problem with seawater is not solved. Steel and aluminum have enough structural strength for wave activated power generation, but they are easily corroded by seawater. The power generation buoy that is bored by corrosion loses buoyancy. Wood also rots by seawater. FRP material is excellent in structural strength and durability. However, its manufacturing cost is expensive because the manufacturing process has not been established.
SUMMARY OF THE INVENTION
To answer the problems and the current state demanded by the use of a wave activated power generation system, the processing technology and concept for them are described herein.
In terms of the wave activated power generation system, the most important problem that should be solved is the manufacturing of a power generation buoy that can endure exposure to seawater. The demand on the power generation buoy is not only the endurance against corrosion. It is necessary that the power generation buoy floats on the sea and stands up vertically in the sea. Moreover, it is preferable that the power generation buoy is filled with the material that prohibits the infiltration of seawater.
Also, a second demand is that the mechanism of converting the vertical movement into the gyration works with good efficiency. It is preferable that the mechanism has the ability to stop power generation system during stormy weather.
To satisfy the first demand, glass fiber FRP material is chosen. Glass fiber FRP is a compound material of the glass fiber and epoxy resin, and neither the glass fiber nor epoxy resin can be corroded by seawater. Moreover, it is easy to get the raw materials as price of such material is low. The process of manufacturing FRP structural material for the wave activated power generation is the same process as the application Ser. No. 13/407,196 “A HONEYCOMB STRUCTURE HAVING HONEYCOMB CORE ARRANGED PARALLEL TO A PANEL SURFACE AND A MANUFACTURING PROCESS THEREFOR”. The FRP structures for power generation buoy are manufactured from four-corner type though the FRP structure shown in application Ser. No. 13/407,196 is a honeycomb structure of six-corner type. This method can mass-produce FRP structural material at low cost.
The honeycomb structure of six-corner type is less limited in the size than four-corner type structure, and is more excellent in structural strength. However, the power generation buoy only moves up and down in the shroud assembly by ocean wave. The power generation buoy does not need special strength. It is enough in the FRP structure of four-corner type.
In application Ser. No. 13/407,196, vapor pressure power is used to pressurize the internal pressure device made of heat proof plastic. In this invention, styrene foam is used instead of the vapor pressure power of water and alcohol. The bead of the styrene foam foams because of steam when heating it filling the bead of the styrene foam in the internal pressure device. The internal pressure device is pressurized by the foaming pressure of the styrene foam. The styrene foam remains in the FRP structure. The styrene foam filled in the internal pressure device prevents seawater from invading into the power generation buoy.
The power generation buoy is filled with the styrene foam, so it floats on the sea. And when the weight of iron is attached at the bottom part of buoy, the power generation buoy stands vertically in seawater. However, because the weight of iron is corroded with seawater, it is inferior to durability. When iron rubbish is filled at the bottom part of the power generation buoy and the iron rubbish is hardened with the urethane resin, the power generation buoy stands vertically in the sea. The iron rubbish does not come in contact directly with seawater because it is hardened with the urethane resin.
To satisfy the second demand, the mechanical method of converting the vertical movement into the gyration is chosen. Current method by compression air is inefficient. The reason is that the energy of the wave is converted into thermal energy by the process into which air is compressed. The thermal energy generated by compressed air is the loss in vain. In this invention, the energy of the wave is taken out as vertical movement generated by a buoyancy of the seawater and the gravity of the earth.
In general, crank and piston mechanism is used to convert the vertical movement into the gyration. It is adopted for the piston engine etc. However, the crank and piston mechanism is not applicable to the power generation buoy. The reason is that the amplitude of the wave is not constant. The crank mechanism does not rotate when the amplitude of the vertical movement is not constant.
In this invention, the mechanism of rack and pinion is adopted. Rack and pinion mechanism can convert the vertical movement of the variable amplitude wave into the gyration. Of course, there is some limitation. The amplitude of the wave at stormy weather has the danger to exceed the length of the rack gear. At stormy weather it is necessary to stop the vertical movement generated by the wave.
The power generation buoy repeats the vertical movement because of buoyancy and gravity. The pinion gear converts the vertical movement of the rack gear, which is attached to power generation buoy into the gyration. The wave activated power generation turns a dynamo with the rotating torque of the pinion gear, and obtains the electric power. The rotating torque load of the dynamo is equal to the frictional force for the power generation buoy. The power generation buoy does not fall down by gravitation when the frictional force is larger than the gravity load. The power generation buoy stops the vertical movement in the air. When the pinion gears are connected to the dynamo with the gearless transmission, the torque of the dynamo can be arbitrarily varied. It becomes possible to stop the power generation buoy at stormy weather.
The speed of the pinion gear is changed by the wave conditions. When rotating movement of the pinion gear generates electricity, the electricity is an exchange current. The rotation speed of dynamo is not constant. The frequency of current is varied by the rotating speed of dynamo. It is preferable that the current of the wave activated power generation is converted into the direct current.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a square pillar internal pressure device using the references of ( 1 ) square pillar internal pressure device, and ( 2 ) beads of styrene foam.
FIG. 2 shows a square pillar internal pressure device assembly that uses the references ( 3 ) square pillar internal pressure device, ( 4 ) square pillar internal pressure device assembly, and ( 5 ) soft FRP prepreg.
FIG. 3 shows a solid-type pressure device using the references ( 6 ) square solid-type pressure device of half cut, and ( 7 ) square vacant space of half cut.
FIG. 4 shows a basic square pillar assembly using the references ( 8 ) square pillar internal pressure device assembly, ( 9 ) square solid-type pressure device of half cut, ( 10 ) soft FRP prepreg, ( 11 ) square solid-type pressure device, and ( 12 ) basic square pillar assembly.
FIGS. 5A-5D show an assembly procedure explanation chart for FRP structure pillar material with the references ( 14 ) basic square pillar assembly, ( 15 ) square pillar unit, ( 16 ) soft FRP prepreg, and ( 17 ) FRP structure pillar material with four basic pillar assemblies.
FIGS. 6A-6C show a power generation buoy of wave activated power generation using the references ( 18 ) power generation buoy, ( 19 ) glass fiber FRP, ( 20 ) styrene foam, ( 21 ) weight mass.
FIGS. 7A and 7B show an wave activated power generation unit with the references ( 22 ) power generation buoy, ( 23 ) shroud assembly, ( 24 ) rack gear, ( 25 ) pinion gear, ( 26 ) gearless transmission, ( 27 ) dynamo, ( 28 ) support roller, ( 29 ) shuttle slide and ( 30 ) rigid barge.
FIGS. 8A-8E show the image chart, which convert the vertical movement of the power generation buoy into the gyration by rack and pinion mechanism, with the references ( 34 ) power generation buoy, ( 35 ) rack gear and ( 36 ) pinion gear.
FIGS. 9A-9E show the free vibration chart of power generation buoy in 2500 mm height of ocean wave with the references (t 0 ) cycle of wave, (t 1 ) period of descent, (t 2 ) period of rise, (Hmg) moving height by gravity, (Hmb) moving height by buoyancy, (Hb) depth of sinking by buoy weight and (Wh) wave height.
FIGS. 10A-10E show the image chart of the power generation buoy movement with torque load (1000 kgf) in 2500 mm height of ocean wave with the references (t 0 ) cycle of wave, (t 1 a ) period of stop in descent, (t 1 b ) period of descent, (t 2 a ) period of stop in rise, (t 2 b ) period of rise, (Hmg) moving height by gravity, (Hmb) moving height by buoyancy, (Hb) depth of sinking by buoy weight, (Htq) depth of sinking by torque load, (Hadd) depth of sinking by buoy weight and torque load and (Wh) wave height.
FIGS. 11A-11F show the image chart of the power generation buoy movement with torque load (2500 kgf) in 2500 mm height of ocean wave with the references (t 0 ) cycle of wave, (t 1 a ) period of stop to balance point, (t 1 b ) period of stop in descent, (t 1 c ) period of descent, (t 2 a ) period of stop in rise, (t 2 b ) period of rise, (t 3 ) reference time to bottom dead center, (Hmg) moving height by gravity, (Hmb) moving height by buoyancy, (Hb) depth of sinking by buoy weight, (Htq) depth of sinking by torque load, (Hadd) depth of sinking by buoy weight and torque load and (Wh) wave height.
FIGS. 12A-12E show the image chart of the power generation buoy movement with torque load (2800 kgf) in 2500 mm height of ocean wave with the references (t 0 ) cycle of wave, (t 1 a ) period of stop to balance point, (t 1 b ) period of descent, (t 2 a ) period of stop in rise, (t 2 b ) period of rise, (t 1 c ) reference time to bottom dead center, (Hb) depth of sinking by buoy weight, (Htq) depth of sinking by torque load, and (Wh) wave height.
FIGS. 13A-13F show the image chart of the power generation buoy movement by torque load (2800 kgf) with freeing the load at the top dead center in 2500 mm height of ocean wave with the references (t 0 ) cycle of wave, (t 1 a ) period of stop to the balancing point, (t 1 b ) period of descending, (t 2 a ) period of stop in rise, (t 2 b ) period of rising, (t 2 c ) period of free rising to top dead center, (Hmg) moving height by gravity, (Hmb) moving height by buoyancy, (Hf) moving height in free rising, (Hb) depth of sinking by buoy weight, (Htq) depth of sinking by torque load, (Hadd) depth of sinking by buoy weight and torque load and (Wh) wave height.
FIGS. 14A-14B show the image chart of the wave activated power generation module with the references ( 37 ) power generation unit, ( 38 ) shroud assembly, ( 39 ) power generation buoy, ( 40 a ) dynamo assembly, ( 40 b ) gearless transmission assembly, ( 41 ) rigid barge, (L 1 ) length of module, (W 1 ) width of module and (H 1 ) height of module.
FIG. 15 shows the image chart of the wave activated power generation module inclined by the wave with the references (L 1 ) Length of module and (An) inclined angle.
FIGS. 16A and 16B show the image chart of the long size wave activated power generation module with the references ( 42 ) rigid barge, ( 43 ) power generation unit, ( 44 ) power generation buoy and ( 45 ) shroud assembly (L 1 ) Length of single module and (L 2 ) Length of double module.
FIG. 17 shows the image chart of the tension buoy and dumping weight for power generation module with the references ( 46 ) long size power generation module, ( 47 ) tension buoy, ( 48 ) cable drum, ( 49 ) tension spring, ( 50 ) dumping weight, ( 51 ) connecting cable, ( 52 ) foundation block, (Lb) length of barge and (Wb) width of barge.
FIG. 18 shows the image chart of the wave activated power generation barge with the references ( 53 ) long size power generation module, ( 54 ) tension buoy and ( 55 ) tying cable.
FIG. 19 shows the image chart of maintenance of the wave activated power generation barge with the references ( 56 ) long size power generation module, ( 57 ) tension buoy and ( 58 ) connecting cable.
FIG. 20 shows the image chart of power generation farm with the references (Lf) length of power generation farm, (Lb) length of power generation barge, (Lms) margin space length between power generation barges, (Wf) width of power generation farm, (Wb) width of power generation barge and (Wms) margin space width between power generation barges.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing as follows, it explains the form of concrete execution of the manufacturing process of power generation buoy and explains wave activated power generation system by rack and pinion mechanism.
FIG. 1 shows a square pillar internal pressure device. The square pillar internal pressure device ( 1 ) is made from heatproof plastic tube and it has enough length and it encloses beads of styrene foam ( 2 ). As for the both ends of square pillar internal pressure device ( 1 ), they are sealed lightly to prevent the beads of styrene foam ( 2 ) dropping off from ( 1 ). The seal is not shown in the figure.
The square pillar internal pressure device ( 1 ) can be made from the tube of heatproof plastic material, so the length of the internal pressure device ( 1 ) is arbitrary. The beads of the styrene foam ( 2 ) are foamed by heat and the pressure of steam.
The reason why every corner of the square pillar internal pressure device is chamfered is following reasons:
A. It is difficult to manufacture the corner part of plastic squarely when the product is manufactured from the metal mold of pushing out or blowing process. B. It is impossible to press every corner of the square pillar internal pressure device when internal pressure expands the internal pressure device.
(a) The internal pressure expands the internal pressure device roundly like the cylinder. (b) Therefore, the internal pressure device cannot pressurize the corner edge.
C. Every four corners of the FRP pillar material are pressurized with a thermal expansion solid resin.
(a) The powder, which generates the bubble by heating, is kneaded to the heat foam resin. (b) When the heat foam powder is heated, the powder generates a large amount of small bubbles. (c) A large amount of small bubbles swells within the resin, and expands the heat foam resin. (d) As for the heat foam resin, a polyethylene system resin or a polypropylene system resin is selected. (e) Those resins have the strength by which a large amount of small bubbles can be maintained at the high temperature.
FIG. 2 shows a square pillar internal pressure device assembly. The square pillar internal pressure device assembly ( 4 ) is manufactured by wrapping the external surface of square pillar internal pressure device ( 3 ) with a soft FRP prepreg ( 5 ) two or more times. The soft FRP prepreg ( 5 ) becomes the internal FRP wall of FRP structure materials.
At room temperature, the soft FRP prepreg ( 5 ) is a wet soft cloth, so it is not difficult to wrap the square pillar internal pressure device ( 3 ) with the soft FRP prepreg ( 5 ). The adhesive of prepreg deteriorates at the room temperature; it is preferable to preserve the product within the freezer at minus 5° C. or less.
FIG. 3 shows a solid-type pressure device. The solid-type pressure device of half cut ( 6 ) is made from the heat foam plastic resin by the metal mold of pushing out. It has the same length as the square pillar internal pressure device assembly and has square vacant space of half cut ( 7 ) inside it. As the solid-type pressure device can be manufactured by metal mold of pushing out, the length of the solid-type pressure device is arbitrary.
The reasons why a square solid pressure device is necessary are as follows.
A. Because the pillars of FRP structure materials are manufactured by assembling the four square pillars, the size accuracy requested to a basic square pillar is severe. B. It is difficult to pressurize a square corner part by the internal pressure device.
(a) The internal pressure device expands to the form of a cylinder.
C. The solid pressure device can pressurize the corner part of a square pillar.
(a) Because the solid pressure device is manufactured from the heat foam resin, the accuracy of the shape size is good. (b) The solid pressure device can make a lot of heat foam resins gather in a square corner part. (c) Big expansion pressure can be generated in a square corner part by a large amount of heat foam.
FIG. 4 is a basic square pillar assembly. When two parts of square solid-type pressure device of half cut ( 9 ) are combined, they are shaped to be square solid-type pressure device ( 11 ) with square vacant space inside it. The square pillar internal pressure device assembly ( 8 ) is stored in the square vacant space of the square solid-type pressure device ( 11 ). The basic square pillar assembly ( 12 ) is manufactured by wrapping the square solid-type pressure device ( 11 ) two or more times by the soft FRP prepreg ( 10 ). This basic square pillar assembly ( 12 ) is used as the base element of FRP structure materials.
At room temperature, the soft FRP prepreg ( 10 ) is the wet soft cloth, so it is not difficult to wrap square solid-type pressure device ( 11 ) with the soft FRP prepreg ( 10 ). Because the adhesive of prepreg deteriorates at the room temperature, it is preferable to preserve the product within the freezer at minus 5° C. or less.
FIGS. 5A-5D show an assembly procedure explanation chart of FRP structure pillar material that illustrates the procedure sequence as follows:
A. The process of preparation is as follows:
(a) Four basic square pillar assemblies ( 14 ) preserved in the freezer at minus 5° C. or less are taken out from the freezer. (b) The adhesive function of FRP prepreg is lost at that temperature therefore it is not difficult to assemble them.
B. The first step is as follows:
(a) Four basic square pillar assemblies ( 14 ) are combined with horizontal direction and the vertical direction. (b) One square pillar unit ( 15 ) with four basic square pillar assemblies is manufactured.
C. The second step is as follows:
(a) FRP pillar structure material with four basic square pillar assemblies ( 17 ) is manufactured by wrapping the square pillar unit ( 15 ) with the soft prepreg ( 16 ).
Theoretically, the square pillar can be infinitely arranged. However the structural position is not unique. It is difficult to connect more than four pillars to one unit. Honeycomb structure is superior for a large-scale structure. But, the square pillar can be manufactured in low-cost when it is compared with the honeycomb structures. The square pillar is suitable for the power generation buoy of wave activated power generation.
The pressurizing process and the heat stiffening process by the internal pressurizing device and the external frame reaction force are the same as the manufacturing process of the application Ser. No. 13/407,196 “A HONEYCOMB STRUCTURE HAVING HONEYCOMB CORE ARRANGED PARALLEL TO A PANEL SURFACE AND A MANUFACTURING PROCESS THEREFOR”.
Internal pressure device by the styrene foam is useful for expanding method instead of the vapor pressure. Water and alcohol need not be drained from the internal pressure device after the heat stiffening process; the process is shown in application Ser. No. 13/407,196. Epoxy resin stiffens completely during the cooling time though epoxy resin, which is the bonding resin of the FRP prepreg, starts stiffening at 130° C. Therefore, the internal pressure device should keep pressurizing the FRP prepreg during the cooling time. The styrene foam is manufactured from cooling gradually with pressurizing it. The manufacturing process is the same.
FIGS. 6A-6C illustrate a power generation buoy for wave activated power generation. FIG. 6B is a front chart. FIG. 6A is a left side chart, and FIG. 6C is a right side chart. The power generation buoy ( 18 ) is composed of 16 basic elements. Each basic element is manufactured from glass fiber FRP ( 19 ), and the styrene foam ( 20 ) is filled. The weight mass ( 21 ) is installed at the bottom part of the power generation buoy. The weight mass is the one that the iron rubbish was hardened with the urethane resin.
The power generation buoy is filled with the styrene foam. Seawater cannot invade into the power generation buoy, so it floats on the sea. And when the weight of iron is installed at the bottom part of buoy, the power generation buoy stands vertically in seawater. The weight mass is the one that the iron rubbish was hardened with the urethane resin. The iron rubbish does not come in contact directly with seawater because it is hardened with the urethane. And, glass fiber FRP is a compound material of the glass fiber and epoxy resin, and neither the glass fiber=nor epoxy resin is corroded by seawater. Therefore, the power generation buoy is not corroded with seawater. The durability of power generation buoy is excellent.
The specs of the power generation buoy of FIG. 6A-6C are shown in Table 1. The length of the power generation buoy is 6,000 mm. The buoyancy of the buoy is calculated to be 13,500 kgf from the volume. Weight material of the buoy is calculated to be 3,222 kgf. The weight force of the iron rubbish is 1,463 kgf. The total weight force is 4,685 kgf, so the power generation buoy sinks by about 2,082 mm, and stands up vertically in the water:
TABLE 1
Weight (kg)
Length
Width
Height
Buoyancy
Weight
(mm)
(mm)
(mm)
(kgf)
Buoy
mass
Total
6000
1500
1500
13500
3222
1463
4685
FIGS. 7A and 7B show a wave activated power generation unit. FIG. 7A shows the power generation buoy in top center of waves. FIG. 7 B shows the power generation buoy in the bottom center of waves. Power generation unit is composed of power generation buoy ( 22 ) and shroud assembly ( 23 ). Rack gear ( 24 ) and shuttle slide ( 29 ) are installed on power generation buoy ( 22 ). Pinion gear ( 25 ), gearless transmission ( 26 ), dynamo ( 27 ), and support roller ( 28 ) are installed in the shroud assembly. Power generation unit is fixed both sides by rigid barge ( 30 ), and is floating on the sea. Power generation buoy ( 22 ) moves up and down in shroud assembly ( 23 ).
FIGS. 8A-8E show the image chart, which convert the vertical movement of the power generation buoy into the gyration by rack and pinion mechanism. The rack gear ( 35 ), which is attached on the buoy ( 34 ), moves up and down because of the vibration of the wave. The pinion gear ( 36 ) converts the vertical movement of the rack into the gyration. The pinion gear ( 36 ) is attached in a shroud assembly. (The shroud assembly is omitted in the figure.) When the movement is analyzed in physics, the power generation buoy ( 34 ) rises by the buoyancy, and descends by gravitation.
Rack and pinion systems are installed in both surfaces of the left and a right of the buoy. Therefore, the hand of cut of the right side pinion is opposite to the left side pinion. The rotation speed of the pinion is varied by the cycle of the wave. When electricity is generated by rotating movement of the pinion, the generated electricity is an exchange current and its frequency is not constant. It is preferable that the current generated by the wave activated power generation is converted into the direct current electricity.
In this invention, the rack and pinion mechanism can convert the vertical movement of the variable wave into the gyration. Of course there is some limitation. The amplitude of the wave at stormy weather has the danger to exceed the length of the rack gear. At stormy weather it is necessary to stop the vertical movement of power generation buoy.
The power generation buoy repeats the vertical movement by the buoyancy and gravity. The pinion gear converts the vertical movement into the gyration. The wave activated power generation unit turns dynamo with the rotating torque of the pinion gear, and obtains the electric power. The rotating torque load of the dynamo is equal to the frictional force for the power generation buoy. The power generation buoy does not fall down by gravitation when the frictional force is larger than the gravity load. The power generation buoy stops the vertical movement in the air. When the pinion gears are connected to the dynamo with the gearless transmission, the torque of the dynamo can be arbitrarily varied. Therefore, it becomes possible to stop the power generation buoy at stormy weather.
The motion of the power generation buoy is simulated by using the sample power generation buoy and ocean wave data. Ocean wave is generated by the wind and gravity. The wave data is observed as a function of the velocity of the wind. Table 2 shows the observational data:
TABLE 2
Amplitude of wave
Velocity of the
Cycle
Wavelength
(m)
wind (m/sec)
(sec)
(m)
1.5
7.07
5.7
50.00
2.0
8.16
6.5
66.67
2.5
9.13
7.3
83.33
3.0
10.00
8.0
100.00
3.5
10.80
8.6
116.67
4.0
11.55
9.2
133.33
4.5
12.25
9.8
150.00
5.0
12.91
10.3
166.67
FIGS. 9A-9E show the free vibration chart of power generation buoy in 2500 mm height of ocean wave. When the torque load of dynamo does not load, power generation buoy vibrates freely by ocean wave. When wave height (Wh) is 2500 mm, cycle of wave (t 0 ) is 7.30 sec. So, the period of descent (t 1 ) by gravity is 3.65 sec and the period of rise by buoyancy is 3.65 sec. Because the power generation buoy vibrates without load restriction, the moving height by gravity (Hmg) and the moving height by buoyancy (Hmb) are the same as the wave height (Wh).
The length of the power generation buoy is 6,000 mm. The buoyancy of the buoy is calculated to be 13,500 kgf from the volume. Weight material of the buoy is calculated to be 3,222 kgf. The weight force of the iron rubbish is 1,463 kgf. The total weight force is 4,685 kgf (46865=3222+1463), so the depth of sinking by buoy weight (Hb) is about 2,082 mm. The power generation buoy sinks 2,082 mm and stands up vertically in the sea.
Electricity is not generated in the system of FIG. 9A-9E . It is necessary to install the dynamo to generate electricity. The buoy that floats on the ocean wave cannot vibrate freely when the dynamo is installed. The power generation buoy receives the resistance force from the pinion, which corresponds to the torque force turning the dynamo.
FIGS. 10A-10E show the image chart of the power generation buoy movement with torque load (1000 kgf) in 2500 mm height of ocean wave. When wave height (Wh) is 2500 mm, cycle of wave (t 0 ) is 7.30 sec. The pinion load from the dynamo torque load is the same as the frictional force for the buoy. The buoy does not rise when the buoyancy of the buoy does not reach 1000 kgf. Similarly the buoy does not descend if the buoyancy of the buoy does not lose 1000 kgf or more. The pinion load becomes 500 kgf because there are two dynamos.
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 444 mm. The depth of sinking by buoy weight and torque load (Hadd) is 2526 mm. The period of stop in descent (t 1 a ) is calculated to be 1.47 sec. The period of descent (t 1 b ) is calculated to be 2.18 sec. The period of stop in rise (t 2 a ) is calculated to be 0.98 sec. The period of rise (t 2 b ) is calculated to be 2.67 sec. The moving height by gravity (Hmg) is calculated to be 2056 mm. The moving height by buoyancy (Hmb) is calculated to be 2056 mm. The data of the torque load and the buoy assembly is shown in Table 3:
TABLE 3
Depth of
Depth of
Sinking
Torque
Sinking
Size of Buoy
Weight of
by Buoy
Load
by Torque
(mm)
Buoy (kgf
Weight (mm)
(kgf)
Load (mm)
1500 × 1500 × 6000
4685
2082
1000
444
Analysis of movement at 2500 mm height, torque load 1000 kgf
1. Analysis of movement by buoyancy
(A) The buoyancy acts at the cycle from the bottom dead center (C) of the wave to the top dead center (E). (B) When there is a torque load, the buoy does not move from the bottom dead center (C) until the buoyancy exceeds the torque load. (C) The torque load and the buoyancy are balanced at the point (D). (D) Then, the buoy rises from point (D) to the top dead center (E). (E) The total buoyancy of the buoy is 13500 kgf, so the buoy buoyancy is much larger than 1000 kgf of the torque load. Therefore, the buoy rises from point (D) to the top dead center (E) without fail.
2. Movement analysis-1 by gravity
(A) The gravity acts at the cycle from the top dead center (A) of the wave to the bottom dead center (C). (B) When there is a torque load, the buoy does not move from the top dead center (A) until the buoyancy loses the force corresponding to the torque load. (C) The torque load and the buoyancy are balanced at the point (B). (D) Then, the buoy descends from the point (B) to the bottom dead center (C). (E) The total weight of the buoy is 4685 kgf, so the buoy gravity is larger than 1000 kgf of the torque load. Therefore, the buoy descends from the point (B) to the bottom dead center (C).
3. Movement analysis-2 by gravity
(A) The buoy should fall down from point (B) to the bottom dead center (C) within 2.18 seconds (t 1 b ). Otherwise, next wave comes. (B) The gravity increases from 0 kgf of point (B) to 3685 kgf (3685=4685−1000) of point (C). The buoyancy that corresponds to gravity (3685 kgf) is 1638 mm. The gravity of 1842.5 kgf acts on the average. (C) The mass of the buoy is 4685 kg. In the equation of Newton, it is F=mα. Therefore it is 1842.5(kgf)=4685(kg)*α (D) α=0.3932764 (kgf/kg), 1 kgf=9.81N, 1N=1(kg)*1(m/sec^2), α=0.3932764*9.81 (N/kg)=3.85804 (N/kg)=3.85804 (m/sec^2) (E) S=(½)*α*t^2, α=3.85804 (m/sec^2), t 1 b= 2.18(sec) (F) S=(½)*3.85804(m/sec^2)*2.18(sec)*2.18(sec)=9.16747(m)=9167.47(mm) (G) The falling distance from point (B) to point (C) is 2056 mm (Hmg). (H) The calculated distance (9167 mm) is larger than 2056 mm (Hmg). Therefore; the buoy will fall down from the point (B) to the point (C) without fail.
4. Actual movement
This calculation is considerably rough. The viscosities etc. of seawater are not considered. Because the buoy receives the torque load in the neighborhood of the bottom dead center, the buoy will stabilize in the neighborhood of the bottom dead center. It is impossible to get the stability point by the hand calculation.
Calculation of work and work rate at 2500 mm height, torque load 1000 kgf:
1. Work by buoyancy
(A) Work by the buoyancy is obtained by multiplying the torque load and the vertical distance between the point (D) and the point (E).
(B) The torque load is 1000 kgf, and the distance is 2056 mm (Hmb).
(C) Therefore, the work by buoyancy: Wb=1000(kgf)*(2056/1000)(m)=2056.0 (kgf*m)
2. Work by gravity
(A) Work by the gravity is obtained by multiplying the torque load and the vertical distance between the point (B) and the point (C).
(B) The torque load is 1000 kgf, and the distance is 2056 mm (Hmg).
(C) Therefore, the work by gravity: Wg=1000(kgf)*(2056/1000)(m)=2056.0 (kgf*m)
3. Total Work
(A) The total work (Wt) is obtained by adding the work by buoyancy (Wb) and work by gravity (Wg).
(B) Wb=2056.0 (kgf*m), Wg=2056.0 (kgf*m)
(C) Therefore, the total work: Wt=2056.0 (kgf*m)+2056.0 (kgf*m)=4112.0 (kgf*m)
4. Work rate
(A) Work by buoyancy (Wb) and work by gravity (Wg) are repeated at the cycle of wave.
(B) Therefore, the total work rate is obtained by dividing the total work by the cycle of wave.
(C) Total work is 4112.0 kgf*m, and the cycle of the wave is 7.30 seconds.
(D) Total work rate: Wr=4112.0(kgf*m)/7.30(sec)=563.28 (kgf*m/sec)
(E) 1(kgf*m/sec)=9.81(W)=0.00981(kW)
(F) Therefore, Wr=563.28*0.00981(kW)=5.525(kW)
FIGS. 11A-11F show the image chart of the power generation buoy movement with torque load (2500 kgf) in 2500 mm height of ocean wave. When wave height (Wh) is 2500 mm, cycle of wave (t 0 ) is 7.30 sec. The pinion load from the dynamo torque load is the same as the frictional force for the buoy. The buoy does not rise when the buoyancy of the buoy does not reach 2500 kgf. Similarly the buoy does not descend if the buoyancy of the buoy does not lose 2500 kgf or more.
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 1111 mm. The depth of sinking by buoy weight and torque load (Hadd) is 3193 mm. The period of stop to balance point (t 1 a ) is calculated to be 1.69 sec. The period of stop in descent (t 1 b ) is calculated to be 1.20 sec. The period of descent (t 1 c ) is calculated to be 1.11 sec. The period of stop in rise (t 2 a ) is calculated to be 1.42 sec. The period of rise (t 2 b ) is calculated to be 1.87 sec. The reference time (t 3 ) from descending point to bottom dead center is 0.76 sec. The moving height by gravity (Hmg) is calculated to be 1389 mm. The moving height by buoyancy (Hmb) is calculated to be 1389 mm. The data of the torque load and the buoy assembly is shown in Table 4:
TABLE 4
Depth of
Depth of
Sinking
Torque
Sinking
Size of Buoy
Weight of
by Buoy
Load
by Torque
(mm)
Buoy (kgf
Weight (mm)
(kgf)
Load (mm)
1500 × 1500 × 6000
4685
2082
2500
1111
Analysis of movement at 2500 mm height, torque load 2500 kgf
1. Movement analysis by buoyancy
(A) The torque load and the buoyancy are balanced at the point (E). Then, the buoy rises from point (E) to the top dead center (F).
(B) The total buoyancy of the buoy is 13500 kgf, so the buoy buoyancy is much larger than 2500 kgf of the torque load. Therefore, the buoy rises from point (E) to the top dead center (F) without fail.
2. Movement analysis-1 by gravity
(A) The torque load and the buoyancy are balanced at the point (C). Point (B) is the reference point on which the weight of the buoy and the buoyancy is balancing.
(B) Then, the buoy descends from the point (C) to the bottom center. It is 0.76 seconds (t 3 ) from point (C) to the bottom center. And the distance corresponding 0.76 sec is 833 mm.
(C) The point (D) is neighborhood of the bottom center.
(D) The total weight of the buoy is 4685 kgf, so the buoy gravity is larger than 2500 kgf of the torque load. Therefore, the buoy descends from the point (C) to the bottom center.
3. Movement analysis-2 by gravity
(A) The gravity force increases from 0 kgf of point (C) to 2185 (2185=4685−2500) kgf of the bottom center. The gravity force of 1092.5 kgf acts on the average.
(B) The mass of the buoy is 4685 kg. F=mα. Therefore it is 1092.5(kgf)=4685(kg)*α
(C) α=0.233191 (kgf/kg)=0.233191*9.81(N/kg)=2.28760(m/sec^2)
(D) S=(½)*α*t^2, α=2.28760(m/sec^2), t 1 c= 1.11(sec), It is 1.11 sec from point (C) to point (D).
(E) S=(½)*2.28760(m/sec^2)*1.11 (sec)*1.11 (sec)=1.4092(m)=1409.2(mm)
(F) The vertical distance from point (C) to point (D) is 1409.2 mm, 1409 mm and 833 mm are numerical values that are very near. The buoy will stabilize in the neighborhood of the bottom center (D). It is impossible to get the stability point by the hand calculation.
Calculation of work and work rate at 2500 mm height, torque load 2500 kgf
1. Work by buoyancy
(A) The torque load is 2500 kgf, and the distance is 1389 mm Hmb).
(B) Therefore, the work by buoyancy: Wb=2500(kgf)*(1389/1000)(m)=3472.5 (kgf*m)
2. Work by gravity
(A) The torque load is 2500 kgf, and the distance is 1389 mm (Hmg).
(B) Therefore, the work by gravity: Wg=2500(kgf)*(1389/1000)(m)=3472.5 (kgf*m)
3. Total Work; Wt=3472.5 (kgf*m)+3472.5 (kgf*m)=6945.0 (kgf*m)
4. Work rate
(A) The total work rate is obtained by dividing the total work by the cycle of wave.
(B) Total work is 6945.0 kgf*m, and the cycle of the wave is 7.3 seconds.
(C) Total work rate: Wr=6945.0(kgf*m)/7.3(sec)=951.3698 (kgf*m/sec)
(D) 1(kgf*m/sec)=9.81(W)=0.00981(kW)
(E) Wr=951.3698*0.00981(kW)=9.33(kW)
The optimization of the torque load is a difficult problem. In the calculation, the torque load that becomes ½ of the height of waves obtains the maximum efficiency. However, the power generation buoy comes not to descend easily by gravity when the torque load becomes large.
The buoyancy that corresponds to the torque load 2800 kgf is 1244 mm. The buoyancy that corresponds to weight (4685 kgf) of the buoy is 2082 mm. The total load that adds torque force (2800 kgf) to weight (4685 kgf) of the buoy is 7485 kgf. The buoyancy that corresponds to the total load (7485 kg) is 3326 mm. The data of the torque load and the buoy assembly is shown in Table 5:
TABLE 5
Depth of
Depth of
Sinking
Torque
Sinking
Size of Buoy
Weight of
by Buoy
Load
by Torque
(mm)
Buoy (kgf
Weight (mm)
(kgf)
Load (mm)
1500 × 1500 × 6000
4685
2082
2800
1244
FIGS. 12A-12E show the image chart of the power generation buoy movement with torque load (2800 kgf) in 2500 mm height of ocean wave. When wave height (Wh) is 2500 mm, cycle of wave (t 0 ) is 7.30 sec. The pinion load from the dynamo torque load is the same as the frictional force for the buoy. The buoy does not rise when the buoyancy of the buoy does not reach 2800 kgf. Similarly the buoy does not descend if the buoyancy of the buoy does not lose 2800 kgf or more.
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 1244 mm. The depth of sinking by buoy weight and torque load (Hadd) is 3193 mm. The period of stop to balance point (t 1 a ) is calculated to be 1.69 sec. The period of stop in descent (t 1 b ) is calculated to be 1.68 sec. The period of descent (t 1 c ) is calculated to be 0.15 sec. The period of stop in rise (t 2 a ) is calculated to be 1.97 sec. The period of rise (t 2 b ) is calculated to be 1.83 sec. Gravity begins to act from the point (C). However, it is only 0.15 second to the bottom dead center. It is thought that the power generation buoy does not move when the torque load is 2800 kgf. In this case, it is impossible to get the answer by the hand calculation.
FIGS. 13A-13F show the image chart of the power generation buoy movement by torque load (2800 kgf) with freeing the load at the top dead center in 2500 mm height of ocean wave. When the wave height (Wh) is 2500 mm, the cycle of wave (t 0 ) is 7.30 sec. The period of stop to the balancing point (t 1 a ) is calculated to be 1.81 sec. The period of descending (t 1 b ) is calculated to be 1.84 sec. The period of stop in rise (t 2 a ) is calculated to be 1.83 sec. The period of rising (t 2 b ) is calculated to be 1.00 sec. The period of free rising (t 2 c ) to top dead center is calculated to be 0.82 sec. The moving height by gravity (Hmg) is calculated to be 2500 mm. The moving height by buoyancy (Hmb) is calculated to be 930 mm. The moving height in free rising (Hf) is calculated to be 1570 mm. The depth of sinking by buoy weight (Hb) is calculated to be 2082 mm. The depth of sinking by torque load (Htq) is calculated to be 1244 mm. The depth of sinking by buoy weight and torque load (Hadd) is calculated to be 3326 mm.
The power generation buoy is assumed to be stopping at the bottom dead center (A). The frictional force does not act on the object that is stopping. Similarly, the torque load does not act on the power generation buoy that is stopping. The power generation buoy does not rise until the buoyancy exceeds the torque load though the power generation buoy obtains the buoyancy as the wave rises.
Buoyancy acts from the point (A) to the point (D). The torque load and the buoyancy do the balance in point (B). When the power generation buoy exceeds the point (B), it rises with turning the dynamo. The torque load is freed a few seconds before the top dead center (D). Point (C) is the point to free the torque load. The weight of power generation buoy and the buoyancy do the balance when the torque load is freed at the point (D). The potential energy of the power generation buoy at the point (D) recovers greatly though power generation is not done from the point (C) to the point (D).
Gravity acts from the point (D) to the point (F). When gravity is larger than the torque loads, the power generation buoy goes down to the bottom dead center (F). The torque load and the buoyancy do the balance in point (E). When the power generation buoy exceeds the point (E), it descends with turning the dynamo. And, the weight of the power generation buoy and the buoyancy do the balance, and the power generation buoy stabilizes in neighborhood of the bottom dead center (F). The dynamo generates electricity from the point (D) to the point (F) by gravitation.
Analysis of movement at 2500 mm height, torque load (2800 kgf) with freeing the load at the top dead center
1. Movement analysis by buoyancy-1
(A) Buoyancy acts from the point (A) to the point (D).
(B) The torque load and the buoyancy do the balance in point (B).
(C) When the power generation buoy exceeds the point (B), it rises with turning the dynamo.
(D) The torque load is freed 0.82 seconds (t 2 c ) before the top dead center (D). Point (C) is the point to free the torque load.
(E) The weight of power generation buoy and the buoyancy do the balance because the torque load is freed.
(F) The potential energy of the power generation buoy at the point (D) recovers greatly though power generation is not done from the point (C) to the point (D).
2. Movement analysis by buoyancy-2
(A) The torque load is freed 0.82 seconds (t 2 c ) before the top dead center (D).
(B) The power generation buoy receives the force corresponding to the opened torque load (2500 kgf).
(C) It is 0.82 seconds (t 2 c ) from point (C) to point (D).
(D) The mass of the buoy is 4685 kg. F=mα. Therefore it is 2500(kgf)=4685(kg)*α
(E) α=0.53367 (kgf/kg)=0.53367*9.81(N/kg)=5.23535 (m/sec^2)
(F) S=(½)*α*t^2, α=5.23535(m/sec^2), t 2 c= 0.82(sec)
(G) S=(½)*5.23535(m/sec^2)*0.82(sec)*0.82(sec)=1.8033(m)=1803.3(mm)
(H) The rising distance from point (C) to point (D) is 1570 mm (Hmf). The calculated distance (1803 mm) is larger than 1570 mm (Hmf). Therefore the power generation buoy will stabilize in the neighborhood of the top dead center (D). It is impossible to get the stability point by the hand calculation.
3. Movement analysis-1 by gravity
(A) Gravity acts from the point (D) to the point (F).
(B) When gravity (4685 kgf) is larger than the torque loads (2800 kgf), the power generation buoy goes down to the bottom dead center (F).
(C) The torque load and the buoyancy do the balance in point (E).
(D) When the power generation buoy exceeds the point (E), it descends with turning the dynamo.
(E) The weight of the power generation buoy and the buoyancy do the balance, and the power generation buoy stabilizes in neighborhood of the bottom dead center (F).
(F) The dynamo generates electricity from the point (D) to the point (F) by gravitation.
4. Movement analysis-2 by gravity
(A) The gravity force increases from 0 kgf of point (E) to 1885 (1885=4685−2800) kgf of the bottom center. The gravity force of 942.5 kgf acts on the average.
(B) The mass of the buoy is 4685 kg. F=mα. Therefore it is 942.5(kgf)=4685(kg)*α
(C) α=0.201174 (kgf/kg)=0.201174*9.81(N/kg)=1.973516(m/sec^2)
(D) S=(½)*α*t^2, α=1.973516(m/sec^2), t 1 b= 1.84(sec), It is 1.84 sec from point (E) to point (F).
(E) S=(½)*1.973516(m/sec^2)*1.84(sec)*1.84(sec)=3.3476(m)=3347.6(mm)
(F) The falling distance from point (E) to point (F) is 2500 mm (Hmg). The calculated distance (3347 mm) is larger than 2500 mm (Hmg). The buoy will stabilize in the neighborhood of the bottom dead center (F). It is impossible to get the stability point by the hand calculation.
Calculation of work and work rate at 2500 mm height, torque load (2800 kgf) with freeing the load at the top dead center
1. Work by buoyancy
(A) The torque load is 2800 kgf, and the distance is 930 mm (Hmb).
(B) The work by buoyancy: Wb=2800(kgf)*(930/1000)(m)=2604.0 (kgf*m)
2. Work by gravity
(A) The torque load is 2800 kgf, and the distance is 2500 mm (Hmg).
(B) The work by gravity: Wg=2800(kgf)*(2500/1000)(m)=7000.0 (kgf*m)
(c) Total Work; Wt=2604.0 (kgf*m)+7000.0 (kgf*m)=9604.0 (kgf*m)
3. Work rate
(A) The total work rate is obtained by dividing the total work by the cycle of wave.
(B) Total work is 9604.0(kgf*m), and the cycle of the wave is 7.30 sec (t 0 ).
(C) Total work rate: Wr=9604.0(kgf*m)/7.3(sec)=1315.6 (kgf*m/sec)
(D) 1(kgf*m/sec)=9.81(W)=0.00981(kW)
(E) Wr=1315.6*0.00981(kW)=12.90 (kW)
When the method of controlling in FIG. 13A-13F is used, the wave activated power generation can be driven by the most efficient torque load. The power generation ability by torque load 2500 kgf is 9.33 kW, and the power generation ability by torque load 2800 kgf is 12.90 kW. 12.90 kW is 1.38 times 9.33 kW. The torque load can be varied with the gearless transmission. If the clutch mechanism is used, the torque load can be easily made free. Both methods are the same in using the rack and pinion and gearless transmission.
The power generation buoy does not descend by gravity when the torque load becomes larger than the weight of the power generation buoy. At stormy weather, the power generation buoy can be stopped by this method.
Because the calculation becomes complex, the following calculations are calculated by the method of uniform torque load. Table 6 shows the forecast of the power generation ability calculated by the method of the uniform torque load as shown below:
TABLE 6
Amplitude of wave
Torque Load
Moving range
Work rate
(m)
(kgf)
(mm)
(kW)
1.5
1500
833
4.30
2.5
2500
1389
9.33
3.5
3300
2033
15.30
4.5
4700
0
0.00
The incidence of the wave in North Ocean is assumed as shown in Table 7:
TABLE 7
Amplitude of
Average
Incidence per year
Time/year
wave (m)
(m)
(%)
Days
(Hours)
1.0~2.0
1.5
10
36.5
876
2.0~3.0
2.5
40
140.0
3504
3.0~4.0
3.5
40
140.0
3504
4.0~more
4.5
10
36.5
876
Power generation (kW) in this sample unit is calculated as shown in Table 8:
TABLE 8
Ampli-
Range
tude
of
Efficiency
Amount of
of
Torque
Move-
Work
of
Rate of
Power
Wave
Load
ment
Rate
Dynamo
Incidence
Generation
(m)
(kgf)
(mm)
(kW)
(%)
(%)
(kW)
1.5
1500
833
4.30
80
10
0.34
2.5
2500
1389
9.33
80
40
2.99
3.5
3300
2033
15.30
80
40
4.80
4.5
4700
0
0.00
80
10
0.00
Amount of Power Generation (kW)
8.13
The amount of power generation (kW*h/year) during year in this sample wave activated power generation unit is calculated as shown in Table 9:
TABLE 9
Ampli-
Range
tude
of
Efficiency
Amount
of
Torque
Move-
Work
of
Time/
of Power
Wave
Load
ment
Rate
Dynamo
Year
Generation
(m)
(kgf)
(mm)
(kW)
(%)
(Hour)
(kW * h/year)
1.5
1500
833
4.30
80
876
3,013
2.5
2500
1389
9.33
80
3504
27,696
3.5
3300
2033
15.30
80
3504
42,889
4.5
4700
0
0.00
80
876
0
Amount of Power Generation (kW * h/year)
75,598
FIGS. 14A-14B show the image chart of the wave activated power generation module. The power generation unit ( 37 ) is composed of the shroud assembly ( 38 ), the power generation buoy ( 39 ), the dynamo assembly ( 40 a ) and the gearless transmission assembly ( 40 b ). Wave activated power generation module is produced by connecting a lot of power generation units to the straight line by rigid barge ( 41 ). In this example, the length of module (L 1 ) is about 36 meters. The width of module (W 1 ) is about 5.1 meters. The height of module (H 1 ) is about 6.3 meters.
The module is produced like the bar in which the rigidity is high. It is desirable that the power generation module is manufactured at the factory. Therefore, the longitudinal length is limited by the size of the manufacturing factory. The power generation module in this image chart is composed by 10 power generation units.
FIG. 15 shows the image chart of the wave activated power generation module inclined by the wave. The wavelength of the wave of 3.0 m in pulse height is 100 meters. The power generation module is inclined by the buoyancy of wave when the length of the power generation module is shorter than that of wavelength. It is not preferable that the length of the power generation module is shorter than the wavelength of the wave. In this sample chart, the length of module (L 1 ) is 36 meters. The inclined angle (An) is 4.0 degrees.
FIGS. 16A and 16B show the image chart of long size wave activated power generation module. The long size wave activated power generation module is a combined one of two power generation modules. The length of single module (L 1 ) is 36 meters. And the (L 2 ) length of double module (L 2 ) is 72 meters. The long size power generation module in the sample chart has 20 power generation units ( 43 ). Rigid barges ( 42 ) support both sides of power generation module. The power generation units ( 43 ) is composed of shroud assembly ( 45 ) and power generation buoy ( 44 ). The power generation buoy ( 44 ) moves up and down with ocean wave inside the shroud assembly ( 45 ).
It is not realistic to manufacture 100 m in length power generation module in one unit. Two power generation modules of 36 m in length are connected, and the long size power generation module is 72 m in length. The long size power generation module will not be inclined greatly by 100 m wavelengths.
FIG. 17 shows the image chart of the tension buoy and dumping weight for power generation module. Long size wave activated power generation module ( 46 ) is a combined one of two power generation modules. Dumping weight ( 50 ) is hung down on the long size power generation module ( 46 ). Tension buoy ( 47 ) is floating on the sea and is connected to foundation block ( 52 ) buried in the bottom of the sea with connecting cable ( 51 ). The connecting cable ( 51 ) always connects the tension buoy ( 47 ) and the foundation block ( 52 ) with constant tension. The constant tension is adjusted by tension spring ( 49 ) and cable drum ( 48 ).
In rack and pinion method, the power generation energy is obtained from the relative movement of shroud assembly and power generation buoy. The power generation buoy always synchronizes with the wave. When the shroud assembly is floating on the sea, it is inevitable to move up and down by the wave. The power generation efficiency worsens when the shroud assembly and the power generation buoy synchronize at the same time. It is necessary to restrain the shroud assembly when we adopt the rack and pinion method in practical use.
It is easy to connect the shroud assembly to the foundation block buried in bottom of the sea with cable. However, this method has some faults. There are a flood tide and an ebb tide in the sea. The cable loosens at the ebb tide when the length of the cable is matched to the surface of the sea of the flood tide. Oppositely, the cable is cut by the tension at the flood tide when the length of the cable is matched to the surface of the sea of the ebb tide. Moreover, the height of the wave is not constant.
The power generation energy is obtained from the relative movement between the shroud assembly and the power generation buoy. It is useless work to manage the absolute position of the shroud assembly. The purpose can be achieved by shifting the phase of movement. Seawater has the viscosity. The phase of the buoy and the shroud assembly shifts by installing the dumping weight to the power generation module.
However, the power generation module should be connected to the bottom of the sea with cable. Otherwise, the power generation module drifts by the wave. A pair of tension buoy is installed at both ends of the power generation module. The tension buoy is connected to the foundation block in the bottom of the sea, and is floating on the sea. In the tension buoy, there is a mechanism that constantly controls the cable tension. The tension mechanisms are composed of the motor drum that winds up the cable and the tension spring that gives cable the tension. The magnitude of the tension is calculated from the buoyancy of the barge. The cable becomes long by the control program at high water. Oppositely, the cable shortens at low water. At stormy weather, the cable tension in leeward is freed. Though the power generation efficiency of the power generation module deteriorates, the power generation module is prevented being damaged.
FIG. 18 shows the image chart of the wave activated power generation barge. The wave activated power generation barge is composed of a lot of long size power generation modules ( 53 ) connected with a lot of tying cables ( 55 ). A pair of tension buoy ( 54 ) is installed at both ends of the long size power generation module ( 53 ). In this sample chart, the length of barge (Lb) is 215 meters. And the width of barge (Wb) is 84 meters.
The wave activated power generation barge in sample chart is composed of 20 power generation modules and is composed of 400 power generation units. The barge is side by side connected by a lot of tying cables. The wave activated power generation barge is produced like a carpet with high flexibility. Each power generation module is almost independent. The wave activated power generation barge is constructed on open sea. There is little limitation in the length of barge.
FIG. 19 shows the image chart of maintenance of the wave activated power generation barge. The wave activated power generation barge is composed of a lot of power generation modules ( 56 ) and is maintained by exchanging old module for new module. Each module ( 56 ) can be removed in an arbitrary part. The tension buoy ( 57 ) cut off from the power generation module ( 56 ) is floating on the sea. The power generation module ( 56 ) is maintained at the factory.
FIG. 20 shows the image chart of power generation farm. The length of power generation farm (Lf) is 1000 meters. The length of power generation barge (Lb) is 215 meters. The margin space length between power generation barges (Lms) is 45 meter. The width of power generation farm (Wf) is 500 meters. The width of power generation barge (Wb) is 84 meters. The margin space width between power generation barges (Wms) is 116 meters. The power generation barge is composed of 400 power generation units. There will be 12 barges arranged in the area of 500 m×1000 m.
Ability of power generation in this sample wave activated power generation unit is calculated as shown in Table 10:
TABLE 10
1 module
1 barge
12 barges
Generation power unit
20
400
4,800
Area (m)
84 × 5
84 × 215
500 × 1000
Power generation (kW)
163
3,252
39,024
Ability of power
1,511,960
30,239,200
362,870,400
generation (kW*h/year)
The wave activated power generation is one of the steadiest power generation methods by natural energy. It is characterized by its large amount of energy. The energy for each area is 20-30 times of photovoltaic generation energy and is five times or more the force of the wind. It is said that the wave activated power generation can generate 30,000 kW in the area of 1K square meters. The sample power generation farm, in which 12 barges are arranged in the area of 500 m×1000 m, is calculated to generate 39,024 kW. And, the ability of power generation per year is calculated to be 362,870,400 kW*h/year. The power generation cost after the equipment cost is redeemed is only maintenance cost. The wave activated power generation will become a cheap, safe, permanent energy source.
It will be appreciated that modifications may be made in the present invention. The usage field of FRP structure materials in this invention is not limited to power generation buoy. The power generation buoy of this invention stands vertically in seawater. Moreover, glass fiber FRP that is the material is not corroded with seawater. The square pillar structure of FRP is the best for the construction materials in the sea.
The spirit of this invention is achievement of an efficient wave activated power generation system. For that purpose, this invention developed the power generation buoy made of FRP, the rack and pinion mechanism and controlling system by gearless transmission. Accordingly, it should be understood that we intend to cover by the appended claims all modifications falling within the true spirit and scope of our invention.
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The present invention is directed to a wave activated power generation system that converts the vertical movement of one or more power generation buoys resulting from interaction with waves into energy producing gyrations via a rack and pinion mechanism. The square-shaped power generation buoys are manufactured from fiber-reinforced plastic material.
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The present invention relates to an arrangement for connecting or bridging adjacent cars of a high speed railway vehicle which is composed of an inflatable chamber bellows section which extends partially or entirely around the external structure of the cars.
In car bridging arrangements which have become known in the prior art, hollow rubber tori cushions are used which are not airtight and which are therefore aerodynamically disadvantageous due to the fact that the gap between adjacent cars is not provided with a covering which is flush with the outer surface of the cars.
Another type of arrangement known in the prior art relates to so-called concertina walls or bellows which also fail to provide a smooth outer surface and which are open at the bottom thereby permitting draft air, dirt, and substantial noise levels to penetrate.
The present invention is directed toward the provision of a car bridging arrangement which will overcome the aforementioned disadvantages and which may be automatically adjusted with respect to its stiffness relative to the respective requirements of travel of the vehicle at high speeds and through curves.
SUMMARY OF THE INVENTION
Briefly, the present invention may be defined as a system for joining adjacent cars of a high speed railway vehicle to provide an aerodynamically advantageous smooth outer surface therefor comprising inflatable chamber bellows means extending essentially about the outer structure of the vehicle between the ends of adjacent cars, said bellows means being structured to define internal pressure chamber means capable of being pressurized to effect inflation of the bellows means, fluid pressure source means for supplying fluid pressure to the chamber means, and a control system for controlling the supply of fluid pressure to the internal pressure chamber means from the fluid pressure source means. The fluid pressure source means of the invention may be the compressed air system of the vehicle itself or the fluid pressure may be supplied from a separate air compressor. The internal pressure chamber means of the bellows means may comprise a single chamber or multiple chambers, and the inflation pressure thereof may be controlled in a stepless manner or in a step-by-step manner.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an end view of a car structure having the hollow chamber bellows section of the present invention attached thereto;
FIG. 2 is a sectional view taken along the line A--A of FIG. 1;
FIG. 2a is a cross-sectional view taken through a multiple chamber bellows section with fastening bulges;
FIG. 3 is a schematic block diagram of a first embodiment for an automatic control system for controlling the internal pressure of the bellows section;
FIG. 4 is a schematic block diagram of a second embodiment of the internal pressure control system of the present invention wherein a multiple chamber bellows system is provided;
FIG. 5 is a sectional view of a multiple chamber section with variable compressed air supply;
FIG. 6 is a block diagram of an embodiment of the invention with analog control;
FIG. 7 is a schematic illustration of the construction according to FIG. 6;
FIG. 8 is a schematic block diagram of an analog control system with additional separate control of a first chamber of the bellows system;
FIG. 9 is a schematic illustration of the structure according to FIG. 8;
FIG. 10 is a schematic block diagram of an embodiment utilizing a compressor;
FIG. 11 is a schematic block diagram of an analog converter system with an integrated impedance converter; and
FIG. 12 is a schematic block diagram of an analog converter system having an integrated electronic circuit for discrete operation of the input signal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein similar reference numerals are used to identify like parts throughout the various figures thereof, there is shown, particularly in FIGS. 1 and 2, a transition portion formed between a pair of adjacent railway cars which are coupled together. As indicated in the drawings, a space or gap 11 is formed between a pair of adjacent cars 12 and the space must be bridged by appropriate means. As previously mentioned herein, this space has in the past either been left free or it has been closed laterally and at the top thereof by means of devices such as hollow rubber tori or concertina walls. No sealing has been provided at the bottom of the space so that in conventional systems, not only does substantial noise penetrate the interior of the vehicle during travel, but also dust and water may also create problems. Embodiments such as these performed in accordance with the prior art have been found unacceptable in high speed vehicles because they result in excessive aerodynamic resistance.
The present invention is directed toward elimination of these disadvantages and with the invention there is provided a single-chamber or multiple-chamber hollow bellows section 10 having a fastening bulge 15 which is arranged in a guide 12a at the outer contour of each of the cars 12. A single-chamber hollow bellows section may be sufficient under certain circumstances. However, in the embodiment illustrated in FIG. 2a there is shown an arrangement comprising multiple chambers.
In the embodiment of FIG. 2a, the multiple hollow chamber bellows section 10 is formed with a plurality of air chambers 16 and with a first chamber K1. These chambers are arranged so as to be automatically controlled by a compressed air system of the vehicle itself so that the stiffness of the bellows section may be adjusted to the respective high speed travel and to travel around curves.
For this purpose, there is shown in FIG. 3 an embodiment of a control system in accordance with the present invention. An existing compressed air line 13 is provided in which a pressure of 6 bar prevails and which is connected through a filter 13a to a pressure regulator 17 which is in communication through a compressed air line 13b with the multiple-chamber bellows section 10 and with the chamber K1. In the line 13b there is connected an electropneumatic position regulator 21 with a pneumatic rotary drive 21a and with a manometer regulator 21b by means of which an automatic control of the internal pressure of the air chambers is performed. An additional control circuit can be arranged in this control system for separate control of the air pressure in the chamber K1 which will ensure constant pressure in the chamber K1 for supporting a connection with the fastening bulge 15 which may comprise a screw connection or for contact pressure of an attachment wire such as an attachment wire 15a. For this purpose a particular regulator 17a with, for example, three bars and a 3/2-way solenoid valve 18a are provided which act directly onto the chamber K1.
FIG. 4 shows an embodiment wherein the internal pressure of each individual chamber 16 in the bellows section 10 may be variably adjusted. Additionally, in the case of the embodiment of FIG. 4, a filter 13a is connected to the compressed air line 13 of the vehicle, a pressure regulator 17 with a multiple-way valve being connected after the filter 13a for each chamber 16 and K1. The valve is, for example, a 2/2-way solenoid valve. An additional control of the air pressure for maintaining the pressure in chamber K1 constant is readily also possible in this case. This control circuit is identified with the reference numeral 30.
An analog control circuit of another embodiment which is illustrated in FIGS. 6 and 7 is identified with reference numeral 40. A speed pressure converter 41 operating in the range between 0 to 2 bars is connected in the compressed air line of the vehicle having a pressure of 6 bars. The figures of the drawing illustrate the features of the invention so that further detailed explanation is considered unnecessary.
FIGS. 8 and 9 show an embodiment which is essentially based upon the arrangement depicted in FIGS. 6 and 7 and which is provided only with an additional control circuit 42 for the separate constant pressure control of the chamber K1 of the multiple-chamber hollow section 10. A pressure reducing valve operating, for example, in the range of 2 bars is connected in the line 43 leading directly from the compressed air line 13 of the vehicle to the chamber K1 so that a constant pressure is always maintained in K1.
As shown in FIGS. 6 and 7, the automatic control of the other section chambers 16 is effected by a speed pressure converter 41. Again, with regard to this aspect of the invention, the drawing makes further explanation superfluous.
FIG. 10 shows an embodiment wherein the compressed air line of the vehicle is not utilized and a compressor 50 is used instead to supply the compressed air. For effecting control of the system, either a tachometer generator 52 or a brake control system are used to which a pulse generator 51 is assigned which is connected to a pressure regulator 53 and performs control of the air chamber 16. For applying constant pressure to the chamber K1, a direct line 54 with a pressure reducing valve 53b leads from the compressor 50 as well as another pressure regulator 53a which ensures that in those cases wherein the pressure exceeds the adjusted value, the excess pressure will be conducted into the atmosphere.
An analog control circuit in accordance with another embodiment of the invention is depicted in FIG. 11. An analog converter with an integrated impedance converter 61a is connected between the compressed air line of the vehicle having a pressure of 6 bars and the tachometer generator 51. The analog converter 61 converts a stepless input voltage from the tachometer generator 51 into a similarly stepless pressure in the multiple-chamber air bellows 16 in accordance with the speed of travel. In this embodiment, a pressure regulator 72 separately applies a continuous constant pressure of 3 bars to the chamber K1.
An analog control circuit in accordance with a further embodiment of the invention is shown in FIG. 12 with this embodiment differing from the arrangement in accordance with FIG. 11 in that, instead of an impedance converter, an electronic circuit 71 for providing a discrete formation of the input signal is used and wherein the pressure is generated in the bellows section 10 in several steps in accordance with the vehicle speed.
As a result of the proposed arrangements of the invention for a car bridging structure, a number of special advantages may be achieved. For example, substantial reduction in aerodynamic resistance will be effected due to the fact that the outer surface of the entire vehicle will be formed with a smooth, flush configuration. This will have a substantial influence upon energy consumption. Furthermore, great stability with respect to shape and air-tightness will be provided and a smooth outer surface may be achieved which will have an effect upon the sound insulation on the inner part of the cars and, thus, on the passenger compartments. As a result of the measures provided in accordance with the invention, the outer car bridging structure will have a stable and aerodynamic outer contour which will produce low friction forces during high speed travel and which will exhibit required flexibility during slow travel through curves.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
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An arrangement for bridging adjacent cars in high speed railway vehicles posed of an inflatable chamber bellows section which extends entirely or partially about the outer structure of the cars wherein the stiffness of the bellows section may be automatically adjusted to respective requirements of high speed travel and travel through curves in such a manner that the internal pressure in the chambers of the bellows section which is produced by inflating the section is controlled in a stepless manner or in individual steps by a control system supplied with fluid pressure through the compressed air system of the vehicle or from a compressor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the connection of a hollow sucker rod with a first and a second torque shoulder, and connecting elements with an axis, which are used to selectively rotate a rotary pump located deep down hole in an oil well from a drive head located at the surface of the oil well. The present invention comprises individual elements referred to herein as a “Hollow Sucker Rod” with at least a first end having a female thread and a “Connecting Element” which may be a separate “Nipple Connecting Element” with a pair of male threads or an integral male thread on a second, upset end of a Hollow Sucker Rod. In order to further optimize the stress distribution between the elements, frustro-conical, non-symmetrical threads with a differential diametral taper and two torque shoulders are used. The primary shoulder is located on the rod end and the secondary shoulder is located on the rod base. The hollow sucker rod and connecting element are dimensioned to obtain high operation torque, good fatigue resistance, good resistance to over torque and a surprising resistance to storing reactive torque, which minimizes dangerous backspin when power to the sucker rod string is interrupted.
[0003] 2. Description of the Related Art
[0004] Non-surging oil well extraction is normally achieved by means of pumping systems. The most common system uses an alternating pump located at the bottom of the well driven by a sucker rod string that connects the bottom of the well with the surface, where an alternating pumping machine to drive the string up and down is located. The sucker rods in the prior art, therefore, were designed originally to simply reciprocate up and down, and were are manufactured to API Specification 11B using solid steel bars with an upset end and a threaded end, each thread being of solid cylindrical section. The rods typically were connected one with the other by means of a cylindrical threaded coupling. More efficient pumping is performed when an oil extracting progressive cavity pump (PCP), or like rotary down hole pump is used. Among other advantages, PCP pumping of oil allows for higher oil extraction rates, reduced fatigue loads, reduction in wear on the inside of production tubing, and the ability to pump high viscosity and high solids component oils. PCP pumps are installed at the bottom of the well and driven from the surface by an electric motor connected to a speed-reducing gearbox by means of a string of torque transmitting rods. Traditionally standard API sucker rods are used to drive PCP pumps notwithstanding the fact that these rods have not been designed to transmit torsional loads. The transmission of torque by means of conventional sucker rod strings presents the following disadvantages, i) low torque transmitting capacity, ii) high backspin iii) low resistance to overtorque, iv) big stiffness differential between the connection and the rod body, all factors that enhance the possibility of fatigue failures. The reason for rupture on this type of conventional rod is failure due to fatigue in the junction zone of the head of the rod with the body of same due to the difference in structural rigidity between both parts—the body of the rod and the head of the rod.
[0005] For a given cross sectional area, torque transmission by a hollow rod with an annular cross section is more efficient than with a narrower, solid circular cross section. With the above mentioned concept in mind the prior art includes a hollow sucker rod that simply uses a standard API external cylindrical thread on a first end connector and an internal API thread on a second end connector, each connector being butt welded to a pipe body, which creates significant and abrupt change in section between the pipe body and each connection body. (See, for example, EP 0145154 and JP04315605). The problem of sucker rod string backspin, and details of a drive head at the surface of an oil well and a rotary pump deep down hole in an oil well operation, which is the specific field of invention being addressed herein, can be found in Mills (U.S. Pat. No. 5,551,510), which is incorporated herein by reference.
[0006] The present invention is both specific to unique problems faced by a Hollow Sucker Rod, and categorically is different from threaded Drill Pipe connections in the following:
1) Drill pipe connections do not have severe constraints on the external dimensions of the pipe body and on the connection size. A hollow sucker rod external diameter is restricted to the internal diameter of the tubing, and typically is 2⅞″ and 3½″. 2) The flow speed of fluid that is conducted in the annular space between a hollow sucker rod and the inside of the well tubing is very limited, unlike the situation for a drill pipe.
[0009] Various thread and shoulder arrangements are discussed in the prior art with respect to joining together oil well drill pipe, well casing and tubing. See, for example, Pfeiffer et al. (U.S. Pat. No. 4,955,644); Carstenson (U.S. Pat. No. 5,895,079), Gandy (U.S. Pat. No. 5,906,400), Mithoff (U.S. Pat. No. 262,086), Blose (U.S. Pat. No. 4,600,225), Watts (U.S. Pat. Nos. 5,427,418; 4,813,717; 4,750,761), Shock et al. (U.S. Pat. No. 6,030,004), and Hardy et al. (U.S. Pat. No. 3,054,628). The Watts patents imply that a pre-1986 API standard for strings of casing and tubing was a straight thread, with a turned down collar and that his improvement comprised a flush joint tubular connection with both tapered threads and a shoulder torque. Watts also refer to API standards for tubing and casing where triangular and buttress threads can be used with a torque shoulder. The 1990 patent to Pfeiffer et al, and the 1996 patent to Carstensen et al, in contrast, refer to a more current API standard (truncated triangular thread, connection using a torque shoulder) for strings of casing and tubing that appears to involve frusto-conical threads and shoulders. Carstensen et al at col 7, line 9+ include a discussion about how a particular conical gradient and length of a thread defines stress distribution results. Likewise, Pfeiffer et al at col 2, line 51+ say their threads are tapered and according to “API standards” with their improvement essentially only having to do with transitional dimensions. Hence, the problem addressed by Pfeiffer is an assembly of drill pipe sections where it apparently was critical to use a compatible and standard non-differential thread according to API standards, and also with no incomplete threads and no torque shoulder specification. The main features of the Pfeiffer thread appear to be symmetrical, truncated triangle threads (between 4 and 6 threads per inch, 60° flank angle) and a thread height that is the same for the male and female thread (between 1.42 and 3.75 mm). Also, there is identical nominal taper on male and female ends (between 0.125 and 0.25). Shock et al. illustrate a particular tool joint for drill pipe where the unexpected advantage for drill pipe applications derives from tapered threads that significantly must be very coarse (3½ threads per inch) and have equal angle (75°) thread flanks and elliptical root surfaces.
[0010] Prior art connections for drillpipe, casing and tubing which employ some manner of a second torque shoulder are shown: Schock (U.S. Pat. No. 6,030,004); Hallez (U.S. Pat. No. 5,169,183); Hori (U.S. Pat. No. 5,549,336); Hall (U.S. Pat. No. 4,548,431); Olivier (U.S. Pat. No. 6,485,063B1); Blose (U.S. Pat. No. 4,192,533); and Stone (U.S. Pat. No. 1,932,427).
[0011] Table 1, below, the principal characteristics of such prior art connections are compared with a Hollow Sucker Rod with Second Torque Shoulder according to the present invention, and also compared to Hollow Sucker Rods with a single torque shoulder as illustrated by SIDERCA (U.S. Pat. No. 6,764,108).
TABLE 1 Principal Characteristics of Hollow Sucker Rods and others Connections with Second Torque Shoulder Thread Diametral Taper in/ Threads in on Diameter Thread height Thread Load and Stab Product Thread Shape per inch (Angle) (mm) Completeness Flank angle [°] (*1) Hollow Rod Non symmetrical 8 Differential N: 1.016 N: Complete LF: 4 with one truncated trapezoid N: 0.0976 (2.79°) P: 1.016 P: Complete and SF: 9 torque P: 0.1 (2.86°) Incomplete shoulder (U.S. Pat. No. 6764108) Hollow Rod Non symmetrical 6-8 Differential N: 1.016 N: Complete LF: 4 with two truncated trapezoid N: 0.0976 (2.79°) P: 1.016 P: Complete and SF: 9 torque P: 0.1 (2.86°) Incomplete shoulder Connections with two or three torque shoulders Schock Pat. Symmetrical 3½ Non Differential N: ≧2.54 N: Complete LF: 32.5/42.5 (U.S. Pat. No. 6030004) truncated trapezoid (API-drill pipe) P: ≧2.54 P: Complete SF: 32.5/42.5 Hallez Pat. Symmetrical 6-8 Non Differential NA N: Complete NA (U.S. Pat. No. 5169183) truncated trapezoid 3-13* N & P: 0.035 a Maybe similar to P: Complete 0.105 (1 a 3°) API Hori Pat. Symmetrical 4-6 Non Differential N & P: 1.42-3.75 N & P: Complete LF & SF: 30 (U.S. Pat. No. 5549336) truncated triangle (API-Drill (API-drill pipe) (API-drill pipe) (API-drill pipe) (API-drill (API-Drill pipe) pipe) pipe) Hall Pat. Symmetrical 4-6 Non Differential N & P: 1.42-3.75 N & P: Complete LF & SF: 30 (U.S. Pat. No. 4548431) truncated triangle (API-Drill (API-drill pipe) (API-drill pipe) (API-drill pipe) (API-drill (API-Drill pipe) pipe) pipe) Olivier Pat. Non symmetrical NA Non Differential N: h1 N: Complete and LF: −15 (U.S. Pat. No. 6485063B1) truncated trapezoid N & P: 0.33 (9.37°) P: h2 Incomplete SF: 20 h1 > h2 P: Complete |SF| > |LF| h1 − h2 = 0.05 mm Blose Pat. Non symmetrical NA Non Differential NA N: Complete LF: −15 (U.S. Pat. No. 4192533) truncated trapezoid P: Complete SF: 30 |SF| > |LF| Stone Pat. Symmetrical NA Non Differential NA N: Complete NA (U.S. Pat. No. 1932427) truncated trapezoid N & P: 0.083 (2.5°) P: Complete (Modified Acme) Union Torque N o of Internal shoulder Torque Clearance Principal Product bore form angle [°] shoulder (mm) (*3) Loads Observations Hollow Rod Conical & 7 1 1st. TS: 0.4 a Torsion- For hollow sucker rod with one Cylindrical 1.1 Tension- Patent granted in USA, torque Bending France and Argentina shoulder (U.S. Pat. No. 6764108) Hollow Rod Conical & 7 2 1st. TS: 0.4 a Torsion- For hollow sucker rod with two Cylindrical 2.5 Tension- Present invention torque 2nd. TS: 0.4 a Bending shoulder 2.53 Connections with two or three torque shoulders Schock Pat. Cylindrical 0 2 NA Torsion- For drill pipe (U.S. Pat. No. 6030004) (Maybe 1st. TS Tension- N: Stress relief Groove & 2nd. TS: 0) Bending Thread: elliptical root surfaces Hallez Pat. Cylindrical <2-6 2 NA Torsion- For drill pipe (U.S. Pat. No. 5169183) (Maybe 1st. TS Tension- N: Discharge groove & 2nd. TS: 0) Bending Thread: Triangular, Trapezoidal or round Hori Pat. Cylindrical 0 2 NA (Maybe Torsion- For drill pipe (U.S. Pat. No. 5549336) (API-drill 1st. TS: 0) Tension- Interchangeable with API pipe) 2nd. TS: 0.1 a Bending drill pipe 0.5 Hall Pat. Cylindrical 0 2 1st. TS: c1 Torsion- For drill pipe (U.S. Pat. No. 4548431) (API-drill 2nd. TS: c2 Tension- 2nd torque shoulder was pipe) c1 ≦ c2 Bending only made for over torque N&P: Relief grooves Olivier Pat. Cylindrical 0 2 NA Torsion- For drill string (U.S. Pat. No. 6485063B1) (Maybe 1st. TS Tension- Thread: LF has S-Shape & 2nd. TS: 0) Bending TS: Curved Surface Thread: Buttress, API, ACME, etc. Blose Pat. Cylindrical 5 3 NA — For tubing, casing, (U.S. Pat. No. 4192533) linepipe and drillpipe Stone Pat. Cylindrical 1st. TS: 2 1st. TS: c1 — For drillpipe and casing (U.S. Pat. No. 1932427) 30 2nd. TS: c2 2nd. TS: c1 ≧ c2 −40 Nomenclature: N = Nipple P = Pipe C = Coupling NA = Not Applicable LF = Load Flank SF = Stab Flank TS: Torque shoulder (*1) Angle defined from a perpendicular to the pipe axis. (*3) Clearance between torque shoulder surfaces of pipe and nipple after the hand-tightened of the connection; 1st. TS: First torque shoulder or external torque shoulder; 2nd. TS: Second torque shoulder or internal torque shoulder
[0012]
TABLE 2
Principal Characteristics of Hollow Sucker Rods and others Connections with only one Torque Shoulder (U.S. Pat. No. 6764108)
Thread
Diametral Taper in/
Threads
in on Diameter
Thread height
Thread
Load and Stab
Product
Thread Shape
per inch
(Angle)
(mm)
Completeness
Flank angle [°] (*1)
Hollow Rod
Non symmetrical
8
Differential
N: 1.016
N: Complete
LF: 4
with one torque
truncated
N: 0.0976 (2.79°)
P: 1.016
P: Complete and
SF: 9
shoulder
trapezoid
P: 0.1 (2.86°)
Incomplete
(U.S. Pat. No. 6764108)
Hollow Rod
Non symmetrical
6-8
Differential
N: 1.016
N: Complete
LF: 4
with two torque
truncated
N: 0.0976 (2.79°)
P: 1.016
P: Complete and
SF: 9
shoulder
trapezoid
P: 0.1 (2.86°)
Incomplete
Connections with one Torque Shoulder
Pfeiffer Pat.
Symmetrical
4-6
Non Differential
N & P: 1.42-3.75
N & P: Complete
LF & SF: 30
truncated triangle
(ApI-drill pipe)
(API-drill pipe)
(API-drill pipe)
(API-drill
(API-Drill pipe)
pipe)
Watts Pat.
Symmetrical
(API-
Differential
Less than API
N: Complete
LF: ≦15
truncated triangle
Tubing)
P: Complete and
(API-Tubing)
Incomplete
Drill Pipe (API)
Symmetrical
4-6
Non Differential
N & P: 1.42-3.75
N & P: Complete
LF & SF: 30
truncated triangle
N & P: 0.125-0.25
Tubing API 8r
Symmetrical
10-6 (*2)
Non Differential
1.8
C: Complete
LF & SF:: 30
truncated triangle
C & P: .0625
P: Complete and
Incomplete
Casing API 8r
Symmetrical
8
Non Differential
1.8
C: Complete
LF & SF:: 30
truncated triangle
C & P: .0625
P: Complete and
Incomplete
Casing API
Non symmetrical
5
Non Differential
1.575
C: Complete
LF: 3
Buttress
truncated
C & P: .0625
P: Complete and
SF: 10
trapezoid
Incomplete
Casing API
Symmetrical
6
Non Differential
C: 1.52
C: Complete
LF: 6
Extreme Line
truncated
C & P: .0625
P: 1.35
P: Complete and
trapezoid
Incomplete
Union
Torque
N o of
External
Internal bore
shoulder
Torque
Surface of
Product
form
angle [°]
shoulder
Connection
Principal Loads
Observations
Hollow Rod
Conical &
7
1
Flush
Torsion-Tension-
For hollow sucker
with one torque
Cylindrical
Bending.
rod
shoulder
Patent granted in
(U.S. Pat. No. 6764108)
USA, France and
Argentina
Hollow Rod
Conical &
7
2
Flush
Torsion-Tension-
For hollow sucker
with two torque
Cylindrical
Bending
rod
shoulder
Present invention
Connections with one Torque Shoulder
Pfeiffer Pat.
Cylindrical
NA
1
Non Flush
Torsion-Tension-
For drillpipe
(API-drill
Bending.
pipe)
Watts Pat.
Cylindrical
—
1
Flush
Tension-
For tubing
Compression-
Internal Pressure-
External Pressure
Drill Pipe (API)
Cylindrical
0
1
Flush
Torsion-Tension-
For drillpipe
Bending.
Tubing API 8r
Cylindrical
NA
1
Non Flush
Tension-
For tubing
Compression-
Internal Pressure-
External Pressure
Casing API 8r
Cylindrical
NA
1
Non Flush
Tension-
For casing
Compression-
Internal Pressure-
External Pressure
Casing API
Cylindrical
NA
1
Non Flush
Tension-
For casing
Buttress
Compression-
Internal Pressure-
External Pressure
Casing API
Cylindrical
0
1
Non Flush
Tension-
For casing
Extreme Line
Compression-
Internal Pressure-
External Pressure
Nomenclature:
N = Nipple
P = Pipe
C = Coupling
NA = Not Applicable
LF = Load Flank
SF = Stab Flank
TS: Torque shoulder
(*1) Angle defined from a perpendicular to the pipe axis.
(*2) Non Upset Tubing 1.66″ to 3.5″: 10 threads per inch., 4″ and 4.5″: 8 threads per inch. Upset Tubing 1.66″ and 1.9″: 10 threads per inch, 2.325″ to 4.5″: 8 threads per inch.
[0013] Table 2, above, illustrates the principal characteristics of a hollow sucker connection with one torque shoulder, as compared to a hollow sucker rod with one torque shoulder. Another version of a single torque shoulder, with a second engagement surface that acts as a seal but does not transmit torque, is illustrated herein at FIGS. 13 and 14 .
[0014] However, the different problem of backspin inherent in the intermittent operation of a sucker rod string when driving a PCP pump is not apparently addressed in any of these references. The design of the invention was made with certain specific constraints and requirements in mind.
[0015] First, the minimum diameter of a tubing on the inside of which the Hollow Rods must operate corresponds to API 2⅞″ tubing (inner diameter=62 mm) and API 3½″ tubing (inner diameter=74.2 mm). The oil extraction flow rate must be up to 500 cubic meters per day, maximum oil flow speed must be 4 meters per second. The above-mentioned values strongly restrict the geometry of the rods under design. Second, to ensure a Hollow Sucker Rod with a high yield torque so that maximum torque is transmitted to the PCP pump without damage to the Hollow Sucker Rod string. Third, to minimize and distribute stresses in the threaded sections. This requirement is met by using a particular conical thread, differential taper, low thread height and a conical bore in the sections under the threads. Fourth, the Hollow Sucker Rod must have good fatigue resistance. Fifth, to ensure low backspin, and high resistance to axial loads. Sixth, ease of make up and break out (assembly of mating threaded parts) must be ensured, and is by a tapered thread. Seventh, to ensure high resistance to unscrewing of the Hollow Sucker Rod due to backspin, or the counter-rotation of a sucker rod string when driving motor stops running and the pump acts as a motor. Eighth, to ensure high resistance to jump out of the Hollow Sucker Rod string (Hollow Rod parting at the threaded sections) by means of adequate thread profile and reverse angle on the torque shoulder. Ninth, to minimize head loss of the fluids that occasionally can be pumped on the inside of the Hollow Sucker Rod through the added advantage of a conical bore on the nipple and the secondary torque shoulder. Tenth, to ensure connection sealabilty due to a sealing at both torque shoulders, and also due to diametrical interference at the threads. Eleventh, a thread profile designed so as to optimize pipe wall thickness usage. Twelfth, to eliminate use of the welds due to susceptibility of welds to fatigue damage, sulphide stress cracking damage and also the higher costs of manufacturing. Thirteenth, when a fluid flows through the interior of the rod with reasonable speed, it produces early wear of the nipple and rod in the area where they connect (overlap), hence, a seal was introduced by virtue of a secondary torque shoulder at each end of the nipple, which also ensures high resistance to an over torque of the connection. Fourteenth, to substantially increase the flow of fluid extracted, holes in the rod body were drilled to allow the fluid flowing through the interior of the rod.
[0016] A first object of the present invention is to provide an assembly of sucker pump rods and either separate threaded unions, or an integral union at the second end of each sucker rod, to activate PCP and like rotary type pumps, capable of transmitting greater torque than the solid pump rods described in the API 11 B Norm and also possessing good fatigue resistance, and improved resistance to over torque. Additionally, the present invention seeks to define a threaded union for hollow sucker rods that is significantly different from, and incompatible with, the standard for sucker rod assemblies as defined in the API 11 B Norm, yet still can easily be assembled. In fact the modified buttress thread is unique in that it is differential. For example, API Buttress Casing requires non-differential threads, with the taper for both a pipe and a coupling being 0.625 inches/inch of diameter. Likewise, API 8r casing and API 8r tubing both also require non-differential threads, with the taper for both a pipe and a coupling being 0.625 inches/inch of diameter. Still further, each of API Buttress Casing, API 8r casing and API 8r tubing do not employ any manner of torque shoulder, let alone first and second torque shoulder. For example, in Table 2 the connections show one torque shoulder.
[0017] A related object of the present invention is to provide an assembly of pump rods and unions with lesser tendency to uncoupling of the unions whenever “backspin” occurs, whether by accident or when intentionally provoked by the deactivation of the pump drive. The present invention surprisingly and significantly decreases the stored torsional energy in a sucker rod string. The stored energy in the string is inversely proportional to the diameter of the rod, and is directly proportional to the applied torque and the length of the string.
[0018] Another object of the invention is to provide for an assembly of sucker rods which are hollow and configured with a bore to permit passage of tools (sensors for control of the well) and/or allow interior circulation of fluids (injection of solvents and/or rust inhibitors).
[0019] The two torque shoulder embodiments disclosed herein have bigger yield torque than a hollow sucker rod with only one torque shoulder, as illustrated by U.S. Pat. No. 6,764,108.
[0020] The two torque shoulder, eighth and ninth embodiments disclosed herein have a yield torque of the connection that is up to 110 percent more than an otherwise corresponding hollow sucker rod with only one torque shoulder.
[0021] Still another object of the invention is to further optimize the stress distribution between the elements, by the combination of using frustro-conical, non-symmetrical threads with a differential diametral taper and two torque shoulders. The primary or first rod torque shoulder is located on rod end and the secondary or second rod torque shoulder is located on the rod base. The hollow sucker rod and connecting element are dimensioned to obtain high operation torque, good fatigue resistance, good resistance to over torque and a surprising resistance to storing reactive torque, which minimizes dangerous backspin when power to the sucker rod string is interrupted.
SUMMARY OF THE INVENTION
[0022] The present invention addresses the foregoing needs in the art by providing a new type of Hollow Sucker Rod consisting essentially of a pipe central section, with or without an upset, with at least one internal or female conical thread at a first end having a thread vanishing on the inside of the rod and a conical external torque shoulder. That first end is configured to engage a corresponding external or male thread that is differential and also to abut against a conical torque shoulder on either another rod with an externally threaded integral Connecting Element as its second end, or one of the shoulders between the external threads of a separate Nipple Connecting Element. If separate Nipple Connecting Elements are used, then the sucker rod second end is always the same as the first end. If separate Nipple Connecting Element are not used, then the sucker rod second end is configured with an upset end having a male conical thread adapted to engage the first end of another Hollow Sucker Rod.
[0023] A Nipple Connecting Element consists essentially of a central cylindrical section with a pair of conical external torque shoulders. The torque shoulders have a maximized mean diameter and cross-sectional area to resist storing reactive torque in the drive string. The nipple preferably also has a wall section that increases towards the torque shoulders from each free end to increase fatigue resistance. In order to further optimize the stress distribution between the elements, a specific type of thread with a differential taper is used. The overall configuration ensures high shear strength, lowered stress concentration a surprising resistance to storing reactive torque, which minimizes dangerous backspin when power to the sucker rod string is interrupted.
[0024] The Nipple Connecting Element member also has trapezoidal, non-symmetric male threads at each end or extreme, separated by a pair of shoulder engaging elements, but that male thread is differential as to the diametral taper of the female thread on at least the first end of a Hollow Sucker Rod. The threaded nipple and the rod can be joined with or without discontinuity of outer diameter. The ratio of the diameter of the union to the diameter of the rod may between 1 without discontinuity of diameters, to a maximum of 1.5. In this manner the mean value of the external diameter throughout the length of the string will always be greater to that of a solid rod with equivalent cross-sectional area mated to a conventional union means. Hence, for a given length of string and cross-sectional area, resistance to “backspin” will be greater in an assembly according to the present invention. The dimensions of the nipple also may be defined with a conical inner bore proximate the length of each threaded extreme, to further enhance an homogenous distribution of tensions throughout the length of each thread and in the central body portion of the Nipple Connecting Element. In this way it is possible to obtain a desired ratio of diameters of the threaded ending of the nipple with respect to the internal diameter, and a ratio of outside diameter of the nipple with respect to the internal diameter and an additional ratio between the external diameter of the nipple and the diameter of each threaded extreme.
[0025] In a first object of the present invention, the essential characteristic of a Hollow Sucker Rod is at least a first end of a tubular element threaded with a conical female thread which is configured as a Modified Buttress or SEC thread and vanishes on the inside of the tubular element, in combination with a conical frontal surface at an angle between 75° and 90°, known as a torque shoulder. The external diameter of the HSR 48x6 External Flush and the HSR 42x5 Upset embodiments comprise a tubular rod body element away from the ends being 48.8 mm or 42 mm and the external diameter of the tubular element in the upset end of a 42 mm rod being 50 mm. These dimensions are critical since sucker rods of that maximum diameter can fit within standard 2⅞ inch tubing (62 mm inside diameter). For 3½ inch tubing (74.2 mm inside diameter) the HSR 48x6 Upset, with a diameter at the upset end of 60.6 mm, can be used for maximum advantage. The thread shape is trapezoidal and non-symmetric, with a Diametrical taper in the threaded section. The Length of threads on at least the first end of the tubular element are incomplete due to vanishing of thread on the inside of the tubular element. There is an 83° angle (Beta) of the conical surface in the torque shoulder as shown in FIG. 2A . There are radii at the inner and outer tips of the torque shoulder. At the end of the threaded section a short cylindrical section on the inside of the threaded area transitions the threaded area to the bore of the tubular element.
[0026] In a first object of the present invention, the essential characteristic of a Nipple Connecting Element is a differential thread engagement on either side of a central section that is externally cylindrical with a larger cross-sectional area in the vicinity of the torque shoulder for surprisingly improved fatigue resistance. At either side of this central section external torque shoulders are located to mate with a torque shoulder on a first end of a Hollow Sucker Rod. The mean diameter and total cross-sectional area of the torque shoulder is maximized, to allow maximum torque handling.
[0027] In addition, either end of the nipple externally threaded is conical so to create a larger cross-sectional area in the vicinity of the torque shoulder and thereby surprisingly improve fatigue resistance. To achieve this advantage a narrowing conical inner bore starts proximate the free end of each threaded extreme and thereby defines an increasing wall thickness cross-section towards the central section of the nipple. The external diameter of the central section of the nipple is 50 mm or 60.6 mm and that central section may have a pair of machined diametrically opposite flat surfaces, to be engaged by a wrench during connection make up. The thread is a Modified Buttress thread, which creates a differential due to slightly different amounts of diametral thread taper on the rod and on the nipple. The thread shape also is trapezoidal and non-symmetric. All threads on the nipple are complete. A pair of conical surfaces act as torque shoulders with a conical frontal surface at an angle between 75° and 90°. There are radii at tips of the torque shoulder, both at an inner corner and an outer corner. Preferably, conical bores under each threaded section of the nipple are connected by a cylindrical bore to create a larger cross-sectional area in the immediate vicinity of the torque shoulder in order to surprisingly improve fatigue resistance.
[0028] The thread taper on the nipple and on the rod is slightly different (Differential Taper) to ensure optimal stress distribution. When the connection is made up the corresponding torque shoulders on the rod and on the nipple bear against each other so that a seal is obtained that precludes the seepage of pressurized fluids from the outside of the connection to the inside of said and vice-versa. This sealing effect is enhanced by the diametrical interference between the two mating threaded sections on the first end of the rod and on the nipple.
[0029] A fluid flowing through the interior of the rod with reasonable speed tends produce early wear of the nipple and rod in the area where they connect (overlap). This phenomenon can be attributed to the existence of an “stagnation area” where the fluids remains almost still (low velocity). To overcome that corrosion problem the invention includes modifications so that the “stagnation zone” does not exist any more and the fluid flows smoothly and with little turbulence. It is important to note that these modifications are small so that they do not alter significantly the stress distribution in the connection or the performance of the nipple.
[0030] For use with various of the embodiments, there is taught an improvement to achieve the objective of a substantially increased flow of fluid extracted, through a further modification to a hollow sucker rod by drilling a series of holes, according to Configurations 1 2 or 3, in the rod at the two extremes of the string, i.e., at the ground level and at the bottom of the well.
[0031] In the eighth and ninth embodiments, a pair of torque shoulders are used in combination with high diametrical interference on the threaded sections and high material mechanical properties.
[0032] The eighth and ninth embodiments represent a significant change from the earlier embodiments. A second torque shoulder and a bigger diametrical interference at the threads are introduced. The second torque shoulder is inside of the rod, near the end of the internal or female threads. The dimensions result from a detailed stress analysis performed to improve significantly its torque resistance. The second torque shoulder serves as a seal in manner of the seventh embodiment, but adds significant additional advantages. The preferred angle of the conical surface in the second torque shoulder is 83 degrees.
[0033] The stress distribution on the nipple and the rod allows a high torque transmitting capacity, a good fatigue resistance and a good resistance to over torque. Torque load to yielding on the eighth embodiment is 2100 lbft (110 percent more than the seventh embodiment, an HR 48x6 External Flush with only one Torque Shoulder).
[0034] The rod dimensions were obtained from a stress analysis. The nominal diameter of the thread also was obtained from a stress analysis. The thread is mainly complete, except for a small length, and is different from the first through the seventh embodiments, which have only one torque shoulder. The diametrical taper in the threaded section is similar to the seventh embodiment.
[0035] The end of the nipple works as a second torque shoulder of the union. The thickness of the end of the nipple is between 3.8 mm-4.2 mm, and the bore of the nipple is conical in each extreme. The preferred angle is between 3° 54′-9° 7′. The total length of the nipple is similar to the seventh embodiment.
[0036] The connection has diametrical interference between the two mating threaded sections on the rod and on the nipple. When the connection is hand-tightened, the clearance between torque shoulder surfaces of rod and nipple are:
[0037] c1=0.4-2.5 mm for primary torque shoulder and c2=0.4-2.8 mm for secondary torque shoulder, where c2≧c1 and 0 mm≦(c2-c1)≦0.3 mm.
[0038] The second torque shoulder is moderately loaded and definitely transmits torque. It also serves as an effective seal and promotes smooth flowing of the fluid.
[0039] Hence the eighth and ninth embodiments suprisingly exhibit high torque transmitting capacity and a high resistance to over torque, as well as good erosion-corrosion resistance when a fluid flows though the inside of the pipe. When a fluid flows though the inside of the pipe, it does it smoothly and presents little turbulence. The preferred ratios for dimensions in the two torque shoulder invention are DHT1/DEN between 0.7 and 0.9; DIN1/DEN between 0.20 and 0.60; DIN1/DHT1 between 0.3 and 0.70; DEVU/DEV between 1.0 and 1.5; DIFR1/DHT1 between 1.0 and 1.1; DIFR1/DEVU between 0.75 and 0.95; DIVU/DIFR2 between 0.65 and 0.90; DIN2/DHT2 between 0.67 and 0.92; DEVU/DIVU between 0.40 and 0.70; DIFR2/DEVU between 0.55 and 0.85; and DIN1/DIN2 between 0.4 and 1.0.
[0040] A better understanding of these and other objects, features, and advantages of the present invention may be had by reference to the drawings and to the accompanying description, in which there are illustrated and described different embodiments of the invention. The embodiments are considered exemplary of parts of useful assembly possibilities, since various of the illustrated male ends will successfully mate with the illustrated female ends.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIGS. 1 A and 1 B, represent a Prior Art configuration of a conventional solid sucker rod as established in the API 11 B Norm specification.
[0042] FIGS. 2A, 2B and 2 C respectively represent general configurations of a Hollow Sucker Rod first end, a Nipple Connecting Element, and an assembly of both elements according to a first embodiment of the invention, with a constant outer diameter.
[0043] FIG. 3A represents a general configuration of the assembly of a Hollow Sucker Rod having first and second female threaded ends and a Nipple Connecting Element according to a second embodiment of the invention, with an upset end, or an enlarged outer diameter.
[0044] FIG. 3B represents a general configuration of the assembly of a Hollow Sucker Rod having a first female threaded end and a second end with a male threaded end according to a third embodiment of the invention, with a constant outer diameter.
[0045] FIGS. 4A, 4B and 4 C respectively represent an axial section view, a shoulder detail view and a cross-section view along Line 4 C- 4 C of a Nipple Connecting Element having first and second male threaded ends, according to a fourth embodiment of the invention, styled Hollow Rod 48x6 External Flush.
[0046] FIGS. 5A and 5B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod having a first female threaded end, according to the fourth embodiment of the invention.
[0047] FIGS. 6A, 6B and 6 C respectively represent an axial section view, a cross-section view along Line 6 B- 6 B and a shoulder detail view of a Nipple Connecting Element having first and second male threaded ends, according to a fifth embodiment of the invention, styled Hollow Rod 42x5 External Upset.
[0048] FIGS. 7A and 7B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod having a first female threaded end, according to the fifth embodiment of the invention.
[0049] FIGS. 8A, 8B and 8 C respectively represent an axial section view, a shoulder detail view and a cross-section view along Line 8 B- 8 B of a Nipple Connecting Element having first and second male threaded ends, according to a sixth embodiment of the invention, styled Hollow Rod 48.8x6 External Upset.
[0050] FIGS. 9A and 9B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod having a first female threaded end, that is upset, according to the sixth embodiment of the invention.
[0051] FIG. 10A represents an axial section view and dimension detail view of a first female threaded end on a Hollow Sucker Rod showing the configuration of a trapezoidal, non-symmetric thread profile that is a Modified Buttress or SEC thread, according to the preferred embodiments of the invention.
[0052] FIG. 10B represents an axial section view and dimension detail view of a first male threaded end on a Nipple Connecting Element showing the configuration of a trapezoidal, non-symmetric thread profile that is a Modified Buttress or SEC thread, according to the preferred embodiments of the invention.
[0053] FIG. 11 illustrates an axial section view of an external flush joint, with Zone A indicating a stagnation zone.
[0054] FIG. 12 illustrates corrosion in a stagnation zone.
[0055] FIG. 13 illustrates an axial section view of a modified external flush joint, with a modified nipple, according to a seventh embodiment of the invention.
[0056] FIG. 14 illustrates an axial section view of a modified nipple, as in FIG. 13 .
[0057] FIG. 15 illustrates an axial section view of a modified rod, as in FIG. 13 .
[0058] FIGS. 16A and 16B illustrate an axial and section view of one extreme end of a modified rod, according to a Configuration 1 ;
[0059] FIGS. 17A and 17B illustrate an axial and section view of one extreme end of a modified rod, according to a Configuration 2 ; and
[0060] FIGS. 18A and 18B illustrate an axial and section view of one extreme end of a modified rod, according to a Configuration 3 .
[0061] FIG. 19 illustrates an axial section view of a modified external flush joint, with a modified nipple and external flush rod end characterized by two torque shoulders, according to an eighth embodiment of the invention, styled Hollow Rod 48x6 External Flush with two torque shoulders.
[0062] FIG. 20A illustrates an axial section view of the modified nipple of FIG. 19 , and FIGS. 20B, 20C and 20 D respectively represent a first nipple torque shoulder detail view, a second nipple torque shoulder detail view and a cross-section view along Line 20 D- 20 D of a Nipple Connecting Element having first and second male threaded ends, according to the eighth embodiment of the invention.
[0063] FIG. 21A illustrates an axial section view of the modified external flush rod of FIG. 19 , and FIGS. 21B and 21C respectively represent a second rod torque shoulder detail view and a first rod torque shoulder detail view according to the eighth embodiment of the invention.
[0064] FIG. 22A illustrates an axial section view of a modified nipple according to a ninth embodiment of the invention, styled Hollow Rod 48x6 Upset Rod End with two torque shoulders, and FIGS. 22B, 22C and 22 D respectively represent a first nipple torque shoulder detail view, a second nipple torque shoulder detail view and a cross-section view along Line 22 D- 22 D of a Nipple Connecting Element having first and second male threaded ends, according to the ninth embodiment of the invention.
[0065] FIG. 23A illustrates an axial section view of a modified external upset rod end according to the ninth embodiment of the invention and FIGS. 23B and 23C respectively represent a rod second torque shoulder detail view and a rod first torque shoulder detail view according to the ninth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] FIG. 1A represents a common solid sucker rod with its conventional threaded first end or head with a cylindrical-type male thread. A large discontinuity between the head of the rod and the body of the rod can easily be seen. Diameters DC and DV, respectively. FIG. 1 B is a schematic of the assembly of that solid pump rod with a conventional threaded union or collar according to the API 11B Norm.
[0067] FIG. 2A-2C respectively represent general configurations of a Hollow Sucker Rod first end, a Nipple Connecting Element, and an assembly of both elements according to a first embodiment of the invention, with a constant outer diameter. FIG. 2A gives references at the female extreme of the hollow rod according to the invention. It is also possible to observe the frustro-conical shape threaded surface in the interior of the rod that diminishes in the internal diameter thereof. FIG. 2B gives references at the nipple or union according to the present invention. The external thread of frustro-conical shape and the presence of two torque shoulders can also be seen. It is also possible to observe the varying of the nipple inner bore diameter with conical shape labeled “Option A”, as indicated by a broken line, which in turn creates a larger cross-sectional area in the vicinity of the torque should and surprisingly improves fatigue resistance.
[0068] FIG. 2C gives further references for the assembly of two hollow pump rods and one threaded union. It can be observed that the two female threads in the internal diameter of rod ( 3 . a and 3 . b ) are joined to the corresponding male ends ( 1 . a and 1 . b ) and how torque shoulders ( 2 . a and 2 . b ) are part of nipple ( 2 ). The union between the corresponding male and female extremes is accomplished by differential engagement of the frustro-conical shape of the threads ( 5 . a and 5 . b ). The fact that the thread shape is frustro-conical facilitates the initial setting of each piece and assembly of both parts. Shoulders located at the extreme free end surfaces of the first and second ends of the hollow rods ( 4 . a and 4 . b ) engage, in the assembled position, against a pair of corresponding torque shoulders formed on the nipple ( 2 . a and 2 . b ). Said contact planes form a torque shoulder angle (angle “Beta” see FIG. 2A ) with respect to the axis of the rod, which angle being between 75° and 90° and most preferably being 83°.
[0069] FIG. 2B shows in general geometry references for a connecting element as a separate nipple and specifically defines outside diameter (DEN), internal diameter (DIN) and the start diameter of the torque shoulder (DHT). The connecting element for the invention is characterized by the ratios of diameters according to the Table 3:
Range Diameter Ratios Min. Max. DHT/DEN 0.60 0.98 DIN/DEN 0.15 0.90 DIN/DHT 0.25 0.92
[0070] FIG. 2B also illustrates, by the broken line, a conical bore option, Option A, for the nipple inner bore configuration, which is preferred. FIG. 2A shows the hollow rod in the union zone with an outside diameter (DEVU) and an internal diameter of the rod at the extreme surfaces of the first and second ends corresponding to the end of the thread (DIFR). It also shows the outside diameter of the hollow rod (DEV) labeled as DEVU=DEV, because there is no upset end acting as the union. The ratio of the maximum external diameter (DEVU), either of a separate connector element or the upset type end of integral connector element union, to the external diameter of the rod (DEV), as illustrated at FIGS. 3A, 7A and 9 A, is maintained within the following range:
1 ≤ DEVU DEV ≤ 1.5
[0071] Hence for a maximum fixed diameter, the mean polar momentum of the hollow rod and connector string is greater than that for a solid pump rod of equal cross section diameter. Transmitted rotation moment or torque is therefore greater in a hollow rod column than in a solid rod column. This is also a determining factor in the resistance to the “backspin” phenomenon or counter-rotation of the rod string. Additionally, the ratio between the starting diameter of the torque shoulder on the connecting element (DHT) and the internal diameter of the hollow rod at the thread free end (DIFR), is maintained, as follows:
1 ≤ DIFR DHT ≤ 1.1
[0072] FIG. 3A gives further references at the assembly in which the ratio of the maximum diameter of the union (DEVU) to the diameter of the body of the rod (DEV) is limited (1<DEVU/DEV≦1.5). FIG. 3B is a possible configuration of the invention in which the female thread is machined on an upset first end of the rod, while the opposite or second end is machined with a corresponding male thread, the two threads being complementary but differential in diametral taper to each other. This configuration will be referred to as an upset rod, or as an integral union version.
[0073] FIGS. 4-10 , inclusive, relate to preferred embodiments where a Hollow Sucker Rod comprises at least a first end of a tubular element threaded with a conical female thread which is configured as a Modified Buttress or SEC thread and which vanishes on the inside of the tubular element, in combination with a torque shoulder angle (Beta) of between 75° and 90°. The external diameter of the tubular element away from the ends being either 42 mm or 48.8 mm and the external diameter of the tubular element in the upset end, if present, being either 50 or 60.6 mm.
[0074] FIGS. 4A, 4B and 4 C respectively represent an axial section view, a shoulder detail view and a cross-section view along Line 4 C- 4 C of a Nipple Connecting Element 402 with a flat 406 having first and second male threaded ends, 401 . and 401 . b , according to a fourth embodiment of the invention, styled Hollow Rod 48x6 External Flush. In FIG. 4A the values are a Modified SEC thread 405 . b , 8 threads per inch; DEN=48.8 mm; DIN=20 mm with an expansion to 26 mm over a length of 44 mm to the extreme end; DHT=39 mm; Beta=83°; overall length=158 mm; thread length=46 mm and central section length=50 mm. The shoulder detail 402 . a in FIG. 4B begins 4.61 mm after the thread, has an inner radius of 1.4 mm and an outer shoulder radius of 0.5 mm.
[0075] FIGS. 5A and 5B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod 403 having a first female threaded end 403 . a , according to the fourth embodiment of the invention. In FIG. 5A the values are a Modified SEC thread 405 . a, 8 threads per inch; DEV=48.8 mm; DIFR=41.4 mm; DIV=37 mm; Beta=83°. The shoulder detail 404 . a in FIG. 5B has a 30° transition at the thread and extends 4.5 mm; has an inner radius of 0.8 mm and an outer shoulder radius of 0.5 mm.
[0076] FIGS. 6A, 6B and 6 C respectively represent an axial section view, a cross-section view along Line 6 B- 6 B and a shoulder detail view of a Nipple Connecting Element 502 with flat 506 and having first and second male threaded ends, 501 . a and 501 . b , according to a fifth embodiment of the invention, styled Hollow Rod 42x5 External Upset. In FIG. 6A the values are a Modified SEC thread 505 . b , 8 threads per inch; DEN=50 mm; DIN=17 mm with an expansion to 25.3 mm over a length of 44 mm to the extreme end; DHT=38.6 mm; Beta=83°; overall length=158 mm; thread length=46 mm and central section length=50 mm. The shoulder detail 502 . a in FIG. 6C begins 4.61 mm after the thread, has an inner radius of 1.4 mm and an outer shoulder radius of 0.5 mm.
[0077] FIGS. 7A and 7B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod 503 having a first female threaded end 503 . a , according to the fifth embodiment of the invention. In FIG. 7A the values are a Modified SEC thread 505 . a , 8 threads per inch; DEVU ranging from 50 mm to DEV=42 mm; DIFR=41 mm; DIV=36.4 mm with a transition at 15° to 30 mm starting at 55 mm from the free end and back to 32 mm over a maximum length of 150 mm; Beta=83°. The shoulder detail 504 . a in FIG. 7B has a 30° transition at the thread and extends 4.5 mm; has an inner radius of 0.8 mm and an outer shoulder radius of 0.5 mm.
[0078] FIGS. 8A, 8B and 8 C respectively represent an axial section view, a shoulder detail view and a cross-section view along Line 8 B- 8 B of a Nipple Connecting Element 602 with flat 606 and having first and second male threaded ends, 601 . a and 601 . b , according to a sixth embodiment of the invention, styled Hollow Rod 48.8x6 External Upset. In FIG. 8A the values are a Modified SEC thread 605 . b , 8 threads per inch; DEN=60.6 mm; DIN=20 mm with an expansion to 33.6 mm over a length of 44 mm to the extreme end; DHT=47 mm; Beta=83°; overall length=158 mm; thread length=46 mm and central section length=50 mm. The shoulder detail 602 . a in FIG. 8C begins 4.61 mm after the thread, has an inner radius of 1.4 mm and an outer shoulder radius of 0.5 mm.
[0079] FIGS. 9A and 9B respectively represent an axial section view and a shoulder detail view of a Hollow Sucker Rod 603 having a first female threaded end 603 . a , according to the sixth embodiment of the invention. In FIG. 9A the values are a Modified SEC thread 605 . a , 8 threads per inch; DEVU ranging from 60.6 mm to DEV=48.8 mm; DIFR=49.4 mm; DIV=44.6 mm with a transition at 15° to 30 mm starting at 55 mm from the free end and back to 35.4 mm over a maximum length of 150 mm; Beta=83°. The shoulder detail 604 . a in FIG. 9B has a 30° transition at the thread and extends 4.5 mm; has an inner radius of 0.8 mm and an outer shoulder radius of 0.5 mm.
[0080] FIG. 10A represents an axial section view and dimension detail view of a first female threaded end on a Hollow Sucker Rod showing the configuration of a trapezoidal, non-symmetric thread profile that is a Modified Buttress or SEC thread, according to the rod first end preferred embodiment. The female thread shape of each Hollow Sucker Rod is trapezoidal and non-symmetric and is incomplete. The thread pitch is 8 threads per inch. The thread height is 1.016+0/−0.051 mm. The Diametrical taper in the threaded section is 0.1 mm/mm. The Length of threads on at least the first end of the tubular element is 44 mm., with part of the threads being incomplete due to vanishing of thread on the inside of the tubular element. The thread taper angle is 2° 51′ 45″; the tooth inner surface is 1.46 mm and the teeth spacing is 1.715 mm; the leading edge has a 4° taper or load flank angle and an inner radius of 0.152 mm while the trailing edge has a 8° taper and a larger inner radius of 0.558 mm. At the end of the threaded section a short cylindrical section on the inside of the threaded area transitions the threaded area to the bore of the hollow tubular element.
[0081] FIG. 10B represents an axial section view and dimension detail view of a first male threaded end on a Nipple Connecting Element showing the configuration of a trapezoidal, non-symmetric thread profile that is a Modified Buttress or SEC thread, according to the nipple first or second end preferred embodiment. The external diameter of the central section of each Nipple Connecting Element is 50 mm or 60.6 mm and the central section can present a pair of machined diametrically opposite flat surfaces, to be engaged by a wrench during connection make up. The male thread is a Modified Buttress thread and is complete across both ends of the nipple. The threaded section pitch is 8 threads per inch. The thread height lies between 1.016+0.051/−0 mm. The diametrical thread taper in the threaded area is 0.0976 mm/mm. The thread shape is trapezoidal and non-symmetric. The length of threads on each extreme of the nipple is 46 mm. All threads on the nipple are complete. The angle of the conical surface in the torque shoulder (Beta) is 83°. The radius at the tips of the torque shoulder is 1.4 mm for the internal radius and 0.5 mm for the external radius. There are preferred conical bores under each threaded section of the nipple, which are connected by a cylindrical bore. The thread taper angle is 2° 47′ 46″; the tooth inner surface is 1.587 mm and the teeth spacing is 1.588 mm; the trailing edge has a 4° taper or load flank angle and an outer radius of 0.152 mm while the leading edge has a 8° taper and a larger outer radius of 0.558 mm.
[0082] FIGS. 11 and 12 illustrate the corrosion problem when a fluid flows through the interior of the rod with reasonable speed. Early wear of the nipple and rod occurs in the area where they connect (overlap). This phenomenon can be attributed to the existence of an “stagnation area” where the fluids remains almost still (low velocity). See Zone A, in FIGS. 11 and 12 .
[0083] To solve the above mentioned problem the nipple and rod of the type shown in FIGS. 2A and 2B were modified. FIG. 11 illustrates such a hollow rod 48x6, external flush, with a stagnation area at Zone A and the resulting corrosion illustrated in a photographic section view, by FIG. 12 . A small seal was introduced at the ends of the nipple, with the corresponding modification of the angle of the internal conical bore (Zone B, C and D in FIG. 13-15 ). With this modification the “stagnation zone” does not exist any more and the fluid flows smoothly and with little turbulence. It is important to note that these modifications are small so that they do not alter significantly the stress distribution in the connection, nor the performance of the product. Note that the illustrated modifications were done on the nipple and the rod ( FIGS. 13-15 ). FIG. 13 represents a slight variation of FIG. 11 . A modification is introduced to the existing Nipple, in terms of a small seal zone, in order to prevent the fluid (when flowing through the inside of the pipe) to remain in the “stagnation area” promoting erosion-corrosion.
[0084] The stress distribution on the nipple and rod are similar to the HR 48x6 External Flush illustrated by FIGS. 2A-2C and FIG. 11 .
[0085] The torque shoulder ( 701 b , FIGS. 13-14 ) is similar to that in FIG. 11 .
[0086] The nominal diameter and diametrical taper in the threaded section ( 702 b , FIGS. 13-14 ) are likewise similar to FIG. 11 .
[0087] The nipple threads are complete and the length of threads ( 703 b , FIG. 13-14 ) is smaller, and different than shown in FIG. 11 . ( 703 a , FIG. 11 ).
[0088] There is an external cylindrical zone betwen the end of the nipple and the threaded section ( 704 b , FIGS. 13-14 ). The length is between 10 mm to 27 mm and the external diameter is 36.8 mm. This is different from FIG. 11 .
[0089] The end of the nipple works as a seal of the union ( 705 b , FIGS. 13-14 ). The thickness of the end of the nipple is 2 mm, which is different from FIG. 11 . ( 705 a , FIG. 11 ).
[0090] The bore of the nipple is conical in the extremes. The preferred angle is 8° 16′ ( 706 b , FIG. 14 ) and is different from FIG. 11 . (3° 46′; See 706 a , FIG. 11 )
[0091] The total length of the nipple ( 707 b , FIG. 14 ) is similar to FIG. 11 . ( 707 a , FIG. 11 )
[0092] The rod likewise has a torque shoulder ( 708 b , FIGS. 13 and 15 ). The dimensions of that shoulder are similar to the shoulder shown in FIG. 11 . Part of the threads on the pipe or rod end is incomplete due to vanishing of thread on inside of pipe ( 709 b , FIG. 15 ), which is similar to FIG. 11 . The nominal diameter and diametrical taper in the threaded section ( 710 b , FIGS. 13 and 15 ) are similar to FIG. 11 .
[0093] There is a seal inside of the rod, near the end of incomplete threads on the rod ( 711 b , FIGS. 13 and 15 ). While that seal may appear to be a second torque shoulder, it does not function as one, and has not been designed to sustain load. The thickness of the seal is between 0 to 1.7 mm and depends on the manufacturing tolerances of the pipe, and is different from the HR 48x6 External Flush version of FIG. 11 . The angle of seal inside of the rod is 90 degrees and the length of it from the end of the pipe is 55 mm ( 711 b and 712 b , FIGS. 13 and 15 ), which is different from FIG. 11 . After “make up” (service torque applied), the separation between the nipple and the rod) at Zone B ranges from about 0 to 0.6 mm ( 713 b , FIG. 13 ). The seal Zone B is lightly loaded and it does not transmit torque. It is used only as a seal and to promote a smooth flowing of the fluid.
[0094] FIGS. 16-18 illustrate another embodiment, where the objective is to substantially increase the flow of fluid extracted, through a further modification to the extreme ends of a hollow sucker rod string, of the type illustrated at FIGS. 2A-2C , FIG. 11 or FIG. 13 .
[0095] A series of holes were drilled in the rod's body at the two extremes (ground level and well bottom level) of the string. In this way, the fluid is allowed to flow also (usually it does through the annular region between the outer surface of the rod and the inner surface of the “tubing”) through the interior of the Hollow Rod. The holes pattern preferrably may be a Configuration 1 with 2 holes per transverse section, alternating at 90°, with a given longitudinal distance between sections ( FIG. 16A , 16 B); a Configuration 2 with holes that follow an helicoidal path with a “separation”in the longitudinal direction, and angle between holes of different sections ( FIG. 17A , 17 B); or a Configuration 3 : Three holes per tranverse section with a given longitudinal distance ( FIG. 18A, 18B ).
[0096] FIGS. 16 A , B illustrate one extreme end of hollow rod 803 with 2 holes, 804 , per transverse section, 180° apart, distributed in an alternate way, each set opposed at 90° to the adjacent set of holes with a given distance between sections, p ( FIGS. 16A and 16B ). The preferred hole diameter, Dh, is between 5 mm to 7 mm. The preferred longitudinal distance between sections, p, is between 50 to 100 mm. The preferred total (longitudinal) length of the zone at each extreme end that has such holes, L, is 3000 mm to 4000 mm, with the zone comprising between 62 to 162 holes.
[0097] FIGS. 17 A , B illustrate one extreme end of hollow rod 805 with 1 hole, 806 , per transverse section. The holes follow a helicoidal path, with a preferred longitudinal separation or pitch, p ( FIG. 17B ), and a rotation angle from one section to the following of 120°. ( FIGS. 17A and 17B ). The preferred hole diameter, Dh, is between 5 mm and 7 mm. The preferred longitudinal distance between sections, p, is between 25 to 50 mm. The preferred total (longitudinal) length of the zone at each extreme end that has such holes, L, is 3000 mm to 4000 mm, with the zone comprising between 61 to 161 holes.
[0098] FIG. 18 A,B illustrate one extreme end of hollow rod 807 with 3 holes, 808 , per transverse section, each about 120° apart about the circumference, with a preferred longitudinal separation or pitch, p ( FIG. 18B ). The preferred hole diameter, Dh, is between 5 mm and 7 mm. The preferred longitudinal distance between sections, p, is between 50 to 100 mm. The preferred total (longitudinal) length of the zone at each extreme end that has such holes, L, is 3000 mm to 4000 mm, with the zone comprising between 93 to 243 holes.
[0099] Therefore, the Modified Nipple (with seal) of FIG. 13 produces smooth fluid flow and little turbulence, when a fluid flows though the inside of the pipe, in turn yielding good erosion-corrosion resistance at Zone B when fluid flows though the inside of the pipe. The nipple of FIG. 14 also is interchangeable with a nipple as in FIG. 11 .
[0100] Hence, for all preferred embodiments, there is a diametral or differential taper. For example the rod first end taper is 0.1 inches/inch, while the corresponding taper of the either nipple end is 0.0976 inches/inch. For all preferred embodiments, the angle of the conical surface in the torque shoulder (Beta) is preferably 83°. The radiuses at the tips of the torque shoulder are 0.8 mm for the internal radius and 0.5 mm for the external radius.
[0101] Likewise, for all preferred embodiments, the Connecting Element has a central section that is externally cylindrical. Close to the outer diameter of this central section external torque shoulders are located to mate with the torque shoulder on a first end of a Hollow Sucker Rod. Both extremes of a nipple are conical and externally threaded, and a conical inner bore proximate the length of each threaded extreme creates an advantageous combination of structure, to ensure an increasing cross-section of the nipple from each free end of the nipple towards the central section, and the torque shoulder locations.
[0102] The main dimensions with respect to the invention illustrated by the eighth and ninth embodiments characterized by two sets of torque shoulders have those dimensions and references illustrated in FIGS. 19-23 . Those dimensions as well dimensions for an intermediate size that is not illustrated [Hollow Rod 42x5 Exter. Upset, with DEVU=50.0 mm] are summarized in the following Table, as follows:
DEVU & DEN DIN1 DHT1 DIN2 DHT2 DIV DIFR1 DIVU DIFR2 (mm) (mm) (mm) (mm) (mm) α (°) DEV (mm) (mm) (mm) (mm) (mm) 48.8 20.0 39.0 26.0 34.3 3° 54′ 48.8 35.4 41.7 26.0 35.2 50.0 17.0 38.6 26.0 33.7 5° 50′ 42.2 32.2 41.0 26.0 34.6 60.6 20.0 47.0 34.0 41.9 9° 7′ 48.8 35.4 49.4 34.0 42.8
[0103] FIGS. 19-23 , inclusive, relate to two torque shoulder embodiments where a Hollow Sucker Rod comprises at least a first end of a tubular element threaded with a conical female thread which is configured as a Modified Buttress or SEC thread and which vanishes on the inside of the tubular element. A cylindrical zone 904 b on the nipple is between the end and the threads, and is about 9.5 mm long and 34.3 in diameter, as shown in FIG. 19 , in combination with a first pair of torque shoulders, 901 b , 908 b , and a second pair of torque shoulders 905 b , 913 b , wherein each set of shoulders are inclined at about 7° to a line perpendicular to the connector centerline, or an angle (Beta) of about 83°. The external diameter or DEVU and DEN of the tubular element away from the ends in the eight and ninth embodiments is 48.8 mm and the external diameter of the tubular element in the upset end, if present, is about 60.6 mm. The material used must have a Yield Stress≧960 MPa (139.2 Ksi) and Ultimate Tensile Stress≧1015 MPa (147.2 Ksi). The connection has diametrical interference between the two mating threaded sections on the rod and the nipple. When hand-tightened, the clearance between the first torque shoulders of rod and nipple are in the range c1=0.4−2.5 mm and the clearance between the second torque shoulders of rod and nipple are in the range, c1=0.4−2.8 mm, wherein c2≧c1 and 0 mm≦(c2−c1)≦0.3 mm. The second torque shoulder in the eighth and ninth embodiments therefore is moderately loaded and transmits torque, while also serving as a seal to promote smooth flow, as in the seventh embodiment ( FIG. 13 ).
[0104] FIGS. 20A, 20B , 20 C and 20 D respectively represent an axial section view, a first shoulder detail view, a second shoulder detail view and a cross-section view along Line 20 D- 20 D of a Nipple Connecting Element 902 with a flat 906 having first and second male threaded ends, according to an eighth embodiment of the invention, styled Hollow Rod 48x6 External Flush with two torque shoulders. In FIG. 20A the values of a Modified SEC thread 902 . b , are 8 threads per inch; DEN=48.8 mm; DIN1=20 mm with an expansion to 26 mm over a length of 44 mm to the extreme end; DIN2=26 mm; DHT1=39 mm; DHT2=34.3 mm; the overall nipple length=159 mm; thread length=41 mm; and a length between the shoulders of 54.59 mm. For the eighth embodiment, the dimension ratios are DHT1/DEN=0.80; DIN1/DEN=0.41; DIN1/DHT1=0.513; DEVU/DEV=1.0; DIFR1/DHT1=1.062; DIFR1/DEVU=0.85; DIVU/DIFR2=0.74; DIN2/DHT2=0.76; DEVU/DIVU=0.53; DIFR2/DEVU=0.72; and DIN1/DIN2=0.77.
[0105] The first nipple shoulder 901 b further detailed in FIG. 20B begins 4.06 mm after an external thread with a 30° inclined trailing surface, has a Beta=83°, has an inner radius of 1.4 mm and an outer shoulder radius of 0.5 mm. The second nipple shoulder 905 b detailed in FIG. 20C begins 9.5 mm ahead of a first external thread, has a Beta=83°, an inner radius of 0.5 mm at a diameter point of 26 mm and an outer shoulder radius of 0.8 mm. at a diameter point of 34.3 mm. The surface has a maximum 125 μin RA value, and α=3° 54′.
[0106] FIGS. 21A, 21B and 21 C respectively represent an axial section view and a shoulder detail view of an external flush Hollow Sucker Rod 903 with a first female threaded end 903 b , a second rod shoulder 913 b detail view, and a first rod shoulder 908 b detail view according to the eighth embodiment of the invention. DEVU=48.8 mm; DIFR1=41.7 mm; DIFR2=35.2 mm; DIVU=26 mm; DIV=35.4 mm; and the rod inner bore=23 mm.
[0107] The second rod shoulder 913 b detailed in FIG. 21B begins 6 mm after an internal thread, has a Beta=83°, has an inner radius of 0.5 mm at a DIVU diameter point of 26 mm. and an outer shoulder radius of 0.9 mm. at a diameter point of 35.2 mm. The surface has a maximum 125 μin RA value. The first rod shoulder 908 b detailed in FIG. 21C begins 4.5 mm ahead of a first internal thread leading surface with a 30° inclined surface, has a Beta=83°, an outer radius of 0.5 mm at a diameter point of 48.8 mm and an inner shoulder radius of 0.8 mm. at a diameter point of 41.7 mm. The distance between the shoulders is 54.55 mm. according to the eighth embodiment of the invention.
[0108] FIGS. 22A, 22B , 22 C and 22 D respectively represent an axial section view, a first shoulder detail view, a second shoulder detail view and a cross-section view along Line 22 D- 22 D of a Nipple Connecting Element 1002 with a flat 1006 having first and second male threaded ends, according to a ninth embodiment of the invention, styled Hollow Rod 48x6 Upset Rod End with two torque shoulders, having an external dimension or DEVU and DEN=60.6 mm. For the ninth embodiment, the dimension ratios are DHT1/DEN=0.776; DIN1/DEN=0.33; DIN1/DHT1=0.425; DEVU/DEV=1.24; DIFR1/DHT1=1.051; DIFR1/DEVU=0.82; DIVU/DIFR2=0.79; DIN2/DHT2=0.81; DEVU DIVU=0.56; DIFR2/DEVU=0.71; and DIN1/DIN2=0.59.
[0109] In FIG. 22A the values of a Modified SEC thread 1002 b , are 8 threads per inch; DEN=60.6 mm; DIN1=20 mm with an expansion to 34 mm over a length of 44 mm to the extreme end; DIN1=20 mm; DHT1=47 mm; DIN2=34 mm; DHT2=41.9 mm; α=9° 7′; thread length=41 mm and an overall length=159 mm.; and a length between the shoulders of 54.56 mm.
[0110] The first nipple shoulder 1001 b detailed in FIG. 22B has a Beta=83°, begins 4.06 mm after an external thread with a 30° inclined trailing surface, has an inner radius of 1.4 mm and an outer shoulder radius of 0.5 mm. The second nipple shoulder 1005 b detailed in FIG. 22C begins 9.5 mm ahead of a first external thread, has a Beta=83°; α=9° 7′; an inner radius of 0.5 mm at a diameter point of 34 mm and an outer shoulder radius of 0.8 mm. at a diameter point of 41.9 mm. The surface has a maximum 125 μin RA value.
[0111] FIGS. 23A, 23B and 23 C respectively represent an axial section view and a shoulder detail view of an upset end of Hollow Sucker Rod 1003 having a first female threaded end 1003 b , a second rod shoulder 1013 b detail view, and a first rod shoulder 1008 b detail view according to the ninth embodiment of the invention. DEVU=60.6 mm; DIV=35.4 mm; DIVU=34 mm; DIFR1=49.4 mm; DIFR2=42.8 mm;
[0112] The second rod shoulder 1013 b detailed in FIG. 23B begins 6.2 mm after an internal thread, has a Beta=83°, has an inner radius of 0.5 mm at a DIVU diameter point of 34 mm. and an outer shoulder radius of 0.9 mm. at a diameter point of 42.8 mm. The first rod shoulder detail 1008 b in FIG. 23C begins 4.5 mm ahead of a first internal thread leading surface with a 30° inclined surface, has a Beta=83°, an outer radius of 0.5 mm at a DEVU diameter point of 60.6 mm and an inner shoulder radius of 0.8 mm. at a diameter point of 49.4 mm. The distance between the shoulders is 54.8 mm. according to the ninth embodiment of the invention. The surface has a maximum 125 μin RA value.
[0113] While preferred embodiments of our invention have been shown and described, the invention is to be solely limited by the scope of the appended claims.
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An elongated drive string assembly comprising a plurality of hollow sucker rods and a connecting elements with an axis, connected together and between a drive head located at the surface of an oil well and a rotary pump located deep down hole in an oil well. Each hollow sucker rod has at least a first end comprising an internal female threaded surface engaging an external male threaded surface on a connecting element, such as a nipple. In order to further optimize the stress distribution between the elements, frustro-conical, non-symmetrical threads with a differential diametral taper are used. Preferably two torque shoulders with a maximized mean diameter and cross-sectional area are used to resist storing reactive torque in the drive string. The nipple free end defines a second torque shoulder that adds to the torque transmission during make-up while also defining a small seal at that free end to decrease corrosion erosion problems. This overall configuration ensures high yield torque, high shear strength, lowered stress concentration and a surprising resistance to storing reactive torque, which minimizes dangerous backspin when power to the sucker rod string is interrupted.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from, and is a 35 U.S.C. §111(a) continuation of, co-pending PCT international application serial number PCT/US00/35563 filed on Dec. 28, 2000 which designates the U.S., which is a continuation-in-part of U.S. application Ser. No. 09/477,918 filed on Dec. 31, 1999 from which priority is also claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A COMPUTER PROGRAM APPENDIX
[0003] Not Applicable
NOTICE OF MATERIAL SUBJECT TO COPYRIGHT PROTECTION
[0004] A portion of the material in this patent document is subject to copyright protection under the copyright laws of the United States and of other countries. A portion of the material in this patent document is also subject to protection under the maskwork registration laws of the United States and of other countries. The owner of the copyright and maskwork rights has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the United States Patent and Trademark Office file or records, but otherwise reserves all copyright and maskwork rights whatsoever. The copyright and maskwork owner does not hereby waive any of its rights to have this patent document maintained in secrecy, including without limitation its rights pursuant to 37 C.F.R. §1.14.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention pertains generally to high temperature kiln access door assemblies, and more particularly to a warp resistant supplemental fuel feed door assembly for a rotating kiln.
[0007] 2. Description of the Background Art
[0008] Rotating cylindrical kilns are frequently used in the production of cement. Because such kilns operate at extremely high temperatures, it is possible to burn various forms of liquid and solid combustible waste materials as a source of supplemental heat. Waste materials tend to completely combust at the high operating temperatures found in such kilns, which are on the order of 3400 degrees Fahrenheit and above, while producing little or no undesirable gaseous or solid emissions. Therefore, these waste materials can serve as a form of supplemental fuel, thereby reducing the demand for and cost of the primary fuel.
[0009] Worn rubber vehicle tires are particularly suited as a supplemental fuel for a rotary cement kiln. The extremely high temperatures within a cement kiln will cause the rubber tires to burn without any significant liquid, solid or gaseous waste byproducts which might otherwise be detrimental to the environment. Since worn out tires currently present a disposal problem, burning the tires in rotary kilns helps alleviate the growing problem of disposal without impairing the environment.
[0010] Various secondary fuel feed mechanisms have been developed to introduce fuel through a kiln wall into the interior of a rotating cylindrical kiln. Typically, these feed systems have an entrance chute which transects the kiln wall with an outer portion protruding through the outer wall of the kiln and an inner portion protruding into the interior of the kiln. The outer portion of the chute normally includes a feed door which opens to allow passage of the secondary fuel into the kiln. Some feed systems positively inject the supplemental fuel into the kiln using a ram or advancing screw mechanism. Other feed systems known tend to use gravity to inject the supplemental fuel into the kiln. A kiln feed door is utilized in both systems to prevent the escape of heat and combustion gases when the supplemental fuel is fed into the interior of the kiln.
[0011] The repetitive opening and closing of the kiln feed door results in the exposure of the door to higher temperatures when closed and lower temperatures when open. Such heating and cooling of the door results in expansion and contraction of the door surfaces and warping of the door over time. Warped doors do not properly seal against the entrance chute and allow heat and combustion gases to escape when the door is closed. Replacement of the warped kiln feed door can be costly requiring the kiln to be shut down during the time a new door is installed.
[0012] In addition, most door actuating mechanisms are mechanically controlled by the use of cams or rollers and operate within a fixed operating cycle. Such mechanical mechanisms must open the door on each revolution of the kiln and can not skip a cycle. Thus, the rate of secondary fuel introduced into the kiln can not be modified efficiently.
[0013] Accordingly, there is a need for a kiln feed door that is resistant to warpage when repetitively exposed to hot and cold temperatures, and which can be opened and closed such that the rate of secondary fuel can be varied. The present invention satisfies those needs, as well as others, and generally overcomes deficiencies found in convention kiln feed door assemblies.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention is a kiln feed door assembly that restricts the loss of heat and combustion gases when feeding tires and other combustible materials into a rotating kiln as a source of supplemental fuel. By way of example, and not of limitation, the apparatus comprises a kiln feed door assembly that preferably includes two feed doors pivotally mounted to a baseplate on the exterior entrance of a chute which transects the wall of the rotary kiln. Each door includes a pivot shaft which preferably pivots within two high temperature pillow block bearings. Preferably four door plate mounting arms are attached to the pivot shaft and extend radially from the center of the pivot shaft. Planar rectangular door plates are mounted to the mounting arms with bolts secured through bores or apertures in the mounting arms.
[0015] In the preferred embodiment, there are at least two apertures in each mounting arm. The apertures are matched in pairs in each mounting arm. Some apertures are oblong in shape with the lengthwise portion of the aperture aligned with the direction of the width of the mounting arm. Other oblong apertures are aligned such that the lengthwise portion of the aperture is in the direction of the length of the mounting arm and perpendicular to the length of the pivot shaft. Still other apertures are circular. Each aperture may be sized to receive a bushing.
[0016] The bushings and linear alignment of the oblong apertures allow the door plates to expand and contract inconsistently without causing stress or otherwise warping the door. An efficient seal against the loss of heat and combustion products is maintained when the door plates keep their planer shape.
[0017] The two kiln doors pivot outwardly from the base plate and center of the kiln. One door assembly has a lip on the outer surface of the door. The lip is positioned to cover and seal the small space between the doors when the doors are in the closed position.
[0018] Each kiln feed door of the door assembly is preferably counterbalanced on the pivot shaft, preferably with two counterweights, one disposed near each of the block bearings. The door and counterweights are equally balanced with respect to the pivot shaft allowing for the opening and closing of the doors with little effort.
[0019] In one preferred embodiment, the kiln doors synchronously open and close using an electric motor, gearbox, actuating arms, rods and transfer arms. An actuating arm is radially mounted to one end of the pivot shaft of one door and a transfer arm is radially mounted to the other end of the shaft. The actuating arm is connected by an actuating rod to a rotating armature from the gearbox. This portion of the mechanism translates the rotational motion of the armature to oscillating motion of the actuating arm and partial rotation of the pivot shaft. Rotation of the pivot shaft results in movement of the transfer arm. An elongate transfer rod is pivotally connected to the transfer arm on one end and to an arm mounted to the pivot shaft of the opposing door on the other. Therefore, both kiln feed doors open simultaneously when the electric motor is activated.
[0020] In one embodiment, the actuating rod that is coupled with the door actuating arm on one end and the rotating linkage of the gearbox on the other includes a dampening member which tempers the impact of the closure of the doors against the rim of the opening to the kiln thereby reducing stress on the doors and linkage.
[0021] In another embodiment, the activity of the motor is regulated during various times of the cycle of the rotation of the gearbox armature with sensors thereby regulating the rate of movement of the door-actuating rod. When the motor is momentarily turned off just before the doors are fully closed or opened, the stress on the seals, doors and linkage of impact against the kiln opening under power is eliminated.
[0022] In operation, tires or other combustible materials are presented to a feed ramp or injection platform. As the kiln rotates, the feed door assembly eventually comes into proper alignment with the feed ramp. The kiln feed doors are mechanically or preferably electrically opened to allow the kiln to receive the combustible materials from the ramp. The doors are closed after the combustible material enters into the kiln to eliminate the loss of heat and combustion products from the kiln during rotation.
[0023] An object of the invention is to provide secondary fuel access doors for a rotating kiln that can expand linearly or laterally without warping.
[0024] Another object of the invention is to provide kiln feed doors that will efficiently prevent the escape of heat and combustion products from the interior of the kiln yet allow the efficient entry of tires or other combustible material into the kiln.
[0025] Another object of the invention is to provide a kiln feed door that can be repetitively exposed to heat extremes and cooling and maintain its shape.
[0026] Yet another object of the invention is to provide a door actuating mechanism that efficiently and reliably allows momentary access to the interior of the kiln without releasing large amounts of heat or combustion gases.
[0027] Still another object of the present invention is to provide a kiln supplemental fuel feed door assembly that can be programmed to open and close at desired times and is capable of skipping cycles.
[0028] Further objects and advantages of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:
[0030] [0030]FIG. 1 is a perspective view of a feed door assembly according to the present invention showing the warp resistant doors in the open position.
[0031] [0031]FIG. 2 is a side view of the feed door assembly of the invention with the doors shown in the open position, and showing the feed door assembly in relation to the fuel guide of a rotating kiln and a feed chute.
[0032] [0032]FIG. 3 is a top view of the warp resistant doors of the present invention showing the positioning of the bores in the arms and pivot shafts, and showing one of the doors partially cut away for clarity.
[0033] [0033]FIG. 4 is a front view of the feed door assembly of FIG. 1 with the warp resistant doors shown in the closed position.
[0034] [0034]FIG. 5 is a rear view of the feed door assembly of FIG. 1 with the warp resistant doors shown in the closed position.
[0035] [0035]FIG. 6 is a perspective view of a rotating kiln with the attached feed door assembly of FIG. 1 shown the warp resistant doors in the open position to receive secondary fuel from the feed chute.
[0036] [0036]FIG. 7 is a side view of an alternative embodiment of the motor and gear mechanism of the feed door assembly of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the apparatus generally shown in FIG. 1 through FIG. 7, where like reference numbers denote like parts. It will be appreciated that the apparatus may vary as to configuration and as to details of the parts without departing from the basic inventive concepts disclosed herein.
[0038] Referring first to FIG. 1 and FIG. 2, the invention comprises a kiln access door assembly 10 that is used to allow the injection of combustible material into a rotating kiln of the type that is commonly used in the production of cement. The invention includes a pair of outwardly opening warp resistant feed doors 12 a , 12 b which provide access to a feed opening 14 in the side wall of a kiln 16 . It will be appreciated, however, that the present invention can be used with any combustion chamber such as a stationary kiln, furnace or boiler that exposes an access door to high temperatures. As can be seen, feed opening 14 is at the exterior end of a fuel feed inlet tube 18 which transects the sidewall of the kiln.
[0039] In the configuration shown in FIG. 1 and FIG. 2, the feed door assembly 10 of the invention is supported by a baseplate 20 mounted on the exterior end of feed tube 18 . Feed opening 14 is an opening in baseplate 20 that allows the passage of combustible material to the interior of the kiln through feed tube 18 .
[0040] Doors 12 a and 12 b include door plates comprising planar members 22 a and 22 b , respectively, which face the interior of the kiln when the doors are in the closed position. Preferably, the periphery of feed opening 14 has a lip 24 that engages the face of planar members 22 a and 22 b sealing the opening when doors 12 a and 12 b are closed.
[0041] A fuel guide 26 is mounted on the baseplate 20 such that the plane of surface 28 of the guide is perpendicular to the baseplate. Preferably door 12 a opens to a position that is perpendicular to the baseplate and then stops. Fuel guide 26 is positioned such that guide surface 28 is substantially contiguous with the inner surface of planar member 22 a when the door is open. In this manner, tires and other combustible materials can be deposited on the surface 28 of fuel guide 26 and slide by the forces of gravity along the guide and the surface of door member 22 a , and through the interior of feed tube 18 into the interior of the kiln as the kiln rotates.
[0042] Door 12 b preferably opens to a position approximately one-hundred and ten degrees from horizontal and then stops. This positioning effectively directs stray fuel into the feed opening 14 as it slides down the guide and into feed opening 14 .
[0043] In FIG. 2, a tire 30 is shown positioned in a feed chute apparatus 32 for delivery into the kiln. In operation, the timing of the release of the fuel from the feed chute should be coordinated with the opening of the doors 12 a and 12 b when in the proper position to receive the fuel. In this regard, it will be appreciated that it is important that the tires not be released from the feed chute apparatus until the feed doors on the kiln are in position and opened to receive the tires. In addition, to ensure that the tires will be gravity fed into the kiln, the feed chute is oriented on the support frame such that the plane of the internal ramp (bottom wall) has an angle of inclination between approximately 33 degrees and approximately 60 degrees, and preferably 47 degrees. The feed chute apparatus with rate regulation capability described in detail in co-pending application Ser. No. 09/448,570 filed on Nov. 23, 1999, which is incorporated herein by reference, can be used for this purpose. It will be appreciated, however, that the feed door assembly of the present invention can also be used with other feed mechanisms known in the art that actively inject the fuel into the kiln without the assistance of gravity.
[0044] Referring also to FIG. 3, the preferred embodiment of the warp resistant feed doors are shown in greater detail. It will be appreciated that the various components described herein can be attached using conventional fastening techniques, such as welding, bolts, pins or the like, as appropriate for the type of attachment made. In the embodiment shown, doors 12 a and 12 b each have a pivot shaft, a plurality of support arms mounted to the shaft and a planar member secured to the arms. Specifically, door 12 a includes a pivot shaft 34 which functions as a hinge and which preferably has grooves to receive splines at both ends. A plurality of arms 36 , 38 , 40 , and 42 are oriented substantially parallel in the same direction and are securely mounted to shaft 34 . Each arm preferably has a horizontal anchor 44 , 46 , 48 and 50 , respectively, which serves as an attachment point with planar member 22 a . Each horizontal anchor is supported by a vertical upright which is perpendicular to the horizontal plane of the anchor. Vertical uprights 52 , 54 , 56 and 58 are attached to pivot shaft 34 as well as to its respective horizontal anchor. Each vertical upright has a top plate 60 , 62 , 64 , or 66 , respectively, attached on the side opposite the anchor.
[0045] Top plates 60 , 62 , 64 , and 66 are also attached to pivot shaft 34 providing additional strength and rigidity to the door. Further rigidity for door 12 a is provided by a cross-brace or beam 68 which cross-links the vertical uprights of the anchor arms.
[0046] Each of the horizontal anchors has one or more pairs of apertures that receive bolts or the like to secure the planar members to the anchors. For example, horizontal anchor 44 has a pair of apertures 70 a and 70 b that have a generally oblong shape with the lengthwise portion of the oblong oriented substantially parallel to the length of shaft 34 and substantially perpendicular to the length of anchor 44 . In other words, the longitudinal axis through the oblong portion of the aperture is generally aligned with the longitudinal axis of the shaft and generally offset with the longitudinal axis of the anchor by approximately ninety degrees.
[0047] Horizontal anchor 46 has two pairs of apertures 72 a , 72 b and 74 a , 74 b that are preferably disposed on either side of vertical upright 54 . Apertures 72 a and 72 b are oversized and circular in shape. In contrast with apertures 70 a and 70 b , apertures 74 a and 74 b have a generally oblong shape with the lengthwise portion of the oblong oriented substantially perpendicular to the length of shaft 34 and generally parallel to the length of the anchor. In other words, the longitudinal axis through the oblong portion of the aperture is offset in relation to the longitudinal axis of the shaft by approximately ninety degrees and is generally aligned with the longitudinal axis of the anchor.
[0048] Apertures 76 a and 76 b in anchor 48 have the same oblong dimensions as apertures 74 a and 74 b and are oriented in the same direction generally perpendicular to the length of the shaft 36 and aligned with the length of the anchor. Likewise, apertures 78 a and 78 b are circular and preferably have the same dimensions as apertures 72 a and 72 b.
[0049] Anchor 50 has apertures 80 a and 80 b which are oblong oriented in a direction substantially parallel to the direction of length of shaft 34 and substantially perpendicular to the length of the anchor. Preferably, apertures 80 a and 80 b have the same dimensions as apertures 70 a and 70 b in anchor 44 .
[0050] One skilled in the art will appreciate the symmetry of the placement of apertures 70 a through 80 b . While this symmetry is preferred, other combinations and placements are anticipated. The orientation and placement of the apertures 70 a through 80 b allow the expansion and contraction of planar member 22 a due to the high temperature gradients associated with opening and closing the doors to occur without causing significant deformation to the door assembly. In addition, appropriately sized bushings may alternatively be placed in the apertures to further reduce stresses. Thus, expansion and contraction of the inventive door assembly from exposure to extreme temperatures does not create sizeable stresses in the door assembly causing warping and a loss of door seal to escaping combustion gases.
[0051] Kiln feed door 12 b has essentially the same structure as feed door 12 a as can be seen in FIG. 3. Pivot shaft 82 preferably has four mounting arms 84 , 86 , 88 , and 90 which are secured to pivot shaft 82 . Each arm has horizontal anchors 92 , 94 , 96 , and 98 , respectively, which are ultimately secured to planar member 22 b . Each anchor has a vertical upright 100 , 102 , 104 and 106 , respectively, mounted radially to shaft 82 and perpendicularly to horizontal anchors 92 , 94 , 96 , and 98 , respectively. The vertical uprights are preferably cross-linked by beam 108 to provide strength to the mounting arm assembly. Top plates 110 , 112 , 114 and 116 are mounted to the vertical uprights on the side opposite the horizontal anchor as well as shaft 82 providing further rigidity to the assembly as shown in FIG. 1. Note that cross beam 108 , cover 130 and top plates 110 , 112 , 114 and 116 , can be seen in FIG. 1, but have been omitted from FIG. 3 for clarity.
[0052] The apertures in the horizontal anchors of arms 92 , 94 , 96 and 98 share the same shape, symmetry, placement and orientation as those apertures in anchors 44 , 46 , 48 and 50 of door 12 a . Apertures 118 a and 118 b in anchor 92 are oblong shaped with the lengthwise portion of the oblong oriented in the direction of the length of shaft 82 . Apertures 120 a , 120 b and 122 a and 122 b are disposed in anchor 94 . Apertures 120 a and 120 b are circular in shape, and apertures 122 a and 122 b are oblong in shape with the lengthwise portion of the oblong perpendicular to the length of shaft 82 .
[0053] Horizontal anchor 96 has apertures 124 a and 124 b which are oblong in shape and 126 a and 126 b which are circular in shape disposed on either side of upright 104 . The lengthwise portion of oblong apertures 124 a and 124 b is perpendicular to the length of shaft 82 .
[0054] Anchor 98 has apertures 128 a and 128 b which are oblong in shape and oriented so that the lengthwise portion of the oblong is parallel to the length of shaft 82 . As can be seen, therefore, door 12 b preferably maintains the same symmetry with respect to the apertures as door 12 a as seen in FIG. 3.
[0055] Referring to FIG. 1, FIG. 4 and FIG. 5, there is a cover 130 that is attached to the outer edge of planar member 22 b and covers the gap between planar members 22 a and 22 b when doors 12 a and 12 b are in the closed position. Cover 130 acts to seal the gap between the doors to prevent the escape of significant amounts of combustion gases and heat from the kiln.
[0056] The door assembly of the present invention has a front or drive side as seen in FIG. 4 and a rear side as shown in FIG. 5. In the embodiment shown, the ends of pivot shafts 34 and 82 rotate in high temperature pillow block bearings 132 a , 132 b and 134 a , 134 b , respectively. The pillow block bearings 132 a , 132 b , 134 a and 134 b are preferably mounted on baseplate 20 .
[0057] Doors 12 a and 12 b are preferably counterweighted to create a zero lift weight and reduce the stress on the door actuating mechanisms. Shaft 34 has a counterweight 136 a on the drive side and a counterweight 136 b on the rear side of the apparatus. Similarly, shaft 82 has a counterweight 138 a on the drive side and a counterweight 138 b on the rear side of the shaft. The counterweights are preferably placed on the shaft such that the pillow block bearings are between the door and the counterweight.
[0058] Referring more particularly to the drive side of the apparatus as shown in FIG. 4, armature 146 is connected to an output shaft 150 (FIG. 5) of gearbox 152 and rotated by the output shaft at a desired speed. Output shaft 150 and gearbox 152 are preferably driven by an electric motor 154 . The proximal end of push rod 142 is rotatably connected to rotating arm 146 by bearing 148 . The distal end of push rod 142 is pivotally coupled to actuating arm 140 by bearing 144 . Thus, it will be seen that the rotation of armature 146 and movement of push rod 142 forces actuating arm 140 to oscillate. Consequently, the force applied to actuating arm 140 will cause pivot shaft 34 to rotate around its axis in block bearings 132 a and 132 b preferably to a point that door 12 a is opened to a vertical position.
[0059] Push rod 142 is preferably coupled to a resistive plunger or spring assembly 156 that will allow the length of pushrod 142 to compress or shorten slightly while resisted by spring assembly 156 . This serves to temper the force applied to arm 140 and shaft 34 by pushrod 142 when door 12 a is opened or closed.
[0060] In one embodiment, the spring assembly 156 includes a spring loaded cylinder with one end of pushrod 142 fixed to actuating arm 140 and the other end of pushrod 142 sliding within the cylindrical body of assembly 156 and resisted by a spring within the body (not shown). The fixed end of the cylindrical assembly 156 is connected to the rotating arm 146 on the output side of the gear box 152 and the sliding pushrod 142 is connected to the actuating arm 140 on the lower kiln door. Thus, when the fixed end shaft of the cylindrical assembly is pushed, the sliding end of pushrod 142 preferably bottoms at the opposite end of the cylindrical body of assembly 156 creating a full positive force. Additionally, when the fixed end of the cylindrical spring assembly 156 is pulled the sliding end of rod 142 extends, thereby compressing the cylinder spring. The strength of the spring determines the force created. Preferably, an internal sleeve on the sliding pushrod 142 limits its travel (not shown).
[0061] Motor 154 may be activated by any number of timing mechanisms known in the art that allow the doors to be opened at the proper position to receive fuel during rotation of the kiln. The opening and closing of the feed doors can be timed for every cycle of rotation of the kiln or for alternate cycles. Alternatively, the doors may be opened more than one time during any one rotation of the kiln. Thus, it will be seen that a kiln mounted, low voltage electrical motor and linkage allows total operational flexibility to control when and where the doors are open and the duration of closure thereby eliminating cumbersome mechanical linkages known in the art.
[0062] Referring now to FIG. 5, the rear side of the inventive apparatus is shown. A transfer arm 158 is mounted to pivot shaft 34 and rotates with shaft 34 in pillow bearings 132 a and 132 b when the shaft is rotated by actuating arm 140 . Transfer arm 158 is pivotally connected to one end of transfer rod 160 by transfer arm bearing 162 . The other end of transfer rod 160 is pivotally connected to arm 164 through bearing 166 . When shaft 34 is rotated, counterweight 136 b rotates downwardly, transfer arm 158 moves upwardly about the axis of shaft 34 and transfer rod 160 forces arm 164 to rotate pivot shaft 82 . Rotation of shaft 82 causes door 12 b to open upwardly and counterweight 136 b to rotate downwardly around the axis of shaft 82 . It is preferred that door 12 b open beyond vertical to approximately one hundred and ten degrees from horizontal.
[0063] In operation, the opening of doors 12 a and 12 b is preferably coordinated with the release of fuel from feed chute 32 . It is also preferred that the doors do not open when the assembly is below forty degrees from horizontal.
[0064] Referring also to FIG. 2 and FIG. 6, in operation a tire 30 is placed on feed chute 32 either manually or by using an auxiliary mechanical feed mechanism (not shown). As kiln 16 rotates, sensor 168 , which is a conventional photosensor or the like, senses an actuator key such as tab 170 and activates motor 154 thereby opening doors 12 a and 12 b . As rotation continues, the doors completely open and fuel guide 26 and feed opening 14 comes into alignment with feed ramp 32 , fuel control sensor 172 detects tab 174 and sends a control signal to feed chute 32 . The tire or other combustible material is timed to slide down the feed chute, along fuel guide 26 and planar member 22 a , and into the kiln since the angle of inclination is sufficient to allow the material to be gravity fed out of the end of the feed chute.
[0065] The number of times that doors 12 a , 12 b open and close may be controlled and coordinated with the release of fuel by feed chute 32 to meter the amount of material injected into the kiln by sensor controllers at the door and feed chute assemblies. (not shown). Accordingly, the door assembly can remain closed until the kiln completes one or more full rotations.
[0066] Referring now to FIG. 7, an alternative embodiment of the actuating mechanism for opening the kiln feed doors 12 a , 12 b is generally shown. In the embodiment shown, the gearbox 152 has an additional mechanism for regulating the activity of the motor through the cycle of the opening and closing of the kiln doors 12 a , 12 b.
[0067] The activity of the motor 154 is regulated during various times of the cycle of the rotation of the gearbox armature 146 by sensors thereby regulating the rate of movement of the door actuating pushrod 142 . Preferably the motor 154 is momentarily turned off just before the doors are fully closed or opened thereby reducing the stress on the seals, doors and linkage from the impact of the doors against the kiln opening that occurs under power.
[0068] Gearbox 152 has a shaft 176 disposed on the side of the gearbox opposite shaft 150 and armature 146 preferably rotates at the same rate as shaft 150 . A rotating disk 178 is coupled with shaft 176 and includes sensor tabs 180 near the periphery of the disk. Detectors 182 are aligned over sensor tabs 180 and activate and deactivate the motor 152 . The input from detectors 182 is preferably coordinated with the input from sensors 168 and 172 .
[0069] Low voltage motor 154 causes armature 146 to rotate and force pushrod 142 to move actuating arm 140 and open the kiln feed doors 12 a , 12 b . This may be considered the positive stroke of the door actuating mechanism. When the armature 146 on the gearbox 152 has rotated one hundred and eighty degrees, the lower door 12 a is preferably perpendicular to the center of the kiln and parallel to the feed chute 32 at the time of material release. It is preferred that a few degrees before one hundred and eighty the disk sensor tab 180 on the disk 178 gear box output shaft 176 align with the detector 182 signifying the proper position. The detector 182 , or other control mechanism associated with the detector, preferably cuts power to the drive motor 154 . As the motor 154 slows to a stop, the doors 12 a , 12 b continue to open to the set position and the disk 180 rotates to one hundred and eighty degrees. The doors 12 a , 12 b remain in this position until they have aligned with the feed chute 32 and the materials are fed to the kiln.
[0070] Once the materials have been fed to the kiln 16 , it is preferred that the power to the motor 154 be regained and armature 146 continue rotating clockwise back one hundred and eighty degrees, creating a pulling action on the pushrod 142 and thus closing the doors. This may be considered the negative stroke of the cycle. The linkage is preferably adjusted so that when the armature 146 on the gearbox 152 has reached a few degrees before one hundred and eighty degrees, the sensor tabs 180 on disk 176 aligns with a detector 182 and cuts power to the motor 154 . Consequently the motor 154 is not active when doors 12 a , 12 b are in the fully closed position and stresses on the doors and linkage are greatly reduced.
[0071] Accordingly, it will be seen that this invention provides a simple and effective way of introducing combustible materials such as tires into a rotating kiln using gravity feed or affirmative injection which can skip one or more revolutions of the kiln. The structure of the fuel feed doors allow for exposure to extreme temperatures and inconsistent expansion and contraction without warping, fracturing the bearings, shaft distortion, jamming or significant release of heat or combustion gases. Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of this invention should be determined by the appended claims and their legal equivalents.
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A warp resistant fuel feed door assembly for use in injecting supplemental fuel into a high temperature combustion chamber such as a rotating cement kiln without substantial loss of heat or combustion gases. The apparatus, which is positioned on the exterior side of a fuel passage transecting the wall of a rotating kiln, opens to receive fuel and then seals during the balance of the rotation of the kiln. Warping, bearing fracture, shaft distortion and jamming due to exposure to extreme heat and cooling are minimized by the sectional construction of the doors. The door includes a plate positioned over the mouth of the passage, a plurality of support arms attached to the plate and a hinge shaft attached to the arms. Stresses on the door structure from inconsistent expansion of the plate are reduced due to symmetrically spaced oblong and oversized bolt attachment bores in the support arms. Synchronous opening of the feed doors is achieved by levered rotation of the hinge shafts by an electric motor. Selective introduction of supplemental fuel into a rotating kiln can be controlled by electrical actuation of the feed doors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates generally to agricultural planting equipment and more particularly to a disc opener assembly for a seed planter.
This section of this document is intended to introduce various aspects of art that may be related to various aspects of the present invention described and/or claimed below. This section provides background information to facilitate a better understanding of the various aspects of the present invention. It should be understood that the statements in this section of this document are to be read in this light, and not as admissions of prior art.
Efficient crop growth requires that seed be planted in different manners that depend at least in part upon soil conditions, fertilizer employed, seed type and anticipated weather and sun exposure conditions. To this end, a seed planter trench opener disc must be capable of opening a seed trench to a selected depth and accurately placing seeds therein to assure that the seed is in proper contact with the soil.
Existing seed planters include various types of depth adjusting mechanisms to control trench depth. One particularly useful type of depth adjusting mechanism provides gauge wheels that, when in a depth adjusting position, have a bottom wheel surface that generally resides proximate and vertically above the bottom disc edge of an associated trenching opener disc. Here, the wheel travels along a field surface and therefore limits disc depth into the soil. In many cases a plurality of disc openers are each independently mounted to a support bar for towing behind a tractor or the like and a separate gauge wheel is mounted to each of the disc openers via an adjustable linkage mechanism so that the vertical height difference (hereinafter “the surface-edge difference”) between the bottom wheel surface and the bottom disc edge is adjustable. For instance, an exemplary disc-wheel configuration may be adjustable so that the surface-edge difference can be set to between one and five inches.
Unfortunately, most depth control mechanisms of the type described above have one or more shortcomings. For instance, some depth control mechanisms of the above type have poorly located depth adjustments that make it difficult for an operator to access the adjusting mechanism. Some adjusting mechanisms require an operator to use two hands to adjust disc depth and to assume awkward positions when performing adjustments. Other adjusting mechanisms utilize a threaded shaft which takes a large amount of time to adjust and which has a tendency to seize up due to rust or become bound up due to accumulation of field debris. Still other adjusting mechanisms utilize one or a plurality of nut and bolt pairs to facilitate adjustment—these mechanisms often require two hands and are time consuming to manipulate. Moreover, many mechanisms require a large number of complex components that require small tolerances, are relatively expensive to manufacture and assemble and are expensive to maintain and replace when damaged. Furthermore, some mechanisms are difficult to manipulate as the mechanical advantage afforded by the mechanism designs is less than optimal. In addition, at least some prior mechanisms have increased the width of an associated seeding row unit disadvantageously.
Thus, it would be advantageous to have a seed planter disc opener assembly that provides a conveniently located depth control mechanism, that is operable via one hand, that requires minimal, simple and robust components and that is inexpensive to manufacture, assemble and maintain.
BRIEF SUMMARY OF THE INVENTION
Certain aspects commensurate in scope with the originally claimed invention are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the invention might take and that these aspects are not intended to limit the scope of the invention. Indeed, the invention may encompass a variety of aspects that may not be set forth below.
It has been recognized that the shortcomings described above with respect to the known prior art can be overcome by providing a simple cooperating coupler configuration where a moveable coupler moves along a coupling axis to engage and disengage another coupler and where the coupling axis is substantially parallel to a pivot axis of a gauge arm to which a gauge wheel is mounted. In some cases it has also been recognized that a handle member can be provided as a mounting base for the moveable coupler where the handle provides a relatively large mechanical advantage when manipulating the moveable coupler. Here, where the mechanical advantage is appreciable, in at least some cases, the force of a biasing member that biases the moveable coupler toward the other coupler may be increased to provide a more robust design. In addition, in at least some cases, the distance over which a disengaging action may occur can be greater than the distances facilitated by other depth control solutions and therefore the margin for manufacturing error can be increased appreciably and overall costs can be reduced.
Consistent with the above comments, at least some embodiments of the invention include a disc opener assembly connected to a tool bar linked to a vehicle for movement over the ground for opening a seed trench therein, the assembly comprising a main arm member attached to the tool bar, a disc mounted for rotation on the main arm, a gauge arm member having proximal and distal ends, the proximal end mounted for pivotal motion about a pivot axis to the main arm member, a gauge wheel mounted to the distal end of the gauge arm member, a first coupler mounted to one of the main arm member and the gauge arm member, a second coupler linked to one of the main arm member and the gauge arm member and juxtaposed proximate and for movement with respect to the first coupler along a coupling axis that is substantially parallel to the pivot axis, the second coupler configured to engage the first coupler when biased there against and a retainer for maintaining the first and second couplers engaged.
In at least some embodiments the first coupler is mounted to the main arm member and the second coupler is linked to the gauge arm member. The retainer or retainer member may be a biasing member or, in some cases, may be a mechanical latching assembly of some type.
In some cases a limit member may be rigidly mounted to and extending from the gauge arm member, the biasing member positioned between the limit member and the second coupler. Here, in some cases, the gauge arm member will form the limit member (i.e., the limit member will be an extension of the gauge arm member.
Some other embodiments of the invention include a disc opener assembly connected to a tool bar for movement over the ground for opening a trench therein, the assembly comprising a main arm member attached to the tool bar, a disc mounted for rotation on the main arm, a gauge arm member having proximal and distal ends, the proximal end mounted for pivotal motion about a pivot axis to the main arm member, a gauge wheel mounted to the distal end of the gauge arm member, a first coupler mounted to the main arm member, a second coupler linked to the gauge arm member and juxtaposed proximate and for movement with respect to the first coupler along a coupling axis that is substantially parallel to the pivot axis, the second coupler configured to engage the first coupler when biased there against, a biasing member mounted between the gauge arm member and the second coupler for biasing the second coupler toward the first coupler and a handle extending from the second coupler for moving the second coupler away from the first coupler to disengage the first and second couplers.
These and other objects, advantages and aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a perspective view of a tractor and a seed planting and depth control assembly according to at least one embodiment of the present invention;
FIG. 2 is a perspective view of depth control assembly of FIG. 1 ;
FIG. 3 is a perspective view of a gauge arm member and handle member sub-assembly of FIG. 2 ;
FIG. 4 is a partial plan view of the components of FIG. 3 ;
FIG. 5 is a partial cross-sectional view of the components of FIG. 4 ;
FIG. 6 is a partial perspective view of a gauge wheel mounting member shown in FIGS. 2 and 3 ;
FIG. 7 is a partial plan view of one of the couplers shown in FIG. 5 ;
FIG. 8 is similar to FIG. 3 , albeit illustrating another embodiment of the present invention; and
FIG. 9 is similar to FIG. 5 , albeit illustrating an embodiment of the present invention that does not include a biasing member but, instead, includes a retainer in the form of a latch assembly.
DETAILED DESCRIPTION OF THE INVENTION
One or more specific embodiments of the present invention will be described below. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
Referring now to the drawings and, more specifically, referring to FIG. 1 , the present invention will be described in the context of an exemplary agricultural tractor 5 including an agricultural implement attached to a rear end 6 thereof. The implement generally includes a tool bar 7 , at least one seed bin 74 and at least one seed planter assembly 10 . Tool bar 7 is generally an elongated rigid bar that extends perpendicular to the direction of tractor travel. Bin or Bins 74 are generally mounted above bar 74 while assembly or assemblies 10 are mounted below bar 7 when in an operating position and may be pivoted up into a position generally above bar 7 when in a stowed position for transport or the like. When in the operating position illustrated in FIG. 1 , an opening or trenching disc 14 cuts a trench in the ground over which tractor 12 travels as disc is pulled through a field. A gauge wheel 46 rides over the soil there below and limits trench depth as described in greater detail below. The present invention relates to the depth setting mechanism associated with wheel 46 .
Herein, while the implement mounted to the rear of tractor 5 may include a plurality of bins 74 and assemblies 10 spaced apart along bar 7 as well known in the art, each of the assemblies and bins would be similarly constructed and operate in a similar fashion and therefore only one of assemblies 10 will be described here in any detail. In addition, it should be recognized that seed planter assemblies 10 like the assemblies described herein may also be used on other types of seeding implements such as larger implements that may be pulled behind a tractor and be supported by separate implement support wheels like a wagon.
Referring now to FIGS. 2 through 7 , an exemplary assembly 10 is illustrated in greater detail and includes, generally, a main arm member 12 , a gauge a gauge arm member 16 , a main arm member extension 17 , a disc scraper 18 , a seed tube 20 , a handle member 24 , a first coupler 26 , a second coupler 22 and a biasing member 40 . Construction and general operation of disc 14 , seed tube 20 and gauge wheel 46 are well known in the art and therefore will not be described here in detail. Here, with respect to gauge wheel 46 , it should suffice to say that wheel 46 may be made from composite elements, such as a tire rim formed from metal or plastic, connected by a suitable fastener and having a semi-pneumatic tire disposed about its periphery. The semi-pneumatic tire helps reduce side-wall compaction of the seed trench 8 while allowing the gauge wheel 46 to move toward and away from the ground as the depth adjustment mechanism is operated.
With respect to disc scraper 18 , here it should suffice to say that scraper 18 is mounted on a scraper mount (not illustrated) attached below main arm member 12 and is aligned with the disc 14 to clean disc 14 . Scraper 18 is a planar member with at least one edge 32 that is aligned with the disc 14 and contacts the disc to clean dirt and plant debris from disc 14 as the disc is rotated. The disc scraper 18 is attached to the scraper mount by fasteners or other convenient and conventional means of mounting. Scraper 18 typically is made from steel which has been treated to have a high surface hardness which increases wear resistance.
With respect to seed tube 20 , it should suffice to say that tube 20 is a hollow cylindrical member that in linked to the interior of seed receptacle 74 (see FIG. 1 ) for receiving metered seed from receptacle 74 and depositing the seed into a seed trench formed by disc 14 . A deflector tab 79 is mounted to the lower end of seed tube 20 . If seed rebounds or deflects from a seed trench 8 there below, the deflector tab 79 redirects the seed back towards the seed trench 8 .
Referring now to FIGS. 1 and 2 , main arm member 12 includes proximal and distal ends 34 and 36 , respectively, the proximal end 34 mounted to tool bar 7 (see again FIG. 1 ) and the distal end 36 extending generally down and rearward therefrom. Distal end 36 forms two substantially horizontal openings (not labeled) that are used to mount many of the other assembly 10 components. For example, main arm extension 17 is mounted to distal end 36 via the openings and suitable mechanical fasteners (e.g., bolts). In addition, opening disc 14 is rotatably mounted via a forward one of the openings in a fashion well known in the art. As illustrated disc 14 is centrally mounted to the distal end 36 of arm member 12 for rotation along an axis generally perpendicular to the direction of tractor travel. Moreover, gauge arm member 16 is pivotally mounted to a rearward one of the openings. Hereinafter the axis about which the second or rearward opening is formed is referred to as a gauge wheel pivot axis or simply as a pivot axis 69 . In at least some embodiments main arm member 12 and extension 17 may be integrally formed such that a first coupler 32 can be said to be located at the distal end of the main arm member.
Referring still to FIG. 2 , when main arm extension 17 is mounted to the distal end of arm member 12 , extension 17 extends generally rearward therefrom and, at a distal end 48 , extends upward to a first coupler 26 . Referring also to FIG. 7 , first coupler 26 is a rigid member including a coupler surface 29 that forms a plurality of teeth or other suitably formed keyed recesses, three of which are collectively identified by numeral 50 . In at least some embodiments the teeth are formed in a uniform pattern wherein they generally extend along trajectories that fan out about a central point as illustrated in FIG. 7 .
Referring now to FIGS. 3 through 6 , gauge arm member 16 is generally a rigid, substantially planar member that has a shape for supporting other components that extend therefrom. In some embodiments member 16 may have some non-planar shape to facilitate unobstructed linkage and relative movement with respect to other assembly 10 components. Member 16 will be described primarily in the context of its orientation in FIG. 3 wherein relative juxtapositions of components are indicated via terms such as below, above, left and right in FIG. 3 .
Referring to FIG. 3 , a pivot post 56 extends substantially perpendicular to member 16 from a lower left hand corner thereof. The lower left hand corner is also referred to herein as the proximal end 21 of member 16 as end 21 is mounted to main arm member 12 . The end of member 16 opposite proximal end 21 is referred to herein as the distal end 19 . A distal end of post 56 forms an opening 57 for receiving a pin 28 to mount and secure post 56 within the second opening formed at the distal end of main arm member 12 (see again FIG. 2 ).
Referring to FIGS. 3 through 5 , two mounting member collectively identified by numeral 58 are welded or otherwise integrally secured to member 16 on the same side from which post 56 extends. Members 58 are secured to member 16 approximately midway between the left and right most edges of member 16 and proximate a lower edge of member 16 and are spaced apart so as to form a space for receiving a cylindrically shaped proximal end of handle member 24 therebetween in a lengthwise fashion. In addition, each of members 58 forms an opening 76 (only one illustrated) where the openings 76 are formed about a rotation axis 68 and are aligned to receive a bolt or other suitable mechanical fastener therethrough. Rotation axis 68 is perpendicular to pivot axis 69 as best seen in FIG. 3 .
Two guide members collectively identified by numeral 60 are welded or otherwise rigidly secured to and extend form the same side of gauge arm member 16 as post 56 . Guide members 60 are positioned above members 58 and such that they form a space therebetween for receiving the shaft of handle member 24 . In at least some embodiments the facing surfaces of members 60 may slope toward each other proximate the surface of member 16 so that when the handle shaft is rotated to a position therebetween the shaft is snuggly received therebetween. Here, the surface of gauge arm member 16 and, in some cases, guide members 60 , form a limit surface or operate as a limit member for limiting the extent of handle member 24 rotation about axis 68 .
Referring to FIGS. 1 , 2 , 3 and 6 , a gauge arm extension 62 extends from the distal end 19 of gauge arm member 16 and includes two sub-members. A first sub-member 64 extends perpendicular to member 16 and in a direction opposite the direction in which post 56 extends. A second sub-member 66 extends from a distal end of member 64 , substantially parallel to member 64 and generally in the direction of tractor travel (i.e., generally to the right in FIG. 3 ). As seen in FIG. 6 , an opening 78 is formed in second sub-member 66 . Gauge wheel 46 is mounted for rotation via a suitable mechanical fastener to opening 78 .
Referring to FIG. 5 , gauge member 16 forms a recess 80 between members 58 and guide members 60 that, when the proximal end of handle member 24 is mounted between members 58 , is aligned with a portion of the shaft of handle member 24 as illustrated. Recess 80 is dimensioned to receive one end of the biasing member or, in the illustrated example, spring 40 therein. In addition, in at least some cases, to help retain a spring within recess 80 , a post 82 may be centrally formed within recess 80 so that the end of the spring 40 received within recess 80 is juxtaposed between facing surfaces of the post 82 and recess 80 .
Referring to FIGS. 1 through 5 , handle member 24 is a rigid elongated member having opposite distal and proximal ends 84 and 86 , respectively. Handle member 24 may be many different lengths but, preferably, is long enough that the distal end thereof extends above other assembly 10 components. In at least some embodiments handle 24 will be longer that a foot long. A cylindrical mounting member 70 is provided at proximal end 86 . Member 70 has a length dimension (not labeled) that fits within the space defined by the facing surfaces of mounting members 58 and forms an opening (not illustrated) having a radius that is similar to the radius of the openings 76 formed by members 58 . To mount handle 24 to gauge arm member 16 , mounting member 70 is placed between the facing surfaces of members 58 such that the openings formed thereby are aligned with rotation axis 68 . Thereafter a bolt or other suitable mechanical fastener is used to secure the mounting members 70 and 58 such that member 70 can rotate about axis 68 .
Referring still to FIGS. 1 through 5 , second coupler 22 has a generally block shaped form and is welded or otherwise rigidly secured on one side to the shaft of handle member 24 approximately midway along the length of member 24 and, in at least the illustrated embodiment, between mounting members 58 and guide members 60 when handle member 24 is secured to gauge member 16 as described above. Second coupler 22 includes a coupling surface 90 that, like surface 29 , forms a plurality of teeth 92 (only three collectively labeled) that extend along trajectories that fan out about a central axis (not labeled) in a fashion similar to that of teeth 50 . The pattern of teeth 92 is a mirror image of teeth 50 formed by surface 29 (see again FIG. 7 ) so that teeth 92 and teeth 50 mesh together. Other surface configurations are contemplated that facilitate rigid coupling of couplers 22 and 26 . For example, in at least some embodiments one of surfaces 29 or 90 may form a single tooth that is receivable between two of the teeth formed on the other of the couplers to secure relative positions. In other embodiments the teeth may be replaced by relatively smooth recesses and ribs that cooperate to maintain relative positions when in contact.
Importantly, the coupling surfaces 29 and 90 have to be able to couple when gauge arm member 16 and handle ember 24 are in any of several different positions. Thus, for instance, referring to FIGS. 3 and 7 , during a first seeding operation member 16 and associated second coupler 22 may be positioned such that second coupler surface 90 engages only the portion of first coupler surface 29 including teeth 50 a . Similarly, during a second seeding operation member 16 and associated second coupler 22 may be positioned such that second coupler surface 90 engages only the portion of first coupler surface 29 including teeth 50 b . During other seeding operations other relative juxtapositions of coupler surfaces 29 and 90 are contemplated for altering trenching depth. Thus, in the illustrated example the central axis from which the trajectories of teeth 50 and 92 fan out should be a common axis to ensure accurate registration of teeth 50 and 92 for coupling purposes.
Referring to FIG. 5 , a post member 98 extends from the surface of the shaft of handle member 24 opposite second coupler 22 . post member 98 has dimensions similar to post member 82 that extends from within recess 80 such that the second end of spring member 40 is receivable thereon for support and guidance.
Biasing spring 40 is generally a helical spring member. Spring 40 has a length dimension such that spring 40 is partially loaded when compressed between the facing surfaces of recess 80 and the shaft of handle member 24 with the first and second couplers 26 and 22 , respectively, engaged. Thus, spring member 40 biases the couplers into engagement.
Referring now to FIGS. 1 through 5 and 7 , it should be appreciated that the depth of a trench formed by disc 14 as assembly 10 is pulled through a field is easily adjustable via manipulation of handle member 24 . To this end, the relative vertical positions of the lower edges of disc 14 and gauge wheel 46 are adjustable by rotating handle member 24 in a clockwise direction about axis 68 as indicated by arrow 100 in FIG. 5 and against the force of biasing spring 40 so that coupler 22 becomes decoupled from coupler 26 , rotating handle member 24 and associated gauge arm member 16 about pivot axis 69 (see also FIG. 4 ) to a different position and then rotating handle member 24 in a counter-clockwise direction about axis 68 as indicated by arrow 102 in FIG. 5 and with the force of biasing spring 40 so that coupler 22 becomes re-coupled to coupler 26 . Referring also to FIG. 4 , when handle member 24 and gauge arm member 16 are rotated in a clockwise direction as indicated by arrow 104 in FIG. 4 , distal end 19 of gauge arm member 16 also rotates clockwise as indicated by arrow 106 and hence gauge wheel 46 is lowered and the trench depth is reduced. Similarly, when handle member 24 and gauge arm member 16 are rotated in a counter-clockwise direction as indicated by arrow 108 in FIG. 4 , distal end 19 of gauge arm member 16 also rotates counter-clockwise as indicated by arrow 110 and hence gauge wheel 46 is raised and the trench depth is increased.
Referring to FIGS. 2 through 5 , when handle member 24 is rotated about rotation axis 68 and such that second coupler 22 disengaged first coupler 26 , the shaft of handle member 24 is received between guide members 60 and is supported there between to reduce the force applied to members 58 during pivoting action about pivot axis 69 . The sloped facing surfaces of members 60 snuggly receive the handle shaft to ensure sufficient support.
While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. For example, FIG. 8 illustrates a portion of another inventive embodiment wherein the portion of handle member 24 between proximal end 86 and second coupler 22 is formed of a resilient steel spring member 24 a that is angled away from the surface of member 16 to which it is attached by a ramp member 112 . In this embodiment spring steel member 24 a provides the biasing means to bias handle 24 and coupler 22 toward and into engagement with first coupler 26 (see also FIG. 7 ). Although not illustrated other biasing assemblies are contemplated such as, for instance, a loaded helical spring within cylinder member 70 or some type of spring or bungee member between the first and second couplers 22 and 26 .
In addition, in at least some embodiments, instead of providing a biasing member to maintain the first and second couplers engaged, some type of mechanical retaining member may be provided. To this end, referring to FIG. 9 , a schematic similar to the schematic of FIG. 5 described above shows one embodiment where a clip assembly 119 includes a member 120 that extends from the top edge of the coupler surface formed by second coupler to a distal end 124 and a latch member 126 that is pivotally linked to the distal end of member 120 . Member 120 is dimensioned to extend past first coupler 26 when the first and second couplers are coupled. A distal end of latch member 126 forms a latching rib 130 . A rear surface 132 of first coupler 26 opposite the coupling surface 29 forms a recess 122 for receiving latching rib 130 . When couplers 22 and 26 are engaged and rib 130 is within recess 122 , the couplers are secured in their engaging state. To decouple the couplers 22 and 26 member 126 is pivoted about end 124 and handle 24 is rotated clockwise about axis 68 as illustrated in FIG. 9 . Other mechanical retaining mechanisms are contemplated.
Moreover, while the invention is described in the context of an assembly 10 where the gauge wheel 46 resides generally behind and partially laterally to one side of the disc 14 , other configurations are contemplated wherein wheel 46 resided entirely behind disc 14 or to the opposite side of disc 14 . Moreover, additional other wheels and assembly components may be secured to the main arm member or the gauge arm member such as, for instance, packer wheels, sensors, fertilizer tubes, etc.
Thus, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. To apprise the public of the scope of this invention, the following claims are made:
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A disc opener assembly connected to a tool bar linked to a vehicle for movement over the ground for opening a seed trench therein, the assembly comprising a main arm member attached to the tool bar, a disc mounted for rotation on the main arm, a gauge arm member having proximal and distal ends, the proximal end mounted for pivotal motion about a pivot axis to the main arm member, a gauge wheel mounted to the distal end of the gauge arm member, a first coupler mounted to the main arm member, a second coupler linked to the gauge arm member and juxtaposed proximate and for movement with respect to the first coupler along a coupling axis that is substantially parallel to the pivot axis, the second coupler configured to engage the first coupler when biased there against and a retainer for maintaining the first and second couplers engaged.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic focusing device for a camera.
In a conventional automatic focusing device, a range finder section, which senses the distance to the object, senses this distance only with respect to a main object, that is, it performs the focusing operation only with respect to an extremely limited portion of the photographing field, such as the central portion. Accordingly, the composition is standardized, and hence the conventional automatic focusing device is not suitable for many picture taking situations.
In order to overcome the above-described difficulty, an automatic focusing device has been proposed in which a range finder section measuring a distance to an object at the center of the photographing field is provided, and the distance data provided by the range finder section is stored. The photographer can then compose a picture by focusing on a desired object and then moving the camera to position the desired object in a location other than at the center of the field. After the composition has been determined in this manner, the shutter is operated. However, with the device, it is necessary for the operator to perform intricate operations to determine the composition before a picture is taken. Accordingly, the device is disadvantageous in that it is difficult for the beginner to use skillfully.
In view of the foregoing, an object of the invention is to provide an automatic focusing device for a camera in which the composition of objects to be photographed can easily be determined as required, and sharp and clear pictures can be taken by simple operations.
SUMMARY OF THE INVENTION
The foregoing object of the invention has been achieved by the provision of an automatic focusing device for a camera which, according to the invention, includes a range finder section in which light emitted by a light emitting section is applied to objects to be photographed, the light reflected from the objects is received by a linear array of light detecting elements and signals are outputted by the various light detecting elements which represent distances to objects in different portions of the photographing field from an image pickup surface; scanning means for causing the range finder section to scan in a predetermined range while directing it towards a main object; a memory section for detecting and storing only the distance signal provided for an object at the shortest distance among the distance signals provided by the range finder section during the scanning operation by the scanning means; and a lens driving section for, in response to the signal stored in the memory section, moving a photographing lens to a focusing position for the object at the shortest distance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the overall arrangement of an automatic focusing device of the invention;
FIG. 2 is a circuit diagram showing a logic circuit used in the device of FIG. 1;
FIG. 3 is an explanatory diagram used for a description of the scanning operation of a range finder section in the device of FIG. 1;
FIG. 4 is an explanatory diagram for a description of a photographing field;
FIG. 5 is an explanatory diagram for a description of another example of a scanning device of the range finder section;
FIG. 6 is an explanatory diagram for a description of another example of a scanning device of the range finder section; and
FIG. 7 is an explanatory diagram showing a modification of the range finder section in which scanning is eliminated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the invention will be described with reference to the accompanying drawings.
First, the arrangement of a range finder section employed in an automatic focusing device of the invention will be described. The range finder section 1, as shown in FIG. 1, includes a light emitting section 2, first and second optical systems 3 and 4, and a light detecting element array 5. The light emitting section 2 is preferably implemented with a light emitting diode. Light emitted by the light emitting section 2 is formed into a light beam by the first optical system 3, namely, a condenser lens, and the light beam thus formed is applied to objects A, B and C. Portions of this light reflected from the objects A, B and C are applied to the light detecting element array 5 through the second optical system 4, namely, an image forming lens. The light detecting elements 5a, 5b, 5c and 5d, which form the light detecting element array 5, are arranged in a line extending perpendicular to the optical axes of the optical systems 3 and 4. For convenience in description, the number of light detecting elements in the light detecting element array 5 is only four, although more such elements may ordinarily be provided.
The range finder section 1 is so designed that it rotates while confronting the objects A, B and C, thereby to scan the objects A, B and C. The image forming position on the light detecting element array 5 is equivalent to the position of an image pickup surface. A rotating drive mechanism, which effects the scanning of the range finder section 1, is so designed as to scan the array 5 through a predetermined range when the shutter button (not shown) is pushed.
The outputs of the light detecting element array 5 are applied to a photoelectric conversion circuit 6 where the output photocurrents of the elements 5a through 5d are converted into corresponding voltages. The outputs of the photoelectric conversion circuit 6 are applied to first input terminals of voltage comparators 7a, 7b, 7c and 7d and there compared with a reference voltage provided by a power source 8. The outputs of the voltage comparators 7a, 7b, 7c and 7d are applied to inputs of a register 9 and are loaded into the register 9 by a pulse from a one-shot multivibrator circuit 10.
The outputs of the register 9 are supplied to a logic circuit (described below in detail). The logic circuit 8 produces as an output the distance signal corresponding to the shortest distance to the objects A, B and C (assumed to be the object A in the case of FIG. 1). The detection output is stored in a register 12, which forms a memory section together with the logic circuit 11 and the register 9. The output stored in the register 12 is applied to a lens driving circuit 13 which moves the photographing lens to the focused position for the object at the shortest distance.
An example of the logic circuit 11 will be described in more detail. As shown in FIG. 2, the circuit 11 has four input terminals 14, 15, 16 and 17. The input terminal 14 is connected directly to an output terminal 18, and further is connected through an inverter 19 to a first input terminal of an AND gate 20. The input terminal 15 is connected to a second input terminal of the AND gate 20, and is connected through an inverter 21 to a first input terminal of an AND gate 22. The second input terminal of the AND gate 22 is connected to the output terminal of the inverter 19, and the third input terminal of the AND gate 22 is connected to the input terminal 16. The input terminal 16 is connected through an inverter 23 to a first input terminal of an AND gate 24, the second and third input terminals of which are connected respectively to the output terminals of the inverters 19 and 21. The fourth input terminal of the AND gate 24 is connected to the input terminal 17. The AND gates 20, 22 and 24 have output terminals 25, 26 and 27, respectively.
In the logic circuit 11 described above, when a high level signal is applied to the input terminal 14, it appears directly at the output terminal 18, and a low level signal is supplied to the first input terminal of the AND gate 20, the second input terminal of the AND gate 22, and the third input terminal of the AND gate 24 through the inverter 19. Accordingly, in this case, a high level signal is obtained at the output terminal 18 whether signals applied to the input terminals 15, 16 and 17 are at the high level or at the low level. In the case where a low level signal is applied to the input terminal 14 and a high level signal is applied to the input terminal 15, the output of the AND gate 20 is raised to the high level, the low level signal appears directly at the output terminal 18, and the first input terminal of the AND gate 22 and the second input terminal of the AND gate 24 are at the low level. Accordingly, in this case, no matter what level signals are applied to the input terminals 16 and 17, low level signals are obtained at the output terminals 18, 26 and 27. In the case where low level signals are applied to the input terminals 14 and 15 and a high level signal is applied to the input terminal 16, the signals at the three input terminals of the AND gate 22 are at the high level, and hence a high level signal is provided at the output terminal 26 while the outputs of the AND gates 20 and 24 are set to the low level. Accordingly, in this case, a high level signl is obtained only at the output terminal 26 no matter what level signal is applied to the input terminal 17.
In the case where a high level signal is applied to the input terminal 17 and low level signals are applied to the remaining input terminals 14, 15 and 16, a high level signal is obtained only at the output terminal 27. When low levels signals are applied to all of the input terminals 14, 15, 16 and 17, then the low level signals are provided at all the output terminals 18, 25, 26 and 27.
The high level signal applied to the input terminals 14, 15, 16 and 17 as described above indicates the object at the shortest distance from the image pickup surface, and the output terminals 18, 25, 26 and 27 instruct different settings of the photographing lens to thus suitably operate the lens driving circuit 13. When low levels signals are applied to all of the input terminals 14 through 17, the focusing position of the photographing lens is set to infinity.
The operation of the automatic focusing device thus constructed will be described. In taking a picture, the shutter button is depressed with the range finder section 1 directed towards th main object (X in FIG. 3). Depressing the shutter turns on the power switch, at which time the light emitting section 2 in the range finder section 1 emits light and, at the same time, the range finder section 1 starts rotating. While the range finder section 1 is turning, the one-shot circuit 10 outputs a pulse, clocking the register 9. The range finder section 1 is turned by the above-described rotating drive mechanism to scan the area F in the predetermined distance measurement range (as indicated by the broken line) thereby to measure distances.
Light emitted by the light emitting section 2 and reflected from the objects is received by the light detecting elements according to the distances to the objects. For instance, in the case where, in the distance measurement range, the objects X, Y and Z are at the shortest distance, at an intermediate distance and at the longest distance, respectively, all the light detecting elements 5a, 5b, 5c and 5d receives light thus reflected. The outputs of the light detecting elements 5a through 5d are applied through the photoelectric conversion circuit to the voltage comparators 7a, 7b, 7c and 7d where they are compared with the reference voltage provided by the reference power source 8. When the outputs are higher than the reference voltage, the outputs of the comparators 7a, 7b, 7c and 7d are raised to the high level. These high level signals are stored in the register 9. Accordingly, the signals applied to the input terminals 14, 15, 16 and 17 by the register 9 are at the high level. Therefore, only the output terminal 18 provides a high level signal, and the other output terminals 25, 26 and 27 provide low level signals, as described above.
The high level signal at the output terminal 18 is supplied to the register 12 where it is stored as the distance signal, that is, the distance signal only for the object X which is at the shortest distance. The lens driving circuit operates according to the output distance data of the register 12 to move the photographing lens as required, and then the shutter is released. These operations are achieved nearly instantaneously. Therefore, in practice, the photographing operation is accomplished merely by depressing the shutter button. In this operation, the image of the main object is clearly formed at any desired position on the image pickup surface.
FIGS. 5 and 6 show other examples of scanning devices. In the first-described embodiment, the range finder section 1 itself is rotated. In the case of FIG. 5, the light emitting section 2 is stationary, and a drive mechanism (not shown) is provided to move the first and second optical systems 3 and 4 in the longitudinal direction of the light detecting element array 5 (in the direction of a arrow n in FIG. 5), that is, the direction along which the light detecting elements are arranged, while maintaining the distance D between the optical axes of the optical systems 3 and 4 unchanged. On the other hand, in the case of FIG. 6, the first and second optical systems 3 and 4 are stationary, and a drive system is provided to move the light detcting element array 5 and the light emitting section 2 in the longitudinal direction of the light detecting element array 5 while maintaining the distance between the light emitting section 2 and the light detecting element array 5 unchanged. With either of the scanning devices shown in FIGS. 5 and 6, the position of the image of the object is changed with the relative movement of the optical systems 3 and 4 and the light detecting element array 5. This effect is equivalent to that which is obtained by rotating the range finder section 1. The other components and their operations are the same as those which have been described before.
FIG. 7 shows another example of the range finder section which in this case, can measure distances without mechanical scanning. In this example, the light emitting section is an elongated light source 28 which extends in a horizontal direction, and the first optical system is a cylindrical condenser lens 29 which is arranged confronting the elongated light source 28. The second optical system is a cylindrical image-forming lens 30 which is disposed in such a manner that there is a distance D between the optical axes of the lenses 29 and 30. An elongated light detecting element array 31 is arranged confronting the cylindrical image-forming lens 30. An imaginary line connecting the optical axes of the lenses 29 and 30 is perpendicular to the longitudinal direction of the elongated light souce 28. The longitudinal direction of each of the elongated light detecting elements 31a, 31b, 31c and 31d which form the elongated light detecting element array 31 is perpendicular to the imaginary line connecting the optical axes of the lenses 29 and 30. A photographing lens 32 is disposed between the lenses 29 and 30 which is movable along the optical axis by the above-described lens driving circuit 13.
In the range finder section 33 thus constructed, the elongated light source 28 extends in the widthwise direction of the photographing field F, and the light detecting elements in the array 31 also extend in the widthwise direction of the photographing field F. Accordingly, the effect of the light fluxes reflected from the objects X, Y and Z is equivalent to the case of scanning in the above-described examples. As the light source 28 extends horizontally, the range of application of light to an object can be adjusted and the range of scanning can be substantially increased. Therefore, an infrared flashgun, for instance, which produces a large quantity of light may be used as the light source 28. In the case of FIG. 7, the logic circuit 11 for processing the outputs of the light detecting element array 31 is the same as that in the abovedescribed example. However, since the time required for the scanning operation to measure distances is eliminated, the width of the output pulse of the one-shot circuit 10 can be greatly decreased. The other components and their operations are the same as those of the above-described examples.
As is apparent from the above description, according to the invention, the distance between the image pickup surface and an object at the shortest distance is measured and the photographing lens is positioned accordingly. Thus, no matter where the main object is positioned, sharp and clear pictures can be taken. Furthermore, as it is unnecessary for the operator to perform inticate operations before pictures are taken, cameras employing the automatic focusing device of the invention are suitable for beginners.
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In automatic focusing device for a camera in which the photographing lens of the camera is automatically focused on a closest object within the photographing field. An array of light detecting elements receives light reflected from a light emitting section by various objects within the photographing field. A logic circuit detects the output from the detector which represents the closest object in the field and positions the photographing lens of the camera accordingly.
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TECHNICAL FIELD
[0001] The invention relates to an overpass, and especially an interchange overpass suitable for city roads and highways.
BACKGROUND
[0002] In order to solve traffic jams at city intersections many types of overpasses have been employed. Generally, triple level and higher grade overpass intersections are built for channeling motor and non-motor vehicles and for enabling transfer without impact and interference. Such high grade overpasses with their extra long ramps inconvenience drivers and occupy too much space. Especially in cities where much repositioning has to be done, the compensation cost for relocation of residents may be high. Providing clover-type overpasses will cause traffic jams in case of increased vehicle flow due to entanglement between the turning vehicles and the circling vehicles.
SUMMARY OF THE INVENTION
[0003] The invention provides a single-level interchange overpass having simple construction and full functionality, and occupying less space.
[0004] The technical solution of the invention is as follows: a single-level interchange overpass according to this invention comprises a main road and an intersected road, wherein a U-shaped circle road is provided on the horizontal level at both ends of the main road, a inner semicircle road and a outer semicircle road are provided at an exit of the said U-shaped circle road, a common road is provided between the inner semicircle road and the outer semicircle road, the common road is connected to an on-ramp of the intersected road through the outer semicircle road, and an off-ramp of the intersected road is connected to the on-ramp of the main road through the inner semicircle road.
[0005] In the above-described technical solution, an arched separated bridge is provided on the main road of the single layer interchange overpass, semi-ramped overhead bridge stages are provided on the intersected road on both sides of the arched separated bridge, the said semi-ramped overhead bridges stages are connected with the arched separated bridge through a connection platform, U-shaped circle roads are provided on the horizontal level at both ends of the arched separated bridge, the arcuate end of the outer semicircle road and the inner semicircle road is connected to the U-shaped circle road, the other end of the outer semicircle road and inner semicircle road of the U-shaped circle road is connected to the connection platform, a branch common road is provided on the off-ramp of the arched separated bridge of the main road, the other end of the common road is connected to the connection platform, a right turn road is provided at the entrance of the upper and lower U-shaped circle roads, and the other end of the right turn road is connected to the on-ramp of the arched separated bridge.
[0006] In the technical solution of this invention, in the single layer interchange overpass, the main road can be a leveled driveway, and the intersected road can be an overhead bridge, the U-shaped circle road comprises the inner semicircle road and the outer semicircle road, the common road is connected with the entrance of the outer semicircle road of the U-shaped circle road on other side of the overhead bridge after passing through under the overhead bridge, and the inner semicircle road is connected to the on-ramp of the main road through the left turn driveway.
[0007] The effects of the invention are as follows:
[0008] Reduction of the traditional 3 or 4 layer overpass to a single layer overpass allowing for transfer of vehicles from different directions and for separation of the motor and non-motor vehicles without inference. Pedestrians can walk on the original road eliminating the need to pass through tunnels or pedestrian overpasses. Reduction of the number of layers in the structures leads to an economic benefit.
[0009] The ramp of the overpass is slow which provides significant advantages of energy saving, noise reduction and wasteful exhaust reduction.
[0010] The compact construction occupies less space, producing high efficiency ramps, while low height of the construction facilities reduction in costs, environmental protection, and improved aesthetic sense.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a plan view and directional scheme of one embodiment of the invention;
[0012] FIG. 2 is a cross-sectional view along the line A-A of FIG. 1 ;
[0013] FIG. 3 is a plan view and directional scheme of another embodiment of the invention;
[0014] FIG. 4 . is a plan view and directional scheme of yet another embodiment of the invention.
[0015] In the Figs: 1 —main road, 2 —arched separated bridge, 3 —intersected road, 4 —inner semi-circular road, 5 —outer semi-circular road, 6 —underpass tunnel, 7 —common road, 8 —semi-ramped overhead bridge, 9 —right on-ramp, 11 —bidirectional median, 12 —non-motor vehicle road, 13 —secondary road, 14 —left turning circle road, 17 —convergent secondary road, 18 —U-shaped circle road entrance, 19 —ventilating window, 23 —connection platform, 24 —U-shaped circle road, 25 —arcuate end, 26 —U-turn median, 27 —straight transition road, 28 —U-turn road, 29 —overhead bridge, 30 —left turn branch lane, 31 —right turn branch lane, 32 —right turn road, 33 —outer pass way.
DETAILED DESCRIPTION
[0016] Conventional circle-type intersections are associated with traffic jams caused by the entanglement and interference between vehicles making turns and vehicles circling on the overpasses. In order to solve this problem, in the overpass of the invention an outer semicircle road 5 and an inner semicircle road 4 are provided on the U-shaped circle road 24 on the upper side of the main road 1 to channel the turning vehicles and the straight-going vehicles. At the same time a common road 7 is provided between the outer semicircle road 5 and the inner semicircle road 4 to prevent the vehicles on the U-shaped circle road 24 from interfering.
[0017] The invention will now be described in detail in accordance with the drawings. In the embodiments the terms “left” and “right” refer to the travel direction of the vehicles, and the terms “upper” “lower” “left” and “right” refer to the orientation of the overpasses. With the overpass forming a base for an off-ramp and an on-ramp, the road entering the overpass is the off-ramp and the road exiting the overpass is the on-ramp.
EXAMPLE 1
[0018] As shown is FIG. 1 , an overpass is provided at an intersection. The intersection is divided into the upper, lower, left, and right roads in which the main road 1 accommodates vehicle flow in the upper and lower direction, and the intersected road 3 accommodates vehicle flow in the left and right direction. The four roads of the overpass are leveled with the driveway's surface and are connected therewith. The straight main road 1 on the overpass is the arched separated bridge 2 which has the highest height at a position where the main road 1 intersects the intersected road 3 . There is a ramp extending from the highest point of the arched separated bridge 2 down the upper and lower direction to connect it in the direction of the main road 1 . The semi-ramped overhead bridge stages 8 are provided at the left and the right of the intersected road 3 at both sides of the arched separated bridge 2 . One end of the semi-ramped overhead bridge stage 8 is connected with the arched separated bridge 2 at the same level and forms a connection platform 23 , and the other end is connected with the driveway in left and right directions, i.e., in the direction of the intersected road 3 . The arched separated bridge 2 and the semi-ramped overhead bridge stage 8 are provided with bidirectional driveways having off-ramps and on-ramps. The U-shaped circle road 24 which is leveled with the connection platform 23 is provided at a height of the upper and lower direction ramps of the arched separated bridge 2 . The U-shaped circle road 24 comprises entrances 18 and exits connected with the left connection platform 23 and the right connection platform 23 , respectively, and also the arcuate end 25 between the entrance 18 and the exit. The exit comprise an inner semi-circle road 4 in proximity to the interior of the main road 1 and an outer semi-circle road 5 positioned on the outer side of the main road 1 . The arcuate end 25 of the U-shaped circle road 24 is higher with respect to the ramp of the arched separated bridge 2 . The other end of the entrance 18 and the exit of the U-shaped circle road 24 are connected with the connection platform 23 of the left and right semi-ramped overhead bridge stage 8 , respectively. A closed-circle road is formed after connecting the upper and lower U-shaped circle roads through the connection platform 23 . The shape of the circle road is similar to that of the racetrack in a stadium. The unidirectional driveway running anticlockwise is used in the above-referenced circle road.
[0019] On the inner side of the outer semicircle road 5 of the upper and lower U-shaped circle road 24 , i.e., between the arched bridges 2 and the outer semicircle road 5 , an inner semicircle road 4 is provided. One end of the inner semicircle road 4 is connected with the arcuate end 25 of the U-shaped circle road and the other end is connected with the connection platform 23 of the arched separated bridge 2 .
[0020] A branch common road 7 is provided as the off-ramp of the arched separated bridge 2 of the main road 1 . The above-referenced common road 7 connects the road surface of the main road 1 with the connection platform 23 or the ramp of the arched separated bridge 2 after passing vertically under the accurate end 25 of the U-shaped circle road 24 . The connector of the common road 7 and the connection platform 23 is located between the connectors of the inner semicircle road 4 and the outer semicircle road 5 and the connection platform 23 , respectively. The inclusion of common road 7 effectively ensures the traveling of vehicles on the connection platform 23 and the U-shaped circle road 24 without interference.
[0021] The right on-ramp 9 is provided at the entrance 18 of the upper and lower U-shaped circle road 24 i.e. the right side of the upper U-shaped circle road 24 and the left side of the lower U-shaped circle road 24 . The other end of the right on-ramp 9 is connected with the on-ramp of the arched separated bridge 2 .
[0022] As shown in FIG. 1 , due to the design of overhead arched separated bridge 2 and the semi-ramped overhead bridge stage 8 , the non-motor vehicle road 12 for bicycles and pedestrians is provided under the overpass. The non-inference with motor vehicles in the areas of the existing intersections fully satisfies the condition of transfer of the pedestrians and bicycles. Therefore the inconvenience that would be caused by construction of the underground passage way is eliminated. In order to improve the illumination under the overpass, ventilation windows 19 passing through the surface of the overpass are formed at the connection platform 23 of the overpass.
[0023] Below the traveling directions of the vehicles on the overpass are explained with reference to arrows indicating the traveling directions in FIG. 1 . (1) Straight ahead from lower to upper side: vehicles pass over the overpass along the right entrance of the bidirectional driveway in the lower main road 1 through the arched separated bridge 2 straight ahead from the lower side under the arcuate part 25 of the U-shaped circle road 24 through to the on-ramp of the upper main road 1 . (2) Straight ahead from left to right: vehicles travel to the left connection platform 23 after entering the left semi-ramped overhead bridge stage 8 from the on-ramp of the bidirectional driveway in the left intersected road 3 , and then enter the connection platform 23 , turn right entering the entrance 18 of the outer U-shaped circle road 24 , again enter the right connection platform 23 from outer semi-circle or road 5 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 ; then turn right and travel across the overpass entering the right off-ramp of the intersected roads from the right semi-ramped over head bridge stage 8 , completing the straight way on the intersected roads via a zigzag manner instead of straight manner. (3) Turn from the lower main road 1 onto the right interested road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the right intersected road 3 and passing through the overpass. (4) Turn from the lower main road 1 onto the left intersected road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then continue straight up to the upper U-shaped circle road 24 , turning around into the left connection platform 23 along the upper outer semicircle road 5 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the left intersected road 3 and passing through the overpass.(5) Turn from the left intersected road 3 into the lower main road 1 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 vehicles enter the connection platform 23 , and then turn right into the lower U-shaped circle road 24 , enter the on-ramp of the lower main road of the right on-ramp 9 which is connected with the lower U-shaped circle road 24 , and so pass through the overpass. (6) Turn from the left intersected road 3 onto the upper main road 1 : after entering the semi-ramped overhead bridge stage 8 through the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 , turn right into the lower U-shaped circle road 24 , and then enter the right connection platform 23 from the inner semi-circular road 4 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 , and enter the on-ramp of the upper arched separated bridge 2 by merging left on the right connection platform 23 , and then pass through the overpass from the on-ramp of the upper arched separated bridge 2 accomplishing the convergence into the main road without interference with the convergent secondary road 17 , and pass through the overpass from the on-ramp of the upper arched separated bridge 2 . (7) Return to the lower main road 1 from the lower main road 1 : The vehicles enter the right common road 7 along the entrance of the bidirectional driveway in the lower main road 1 , and enter the right connection platform 23 from the common road 7 , straightway to the upper U-shaped circle road 24 , then enter the left connection platform 23 passing around the inner semicircle road 4 of the upper U-shaped circle road 24 along the upper U-shaped circle road 24 , and then enter the left connection platform 23 into the on-ramp of the lower arched separated bridge 2 by merging left off of the left connection platform 23 , turning back to the on-ramp of the lower main road 1 from the on-ramp of the lower arched separated bridge 2 . (8) Return to the left intersected road 3 from the left intersected road 3 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 and turn right into the lower part of connection platform 23 , then turn around into the inner semi circle road 4 of the lower U-shaped circle road 24 along the lower U-shaped circle road 24 , and then enter the right connection platform 23 , and then enter the upper U-shaped circle road 24 by bearing right on the right connection platform 23 , then enter the left connection platform 23 from the outer semi circle road 5 of the upper U-shaped circle road 24 , along the arcuate part 25 of the upper U-shaped circle road 24 , then turn right to enter the right on-ramp of the left intersected road 3 from the left semi-ramped overhead bridge stage 8 , thus accomplishing the turnaround.
[0024] From the foregoing it is clear that that the height of the overpass of the invention is reduced compared with the typical multilayer overpass, and also the occupied ground area and ramp size have been reduced. Compared with the clover-like overpass there is no interference on the main roads which facilities turning of the vehicles on the overpass in left and right direction and turning back.
[0025] Because the overpass of the invention is of single layer, not including the ground, therefore the height from the ground is limited only by the U-shaped circle road and generally is about 5 meters of clearance.
[0026] In order to increase the driving safety, the double solid line or the bidirectional median 11 between the bidirectional driveways is used to separate the driveways in two directions. In the case of driving to the on-ramp of the arched separated bridge 2 from the inner semicircle road 4 through the connection platform 23 , a convergent secondary road 17 is provided at the right side of the on-ramp of the arched separated bridge 2 for avoiding accidents caused by the abrupt entering of vehicles.
[0027] In this embodiment, vehicles are assumed to drive on the right side of the road; for other countries or regions where vehicles travel on the left side of the road, arrangement of the driveways on the overpass can be changed accordingly, and this is also contemplated by the invention.
EXAMPLE 2
[0028] The U-shaped circle road 24 is relatively long because the ramp length of the arched separated bridge 2 must satisfy the regulation of the ramp of the driveway and ensure clearance between the arcuate part 25 of the U-shaped circle road 24 and the arched separated bridge 2 . As shown in FIG. 2 , in order to shorten the length of the U-shaped circle road 24 , construction of the embodiment 1 is partially modified by allowing the height of the arcuate part 25 of the U-shaped circle road 24 to exceed the height of the connection platform 23 , so that the combination of the upper and lower U-shaped circle roads 24 has a saddle-like shape. Thus, in order to shorten the length of the U-shaped circle road 24 , vehicles will enter an up-ramp when traveling from the connection platform 23 onto the U-shaped circle road 24 , and will enter a down-ramp when traveling from the U-shaped circle road 24 onto the connection platform 23 .
[0029] Because vehicles enter an up-ramp after entering the entrance 18 of the U-shaped circle road 24 , the speed of the vehicles is automatically reduced and the margin for safely turning the vehicle on the arcuate end 25 increased.
[0030] If there is no need to provide non-motor vehicle and pedestrian ways under the overpass then the arched separated bridge 2 can be constructed as a flat driveway, and accordingly the connection platform 23 can be provided on the ground, thereby avoiding the need for vehicles to enter the connection platform 23 and the ramp of the arched separated bridge 2 . Raising the arcuate part 25 of the U-shaped circle road 24 to a certain height will ensure that the vehicles on the main road 1 pass under the arcuate part 25 of the U-shaped circle road thus allowing for a large reduction in the overall height of the overpass.
EXAMPLE 3
[0031] As shown in FIG. 3 in order to reduce the driving distance of vehicles turning around on the intersected road 3 in embodiments 1 and 2, medians 26 for turning around are provided on the left and right connection platforms 23 , respectively. The median 26 for turning around separates the connection platform 23 into the straight transit driveway 27 between the upper and lower U-shaped circle roads 24 and the U-turn driveway 28 , which not only ensures a straight-way driving between the upper and lower U-shaped circle roads 24 , but also allows vehicles turning around on the intersected road 3 to enter the on-ramp through the U-turn driveway 28 directly after entering the connection platform 23 from the off-ramp, thus decreasing the turnaround distance on the U-shaped circle road 24 .
[0032] If the topographic condition permits or if there is a need to expand capacity, an underpass tunnel 6 in the direction of the left and right intersected road 3 can be added beneath the walking way surface extending through the main road 1 . By doing so, the straight-driving vehicle from left to right or vice versa don't need to travel around the connection platform 23 and the U-shaped circle road 24 , and as a result vehicles can be driven faster and more conveniently, to meet the larger traffic flow. If there is no need to consider the pedestrian and non-motor vehicle ways under the overpass, such as in the highways and suburbs, then the underpass tunnel 6 can be constructed as a semi-sinking underpass tunnel passing the arched separated bridge 2 resulting in a reduction of construction costs and improvement in ventilation and in water-removal from the tunnel. Alternatively, it is also possible to provide the overhead bridge passing through the upper side of the connection platform 23 and the arched separated bridge 2 between the left and right intersected roads 3 . Therefore the vehicles on the intersected road 3 can travel straight-though, thus enabling the overpass to be constructed by several periods and added with one more layer of single span bridge to form another main road.
EXAMPLE 4
[0033] As shown in FIG. 4 , the overpass of the embodiment is suitable for use in highways and expressways. A level driveway is provided between the upper and lower sides of the main road 1 while at both sides of the main road 1 a secondary road 13 parallel with the main road 1 is provided. The outer pass way 33 connects the main road 1 and the secondary road 13 . The overhead bridge 29 passing above across the main road 1 is provided between the left and right sides of the intersected road 3 .
[0034] The U-shaped circle roads 24 are provided at the horizontal level at both the upper and lower sides of the main road 1 . The U-shaped circle roads 24 include the inner semicircle roads 4 and the outer semi circle roads 5 . The branch common road 7 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The lower common road 7 is connected with the entrance of the outer semicircle road 5 of the upper U-shaped circle road 24 after passing through under the overhead bridge 29 , while the upper common road 7 is connected with the entrance of the outer semicircle road 5 of the lower U-shaped circle road 24 after passing through under the overhead bridge 29 . The outer semicircle road 5 is connected with the on-ramp of the overhead bridge 29 after passing across the arcuate end 25 of the main road. The left turn branch lane 30 is connected with the on-ramp of the inner semicircle road 4 from the off-ramp of the overhead bridge 29 on the intersected road 3 while the inner semi circle road 4 is connected with the on-ramp of the secondary road 13 through the left turn driveway 14 after passing across under the arcuate end 25 of the main road.
[0035] The right turn branch lane 31 is provided between the overhead bridge 29 and the secondary road 13 connected with the on-ramp of the main road. The right turn branch lane 31 is connected with the secondary road 13 through the lower ramp. The right turn road 32 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The right turn road 32 is connected with the on-ramp of the overhead bridge 29 through the upper ramp. The pavement and non-motor vehicle way 12 are provided on the outer side of the secondary road 13 .
[0036] Below the driving directions of the vehicles on the overpass will be described with connection to the arrows in FIG. 4 indicating the driving direction of the vehicles. (1) Straight through from the lower side to the upper side: the vehicles travel straight-ahead to the upper part of the road along the lower part of the main road 1 . (2) Straight through from the left to right: the vehicles travel straight to the right part of the road from the left part of the road of the overhead bridge 29 on the intersected road 3 . (3) Turn from the lower main road 1 onto the right intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the right turn road 32 connected with the secondary road 13 turn right by the upper ramp entering the on-ramp of the overhead bridge 29 of the intersected road 3 . (4) Turn from the lower main road 1 onto the left intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the common road 7 connected with the secondary road 13 enter the on-ramp of the U-shaped circle road 24 after passing under through the overhead bridge 29 , then after entering the outer semicircle road 5 through the arcuate end 25 enter the on-ramp of the overhead bridge 29 . (5) Turn from the left intersected road 3 onto the lower main road 1 : the vehicles enter the on-ramp of the main road via the lower ramp of the right turn branch lane 31 of the over head bridge 29 . (6) Turn from the left intersected road 3 onto the upper main road 1 : the vehicles enter from the off-ramp of the overhead bridge 29 on the intersected road 3 onto the on-ramp of the inner semicircle road 4 through the left turn branch lane 30 , and then enter the secondary road 13 after passing through the left turn road 14 by the lower ramp of the arcuate end 25 , then enter the on-ramp of the main road 1 through the outer pass way 33 .
[0037] Since the height of the overpass of the embodiment is the height of the overhead bridge 29 or the arcuate end 25 of the U-shaped circle road 24 , the overpass belongs to a single laver type. The transfer of the vehicles on the overpass will not cause any inference.
[0038] It should be noted that while the foregoing description is aimed to illustrate the principle of the invention, those skilled in the art will appreciate that certain variations and modifications of the basic embodiments are possible.
[0000] Therefore, the invention is not limited by any particular construction of the embodiments, and all of the modifications are within the scope of the invention.
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This invention discloses a single layer interchange overpass. The overpass comprises a main road ( 1 ) and an intersected road ( 3 ), a U-shaped circle road ( 24 ) is disposed at a predetermined level above both ends of the main road ( 1 ), an inner circle road ( 4 ) and an outer circle road ( 5 ) are disposed at the exit of each U-shaped circle road ( 24 ), a common ramp ( 7 ) is located between the inner and the outer circle roads ( 4, 5 ), the common ramp ( 7 ) is joined with an on-ramp of the intersected road ( 3 ) via the outer circle road ( 5 ); and an off-ramp of the intersected road ( 3 ) is joined with an on-ramp of the main road ( 1 ) via the inner circle road ( 4 ).
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BACKGROUND OF THE INVENTION
The present invention is in the general area of polymeric device processing and in particular is a method of making bonded fiber structures of biocompatible polymers for use in cell culture and implantation.
The use of biodegradable polymers to regenerate metabolic organs, such as the liver and pancreas, and repair structural tissues like cartilage and bone by cell transplantation was recently reviewed by Cima, et al., "Hepatocyte Culture on Biodegradable Polymeric Substrates," Biotechn. Bioeng., 38, 145-158 (1991); Langer, et al., "Future Directions in Biomaterials," Biomaterials, 11, 738-745 (1990); Vatanti et al., "Selective Cell Transplantation Using Bioabsorbable Artificial Polymers as Matrices," J. Pediatr. Surg., 23, 3-9 (1988); and Vacanti, "Beyond Transplantation," Arch. Surg., 123, 545-549 (1988). To create organ function, donor material is obtained, the tissue is dissociated into individual cells, the cells are attached to a proper device, and the device is implanted to a place where the immobilized cells grow and function.
In addition to being adhesive substrates for cells, promoting cell growth, and allowing retention of differentiated cell function, materials used as templates for cell transplantation must be biocompatible and biodegradable, processable into desirable shapes, highly porous with large surface/volume ratios, and, finally, mechanically strong.
The polymer provides a sturdy scaffold to the transplanted cells and the means of organization to the ingrowing tissue. High porosity values are required in order to accommodate a large number of cells. As most cells are anchorage-dependent, large values of the total pore area are necessary for high cell growth rates. Also, the pore diameter or the interstitial distance must be much larger than the particular cell diameter and an interconnecting pore network structure is essential for tissue ingrowth, vascularization, and diffusion of nutrients, as reviewed by Vacanti, "Synthetic Polymers Seeded with Chondrocytes Provide a Template for New Cartilage Formation," Plast. Reconstr. Surg., 88, 753-759 (1991).
Poly(lactic-co-glycolic acid) (PLGA) fiber tassels and fiber-based felts fulfill many of the above material requirements and were initially utilized, as reported by Vacanti (1991) and Cima, et al., "Tissue Engineering by Cell Transplantation Using Degradable Polymer Substrates," J. Biomech. Eng., 113, 143-151 (1991), as transplantation devices for hepatocytes and chondrocytes to regenerate liver and cartilage function, respectively. In a recent paper, Freed, et al., "Neocartilage Formation In Vitro and In Vivo Using Cells Cultured on Synthetic Biodegradable Polymers," J. Biomed. Mater. Res., (in press), showed that chondrocytes cultured in vitro on poly(glycolic acid) (PGA) fiber meshes yielded after six weeks a cell density 8.3-fold higher than that at the first day and equaled the cellularity reported for normal bovine articular cartilage. However, although tassels and felts were useful in demonstrating the feasibility of organ regeneration, they sometimes lack the necessary structural stability. In order to be used for cell attachment and transplantation, they must often be configured into shapes similar to those of the repaired tissues, and also provide a firm substrate to the transplanted cells.
There remains a need for an improved method for making polymeric substrates for use in cell culture and implantation, which is efficient, economical and reproducible.
There is a further need for a method which yields polymeric matrices with the appropriate structure and porosity for use in maintaining cell viability and surfaces for attachment following implantation, even when cell masses and internal pressures on the implant increase.
SUMMARY OF THE INVENTION
A method was developed to prepare three-dimensional structures with desired shapes for use as templates for cell transplantation. Both biodegradable and degradable biocompatible synthetic polymers can be used. The resulting materials are highly porous with large surface/volume and provide the necessary space for attachment and proliferation of the transplanted cells. The processing technique calls for the formation of a composite material with non-bonded fibers embedded in a matrix followed by thermal treatment and the selective dissolution of the matrix.
An example of the method uses poly(glycolic acid) (PGA) fiber meshes bonded using poly(L-lactic acid) (PLLA) as a matrix. The bonded structures are highly porous with values of porosity up to 0.81 and area/volume ratios as high as 0.05 μm -1 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the steps in the processing technique to bond non-woven polymeric fibers.
FIG. 2A, 2B, 2C and 2D are schematic presentations of the change of fiber configuration upon heating of a PLLA-PGA composite material at a temperature above the PLLA and PGA melting temperatures.
DETAILED DESCRIPTION OF THE INVENTION
The process involves (1) selection of polymers to form fibers and to form a matrix around the polymeric fibers, (2) selection of a solvent or temperatures required to produce a solution of the matrix polymer that does not liquify the fiber polymer, (3) solidification of the matrix polymer around and between the polymeric fibers, (4) heat treatment of the fiber-matrix to immobilize the fibers where they overlap or are crosslinked and (5) removal of the matrix polymer to leave immobilized crosslinked fibers.
SELECTION OF POLYMERS
Synthetic biocompatible polymers may be biodegradable, either by enzymatic action or hydrolysis, or non-biodegradable. Biodegradable polymers are preferred. Such polymers are commercially available or can be synthesized using methods published in the literature and known to those skilled in the art. Examples of biodegradable materials include polymers which degrade by surface erosion or bulk erosion such as poly(lactic acid) (PLLA), poly(glycolic acid) (PGA), poly(lactide-co-glycolide) (PLGA), polyorthoesters, polyanhydrides, polyphosphazines, and blends and copolymers thereof. Examples of non-biodegradable polymers include ethylene vinyl acetate and polymers of acrylic acid and methacrylic acid. Biodegradable materials are preferred for implantation.
Suitable solvent systems and relative melting temperatures are published in standard textbooks and publications. Many of these materials can be formed into fibers by standard processing techniques such as melt extrusion and spin casting, or are commercially available in woven or non-woven form or as sutures.
PROCESSING CONDITIONS
The generalized scheme to bond non-woven fibers involves four steps which are depicted in FIG. 1, once the polymers have been selected.
First, a non-bonded fiber structure of polymer A is immersed in a solution of polymer B or a solution of polymer B is poured into a mold containing a non-bonded fiber structure of polymer A. The solution is formed either by dissolution of polymer B in a solvent which is a non-solvent for polymer A, or by melting polymer B at a temperature less than the melting temperature of polymer A. Polymers A and B must also be incompatible so they are immiscible in their melt state.
Second, the solvent is allowed to evaporate, or the melted polymer allowed to cool, resulting in the formation of a polymer-polymer composite consisting of fibers of polymer A embedded in a matrix of polymer B.
Third, the composite is heated above the melting temperature of polymer A, where the matrix is formed by solvent evaporation, for a short time period to weld the fibers at their cross-points.
Fourth, polymer B is selectively liquified to produce a bonded fiber structure.
In the preferred embodiment, the melting temperature of polymer A is less than the melting temperature of polymer B, the matrix is formed by solvent evaporation of the solution of polymer B around fibers of polymer A, the fibers are welded by heating of the fiber-matrix composite, and the matrix is removed by dissolution in a non-solvent for polymer A.
The resulting polymeric fibrous structure.
The resulting polymeric structure is fibrous, with the crosspoints or fiber interfaces secured by the second polymer blending with the first polymer which forms the fibers as a result of the heat treatment. For use in culturing of mammalian cells, in particular for implantation, the fibrous matrix has a porosity of between approximately 100 and 500 microns, although a range of 50 microns to millimeters can be useful. Fibers need only to be sufficiently large enough in diameter to provide a site of attachment for the cells, generally, in excess of a few microns.
The present invention is further exemplified by the following non-limiting example.
This processing technique was evaluated by binding poly(glycolic acid) (PGA; polymer A) fibers embedded in a poly(L-lactic acid) (PLLA; polymer B) matrix. The PLLA-PGA composite was prepared by casting of a methylene chloride solution of PLLA into a petri-dish containing a PGA non-woven fiber mesh. PLLA, which is incompatible with PGA, was dissolved after heat treatment by methylene chloride to yield a bonded PGA fiber mesh. Methylene chloride, which is a good solvent for PLLA and a non-solvent for PGA, was also selected because of its high volatility (its normal boiling temperature is 39.8° C.).
EXAMPLE 1: PREPARATION OF POLYMERIC COMPOSITE.
Materials
Poly(glycolic acid) (PGA) non-woven fiber meshes were isolated from a multi-laminated fabricate of approximate thickness 0.15 cm and fiber density 8.5 mg/cm 2 (Acufex Microsurgical, Mansfield, Mass.). The fiber diameter was 14 μm and the PGA viscosity average molecular weight was 60,000. Poly(L-lactic acid) (PLLA) was supplied by Medisorb (Cincinnati, Ohio). The polymer number average molecular weight was determined by gel permeation chromatography (Perkin-Elmer, Series 10, Newton Centre, Mass.) as M n =105,000 (M w /M n =1.13), where M w is the weight average molecular weight and M n is the number average molecular weight. Methylene chloride was furnished by Mallinckrodt (Paris, Ky.).
METHODS
1. Preparation of Composite Membranes
In a typical experiment, 1 g of PLLA was dissolved in 8 ml of methylene chloride. The polymer solution was cast into a petri-dish of 5 cm diameter containing a non-woven mesh of PGA fibers with a weight of approximately 0.02 g. The bottom of the petri-dish was covered with an aluminum backed overlay (Cole-Parmer, Chicago, Ill.) to prevent the adhesion of the produced composite membrane to the glass bottom during the heat treatment step. The covered petri-dish was placed in a fume hood for 24 hours. Residual amounts of methylene chloride were removed by vacuum-drying at 100 μm Hg for 24 hours.
2. Heat Treatment
PLLA-PGA composite membranes placed in covered glass petri-dishes were heated in a convection oven (Model OV-490A-3, Blue M, Blue Island, Ill.) at a temperature T 1 =195° C. for t 1 =90 min and at a higher temperature T 2 for t 2 min. They were then taken from the oven and were immediately immersed in liquid nitrogen for 15 min. The quenched membranes were air-dried for 15 min before they were vacuum-dried at 100 μm Hg for 24 hours. The drying was essential so as to remove any condensed water vapors. The values of T 2 , t 2 , and those of the time, t 12 , required to reach the temperature T 2 from that of T 1 are presented in Table I. Control samples of PGA non-woven fiber meshes were also heated under the same conditions as the PLLA-PGA composite membranes. The previously mentioned temperatures correspond to the interior of the oven. Because of heat transfer limitations due to the covered glass petri-dish containing the sample, the temperature in the sample is expected to be slightly lower than the oven temperature. The temperature accuracy of the oven was ±1° C.
TABLE I______________________________________Heat Treatment Conditions ofPLLA-PGA Composite Membranes T.sub.1 t.sub.1 t.sub.12 T.sub.2 t.sub.2Sample (°C.) (min) (min) (°C.) (min)______________________________________1 195 90 6 230 52 195 90 7 235 53 195 90 9 240 54 195 90 7 235 7.55 195 90 7 235 10______________________________________
3. Dissolution of Matrix
After heat treatment, the PLLA matrix of a PLLA-PGA composite membrane was selectively dissolved in 8 ml of methylene chloride for 75 min (the methylene chloride was changed every 15 min). The bonded PGA fibers were vacuum-dried at 100 μm Hg for 24 hours and stored in a desiccator under vacuum until use.
CHARACTERIZATION
1. Light Microscopy
A zoom macroscope (Model M420, Wild Heerbrugg, Heerbrugg, Switzerland) was used to observe the structure of composite membranes before the dissolution of the matrix. The total magnification of the micrographs was 40X.
2. Scanning Electron Microscopy
The samples were coated with gold using a Sputter Coater (Model Desk II, Denton Vacuum, Cherry Hill, N.J.). The gas pressure was set at 50 mTorr and the current was 40 mA for a coating time of 75 s. Cell cultures were first fixed in Karnovsky's fixative at 37° C. for one hour, washed with 0.1M cacodylate buffer (pH 7.4), postfixed for 1 hour in 1% osmium tetroxide, dehydrated in a graded series of ethanol/water solutions, dried in a critical point drier (Ladd Research, Burlington, Vt.) with supercritical CO 2 , and then were sputter-coated with gold. A Hitachi (Model S-530) Scanning Electron Microscope was used in the studies and was operated at a 15 kV voltage.
3. Mercury Porosimetry
The void volume of PLLA-PGA composite membranes as well as the porosity and the area/volume ratio of bonded PGA fibers were measured by mercury intrusion porosimetry (model Poresizer 9320, Micromeritics, Norcross, Ga.). A solid penetrometer with 5 ml bulb volume (Model 920-61707-00, Micromeritics) was used with samples of approximate weight 0.15 g for composite membranes and 0.005 g for fibers. The filling pressure of the penetrometer was 0.5 psi and the maximum pressure was 30 psi. At the pressure of 30 psi, the total intrusion volume had reached a plateau value. The PGA fiber density used to calculate the porosity from the measured value of the intrusion volume was determined by micropycnometry (model Accupyc 1330, Micromeritics) as 1.68 g/ml.
4. Differential Scanning Calorimetry
A 7 Series Thermal Analysis system of Perkin-Elmer was utilized to measure melting (and crystallization) enthalpy changes of a variety of materials. For composite membranes, approximately 10 mg of sample were tested, and for fibers, 1 mg. A heating rate of 10° C./min was applied in all measurements.
Photomicrographs of PLLA-PGA composite membranes heated at 195° C. for 90 min and three different temperatures of 230° C., 235° C., and 240° C. for 5 min were compared. For the temperature of 230° C., no fiber bonding was observed. Contrary to welding of amorphous polymers at temperatures slightly above the polymer glass transition temperature, bonding of semicrystalline fibers only occurred above the fiber melting temperature. For composites heated at 235° C., patterns of joined fibers were detected, whereas at 240° C. a different morphology of dispersed globules was evident. The cylindrical fiber geometry is not a stable one for melts. A sphere possesses the minimum surface for the same volume and is energetically favored. Thus, the dispersed fibers of a composite material are gradually transformed into spherical domains at temperatures above the highest melting temperature to minimize the total interfacial energy.
The morphology evolution of a melted polymer-polymer fiber composite is illustrated in FIGS. 2A, 2B, 2C, and 2D. At short times, the PGA melting results in joint welding of the fibers at their cross-points and the formation of an interconnecting fiber network structure similar to that of the initially non-bonded fibers. The minimization of the total interfacial energy calls for the growth of the fiber cross-points and the formation of globules along the fiber strands. Consequently, the diameter of the remaining cylindrical fiber strands gets smaller and smaller and eventually the initial fiber composite disappears yielding a new composite consisting of PGA spherical domains embedded in PLLA.
SEM photomicrographs of bonded fiber meshes produced by the dissolution of the PLLA matrix of PLLA-PGA composite membranes heated at 235° C. for 5 min and 7.5 min support the above mechanism of fiber bonding. At 5 min, the fibers were joined at their cross-points without any macroscopic change of the fiber geometry. The porosity of the bonded fiber mesh was measured by mercury porosimetry as 0.81 and its area/volume ratio as 0.05 μm -1 . These values are typical of materials used for cell transplantation. At 7.5 min, globules were developed not only at fiber intersections but also along individual fiber strands. For composites heated at 235° C. for 10 min, only scattered microparticulate and agglomerate structures were recovered after the dissolution of the PLLA matrix.
The importance of the formation of a polymer-polymer composite formed of a fiber mesh embedded in another polymer was evaluated by comparing the morphology of PGA non-woven fiber meshes heated at 195° C. for 90 min and 235° C. for 5 min while embedded in PLLA and surrounded by air. From the SEM photomicrographs of the produced structures, it is deduced that the PLLA matrix prevents the destruction of the fiber configuration observed for the plain PGA fiber mesh and confines the melted PGA in a fiber like shape. Also, PGA fiber meshes without the PLLA matrix heated at temperatures above their melting temperature in air collapsed and did not retain their initial three dimensional shape.
The dynamic behavior of the dispersed phase depended on the rheological properties of both the fiber and the matrix. The terminal relaxation time of entangled polymers in a melt scales to the cube of the chain molecular weight and decreases exponentially with temperature, as described by DeGennes, Scaling Concepts in Polymer Physics, Cornell University Press, Ithaca, 1979, and Tirrell, "Polymer Self-Diffusion in Entangled Systems," Rubber Chem. Technol., 57, 523-556 (1984), the teachings of which are incorporated by reference herein. The interfacial tension between polymers does not vary significantly with the molecular weight and the temperature, as reported by Wu, Polymer Interface and Adhesion, Marcel Dekker, New York, 1982, and is not expected to affect the fiber transformation. Thus, one infers that the higher the molecular weight of the surrounding matrix, the smaller the fiber distortion under the same processing conditions. The crosslinking of the matrix may also limit the extent of fiber distortion. Keville et al., "Preparation and Characterization of Monodisperse Polymer Microspheroids," J. Colloid Interface Sci., 144, 103-126 (1991), reported a technique to prepare monodisperse polymer microspheroids by uniaxial deformation of a composite material consisting of polymer microparticles embedded in a crosslinked matrix.
In addition to being incompatible with PGA, PLLA was also selected as an embedding medium because it melts at a lower temperature than PGA. From DSC measurements, T m =173.7° C. for PLLA, and T m1 =217.7° C. and T m2 =224.2° C. for PGA. The rationale for heating PLLA-PGA membranes at 195° C. (i.e., at a temperature above the melting temperature of PLLA and below that of PGA) for 90 min was to melt the PLLA and fill the pores within the membrane. Composite membranes produced by solvent evaporation are porous and their porosity depends on the size and the relative amount of the dispersed phase. Thus, the melting of the dispersed phase is confined to its volume. The void volume of a PLLA-PGA composite as measured by mercury porosimetry was 0.14 ml/g before and 0.04 ml/g after heating at 195° C. for 90 min.
Provided that the degree of crystallinity of a solvent cast membrane is not affected by the presence of a dispersed phase, from the thermogram of the methylene chloride cast PLLA-PGA membrane, the relative amounts of each polymer can be calculated as: ##EQU1## Here, w A is the weight fraction of polymer A (PGA), ΔH A and ΔH mB are the measured enthalpies of melting of polymers A and B (PLLA) per gram of composite material. The symbols ΔH° mA and ΔH° mB also designate the enthalpies of melting per gram of pure polymer. From the DSC thermograms of PGA fibers and a methylene chloride cast PLLA membrane, the value of ΔH° mA was measured as 74.1 J/g and that of ΔH° mB as 49.0 J/g. These values correspond to degrees of crystallinity of 0.39 for PGA and 0.24 for PLLA. (The values of the enthalpies of melting of 100% crystallized polymers used in the calculations were 191.2 J/g for PGA, as reported in Chu and Browning, "The Study of Thermal and Gross Morphologic Properties of Polyglycolic Acid upon Annealing and Degradation Treatments," J. Biomed. Mater. Res., 22, 699-712 (1988), and 203.4 for PLLA, as reported by Jamshidi, et al., "Thermal Characterization of Polylactides," Polymer, 29, 2229-2234 (1988). The value of w A was calculated as 0.03 from the DSC thermogram.
From the measured values of the enthalpies of crystallization and melting for PLLA of a sample heated at 195° C. for 90 min and 235° C. for 5 min and quenched with liquid nitrogen, the PLLA matrix was found to be 100% amorphous. Nevertheless, the crystallinity of the bonded PGA fibers as calculated from the integration of the area under the peaks of T m1 =221.2° C. and T m2 =231.5° C. was also 0.39. The PGA fibers, while embedded in PLLA, were annealed for over 90 min, resulting in lamellar thickening of the existing crystallites. This annealing process caused an increase in the melting temperature of PGA by about 5° C. When the fibers were heated to 235° C. for 5 min, part of the crystallites melted. Thus, the sequence of annealing and partial melting explains why the degree of crystallinity of PGA appeared invariant. The absence of any endothermic peaks at 174° C. in the DSC thermogram of the bonded fibers after the dissolution of the PLLA matrix indicated that the bonded fibers were PLLA-free.
It is concluded that the bonded fibers produced by this method have the same chemical composition and shape as the original non-bonded ones. Therefore, to screen candidate biomaterials according to scaffolding for cell transplantation, the adhesion, growth, and differentiated function of attached cells can still be tested in vitro with non-bonded fibers before the construction of three-dimensional scaffolds.
EXAMPLE 2: SEEDING OF MATRICES WITH HEPATOCYTES
PGA bonded fiber structures were seeded with hepatocytes for use as transplantation devices for hepatocytes.
Cells were isolated from 180-250 g male Fisher rats using a modification described by Cima, et al., (1991) of the two-step collagenase procedure of Seglen, "Preparation of isolated rat liver cells", Meth. Cell biol. 13, 29-83 (1976). Cells were dispersed in chemically defined serum-free culture medium (William's E with 10 ng/ml Epidermal Growth Factor (EGF) (Collaborative Research, Bedford, Mass.), 20 mU/ml insulin (Gibco, Grand Island, N.Y.), 5 nM dexamethasone (Sigma, St. Louis, Mo.), 20 mM pyruvate (Gibco), and 100 U/ml penicillin/streptomycin (Gibco)). This medium was used in all subsequent isolation and culture steps. Cell viability following dispersion was 80-90%, as determined by trypan blue exclusion.
For plating onto polymer meshes, cells were suspended in medium at a concentration of 1×10 7 cells/mi. The PGA meshes, which are hydrophobic, were prewetted with medium and excess medium was aspirated. A drop of cell suspension (0.1 ml) was placed in the center of a 0.6 cm×0.6 cm square and allowed to wick into the mesh. The meshes were then placed in a humidified 37° C. cell culture incubator with a 5% CO 2 environment. Previous studies, Cima, et al., (1991), have shown that cell attachment plateaus after about 1.5 hours, and thus fresh medium was added to completely cover the meshes after a two hour attachment period.
In vitro studies indicated that hepatocytes attached to PGA meshes primarily as individual, isolated cells. There was a high degree of interaction between hepatocytes and fibers 18 hours after plating. By the third day in culture, the cells started to form large clusters and by the end of one week, the major interactions were cell-cell rather than cell-polymer.
Modifications and variations of the method of the present invention, and the products thereof, will be obvious to those skilled in the art from the foregoing detailed description. such modifications and variations are intended to come within the scope of the appended claims.
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A novel processing technique is reported to bond non-woven fibers and, thus, prepare structural interconnecting fiber networks with different shapes for organ implants. The fibers are physically joined without any surface or bulk modification and have their initial diameter.
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REFERENCE TO RELATED APPLICATIONS
The present application is being concurrently filed with commonly assigned U.S. patent applications, Ser. No. 09/026,065 entitled "QUICKLY REMOVABLE RF SEALED COVER FOR TEST FIXTURE", the disclosure of which is incorporated herein by reference; Ser. No. 09/025,982 entitled "DOCKING STATION FOR AUTOMATED COMMUNICATIONS TEST FIXTURE", the disclosure of which is incorporated herein by reference; Ser. No. 09/026,083 entitled "REMOVABLE FIXTURE ADAPTER WITH RF CONNECTIONS", the disclosure of which is incorporated herein by reference; and Ser. No. 09/026,066 entitled "REMOVABLE FIXTURE ADAPTER WITH PNEUMATIC ACTUATORS", the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
This application relates in general to automatic testing machines, and in specific to a test fixture for an automatic testing machine which includes a RF door that is connected to the fixture or to an adapter of the fixture.
BACKGROUND OF THE INVENTION
An automatic testing machine (ATM) operates in a production environment to rapidly and accurately test the operation and performance of various types of devices under test (DUT), including RF communication devices. The DUTs could be a finished product or a component of a larger system.
The ATM is programmed to perform various tests on the DUT automatically. For example, RF signals are transmitted to a finished cellular telephone DUT to determine if the telephone activates. Other tests could include environmental tests, such as temperature or vibration tests.
Depending upon the nature and number of the tests being performed, the testing may last from a couple of milliseconds to several minutes. The information from the testing is compared with expected test results. If there is some defect so that the DUT falls below specifications, the ATM will designate the DUT as failed, either by marking the DUT, placing the DUT in a failure area, or indicating the failure to an operator.
The ATM is then loaded with the next DUT, either manually or automatically, and the testing procedure is repeated for this DUT. The information from the testing can be used to evaluate the fabrication process for possible changes, as well as to perform failure analysis on individual failed devices.
Typically, each ATM is designed to perform a specific class of tests on the DUT, and are not able to perform other classes of tests. For example, a vibration ATM may not be able to perform electrical signal tests. However, different types of DUTs may require the same tests to be performed. For example, all types of microcomputer chips are tested for electronic performance characteristics, but different chips will have different locations for power, inputs and outputs. ATMs are made flexible by the use of test fixtures. The test fixture provides an interface between the device under test DUT and the ATM. Thus, a single ATM can perform tests on different types of devices when connected via different fixtures.
However, fixtures tend to be large and bulky. Moreover, they have numerous connections to the ATM for the required resources to allow testing, e.g. power, electronic signals, RF signals, and pneumatic air pressure. Thus changing fixtures is time consuming, as each individual connection to the ATM must be separated, the current fixture removed, and then the new fixture installed. During the replacement process, the production line is shut down, which results in lost production time. If the fixture needs to be repaired, then this process must be undertaken, and the lost production time is unavoidable. However, if the fixture is to be changed merely to accommodate a different DUT, then the lost production time can be mitigated by using an adapter. An adapter is a DUT holder that is coupled to the fixture. The adapter is customized to hold a specific type of DUT. If a different DUT needs to be tested then the adapter in the fixture is swapped for the proper adapter.
A particular class of fixtures are RF fixtures. RF fixtures are used in the testing of DUTs that operate with radio waves, e.g. cellular telephones, pagers, CB radios, etc. The RF fixture is sealed such that external electromagnetic fields or radio waves do not affect the testing of the DUT. Thus, the RF testing being performed on the DUT will be performed accurately, as the DUT will receive only the test RF signals and not any external RF signals which may skew the operation of the DUT. In order to load the DUTs into the fixture, a drawer mechanism is used. A problem arises when adapters are used with RF fixtures having a drawer mechanism.
As shown in FIG. 3, adapter 31 is connected to drawer 34 of fixture 33. RF door 32 is rigidly connected to drawer 34. The arrows 35 indicate the path taken by adapter 31 during its removal from fixture 33. To avoid door 32 and the top of fixture 33, adapter 31 must be lifted vertically to clear door 32, then horizontally to clear the top of fixture 33. Adapters generally are heavy and have fragile connections that are easily damaged. Thus, if adapter 31 collides with either door 32 or the top of fixture 33, then it is likely that adapter 31 will be damaged in some manner.
The damage to adapter 31 may occur without notice by the technician. Thus, when the damaged adapter is subsequently used, then incorrect information about the DUT may be collected. The incorrect information could lead to improperly passing a defective DUT or failing a passing DUT. The incorrect information may also result in incorrect or unnecessary changes being made to the production process. Moreover, the damaged adapter may cause damage to the DUT, the fixture, or the ATM.
Furthermore, since adapter 31 is customized to a particular DUT, multiple copies of the adapter are not usually maintained. Thus, if the adapter is damaged, a backup is not likely to be available. Thus, the production line of the DUT may be halted until the damaged adapter is repaired.
Therefore, there is a need in the art for a system and method that allows for the rapid and reliable replacement of fixture adapters in a production environment.
SUMMARY OF THE INVENTION
These and other objects, features and technical advantages are achieved by a system and method that has the RF door separate from the drawer of the ATM fixture, Since the door is detached from the drawer of the fixture, changing the adapter is simplified and the likelihood of damage to the adapter is lowered. The RF door can be either be fixedly or removably attached to the adapter. The RF door can be attached to a portion of the fixture, such as a peripheral side portion. When the drawer is in a closed position, the door meshes with the fixture to provide an RF sealed area for RF testing a device.
A technical advantage of the present invention is reduction in downtime and errors caused by damaged adapters.
Another technical advantage of the present invention is that the RF door is detached from the drawer mechanism of the fixture.
A further technical advantage of the present invention is that the RF door is attached to the adapter.
A further technical advantage of the present invention is that the RF door is attached to a portion the fixture.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIGS. 1A and 1B depict the inventive mechanism of an adapter having an attached RF door;
FIGS. 2A, 2B, and 2C depict the inventive mechanism of a peripheral portion of the fixture having an attached RF door; and
FIG. 3 depicts a prior art arrangement having the RF door attached to the drawer mechanism of the fixture.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A depicts adapter 11 with an attached RF door 12. FIG. 1B depicts the adapter 11 of FIG. 1A in a partially removed state from the drawer 14. The arrow 15 indicates the path taken by adapter 11 during its removal from fixture 13. Since door 12 is attached to adapter 11, adapter 11 only needs to be lifted slightly to de-couple from a retaining mechanism on drawer 14, such as alignment pins (not shown). Adapter 11 is then moved horizontally. Since little vertical movement is required, adapter 11 is not likely to collide with the top of fixture 13. Since RF door 12 is connected to adapter 11 and is removed from drawer 14 with adapter 11, adapter 11 will not collide with door 12. Therefore, any errors, such as incorrect information or damage to the DUT, fixture, or ATM, which would have arisen from damage to the adapter from collisions with the fixture, are avoided.
RF door 12 is fixedly attached to adapter 11, forming a single, integral piece. Adapter 11 has a rigid mechanical connection, such as pins and/or screws, that takes the load of the drawer sealing. Thus, door 12 will not become dislodged from adapter 11 during repeated cycles of opening and closing during operational use in testing DUTs or otherwise lose RF seal with fixture 13. Moreover, door 12 can optionally include a label, identifying adapter 11 either in terms of the type of DUT for which adapter 11 is specifically customized, or merely identifying the particular adapter. Thus, adapter 11 can be readily identified, even though it is inside fixture 13.
Alternatively, RF door 12 is removably attached to adapter 11. This permits easier storage of adapter 11, as space for door 12 is not needed. Moreover, the number of doors that would have to be maintained would be greatly reduced, as the same few doors could be used for many different adapters. Door 12 could be secured to adapter 11 by using retaining pins or 1/4 turn screws. Other securing mechanisms could be used so long as the connection of door 12 to adapter 11 is durable enough to withstand numerous production cycles and maintain a RF seal with fixture 13.
Alternatively, FIGS. 2A, 2B and 2C depict different peripheral portions of fixture 13 having an attached RF door 12. FIG. 2A depicts door 12 pivotally attached to the lower peripheral portion of fixture 13. Door 12 could be opened and closed pneumatically by a fixture actuator (not shown). Door 12 could also be opened via a mechanical attachment to drawer 14, such that as drawer 14 moves, door 12 also moves. FIG. 2B depicts door 12 pivotally attached to a side peripheral portion of fixture 13. Note door 12 could be connected to either side of fixture 13, and would operate in a similar manner to the door of FIG. 2A. FIG. 2C depicts door 12 pivotally attached to the upper peripheral portion of fixture 13. Door 12 is shown to open into fixture 13, and thus will not impede the removal of the adapter. However, door 12 could open outward if removal of the adapter is unhindered by the open position of the door, especially if door 12 opens to an approximated vertical position. Door 12 would operate in a similar manner to the door of FIG. 2A. The pivotal connection of FIGS. 2A, 2B, and 2C could be either an internal or external hinge, or pivot pins mounted into peripheral portions of fixture 13 that are adjacent to door 12. Other mechanisms could be used so long as the connection of door 12 to fixture 13 is durable enough to withstand numerous production cycles and maintain a RF seal with fixture 13.
The interior of door 12 and the interior of fixture 13 can optionally be layered with a commercially available RF absorber material. The material typically comprises iron filings in a rubber base. The RF absorber will dampen internal reflections which occur inside the fixture from the test signals and other RF sources located inside the fixture. This prevents any errors from arising during the testing of an RF DUT, which may occur from an echoing of RF energy.
At least one interior surface of door 12 and fixture 13 can optionally be layered with an acoustic absorber material. Such material would be used if the DUT generates or uses noise, for example, a telephone generates a ring, and converts noise to signal and signal to noise. The use of acoustic absorber material would form an anechoic chamber inside the fixture. The material could be foam glued to at least one interior surface of the door and fixture. Alternatively, the absorber could be formed by milling at least one cavity in the door and sides of the fixture. The cavity is then filled with a rubberized adhesive or other sound damping material and sealed with sheet metal, thus forming a sandwich comprising a layer of the fixture (or door) panel, a layer of rubberized adhesive, and a layer of sheet metal. The sheet metal could form the exterior sides of door and fixture, or form the interior sides of the door or fixture. This arrangement is known as a constrained layer dampener. Thus, the DUT will not be improperly influenced by echoing noises, which may cause errors in testing.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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The inventive mechanism has an RF door separate from the drawer of an automatic testing machine fixture. The door is either attached to an adapter which holds a device that is to be tested, or attached to a peripheral portion of the fixture. Consequently, changing the adapter is simplified, and the likelihood of damage to the adapter is lowered. When the drawer is in a closed position, the door meshes with the fixture to provide an RF sealed area for RF testing a device.
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GOVERNMENT INTEREST STATEMENT
The invention described herein may be manufactured, licensed, and used by or for governmental purposes without the payment of any royalties thereon.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process of producing a high-nitrogen, high-phosphorus fertilizer from animal wastes as well as a product of this process. Specifically, it relates to a process for treatment of animal wastes wherein nitrogen and phosphorus are retained and parasites and pathogenic bacteria are destroyed.
2. Prior Art
Present methods of composting animal wastes, e.g., poultry litter and cattle manure, tend to release nitrogen in the form of ammonia and create nuisance odors. Conventional composting allows the survival of parasites and pathogenic bacteria. Moreover, phosphates tend to leach away into the ground during conventional composting owing to their high solubility in water.
U.S. Pat. No. 4,486,216 discloses a process wherein fecal waste is treated with a smectite clay and lime by fermentation with aerobic and anaerobic microorganisms. U.S. Pat. No. 4,997,572 discloses a process wherein wastewater treatment sludge or animal wastes are treated with quicklime, with the loss of ammonia. U.S. Pat. No. 5,466,273 provides a process wherein organic wastes are treated with sulfuric acid and anhydrous ammonia, steam is introduced, and dolomite, potash, urea, and phosphate rock are added.
SUMMARY OF THE INVENTION
The method of the present invention overcomes the drawbacks of conventional composting. According to the method of this invention, the waste is mixed with soft-burned dolomite (calcium magnesium carbonate that has been calcined at approximately 900° C.). While soft-burned dolomite is preferred, any source of magnesium oxide is acceptable. The presence of magnesium is critical because of the formation of ammonium magnesium phosphate in the process, as explained below.
Water is added to a mixture of animal waste and calcined dolomite, principally CaO and MgO, whereby the heat of hydration of these oxides to the respective hydroxides is liberated and the mixture heats up to above 100° C. The strong alkalinity (pH>12.5) and elevated temperature of the mixture destroy parasites and undesirable bacteria in the animal waste. Ammonia that is emitted by the hot alkaline mixture is absorbed in a separate vessel in a dilute acidic medium, e.g., acetic, citric, nitric, sulfuric, or phosphoric acid, acid potassium phosphate or any other acidic salts that form ammonium salts. The mixture is allowed to cool to ambient temperature.
The mixture is neutralized by the introduction of carbon dioxide gas, whereby the pH is lowered. The ammonium salt recovered during the earlier evolution of ammonia is added back into the mixture. An inoculum of bacteria, such as a suspension of natural guano, is added to the mixture. The mixture is incubated in a closed vessel, whereby the mixture becomes anaerobic. The mixture is allowed to release carbon dioxide, whereby the pH rises. The solids of the mixture are recovered by drying, or filtration followed by drying of the filtercake. Any filtrate, since it contains some N and P, may be combined with a subsequent batch to preserve N and P values.
The process of this invention preserves nitrogen and phosphorus from the original waste in the form of relatively water-insoluble ammonium magnesium phosphate, which provides slow release of N and P into the ground when the product is used as fertilizer.
DETAILED DESCRIPTION OF THE INVENTION
Soft-burned dolomite for use in the process of this invention is prepared by calcination of finely-ground calcium magnesium carbonate at approximately 900° C. for about 30 minutes. A temperature range of 850-950° C. and a calcination time of 15 to 60 minutes is considered acceptable. The magnesium content of the calcined product ranges from 20 to 25 percent by weight. Soft-burned dolomite is the preferred source of magnesium oxide in this process, though other sources of magnesium oxide as well as higher calcination temperatures are acceptable.
The quantity of calcined dolomite mixed with the waste should exceed the stoichiometric requirements to form ammonium magnesium phosphate by about 10%. Poultry litter containing about 4% of nitrogen, or 40 parts of nitrogen, would require about 68 parts of Mg or 300 parts of calcined dolomite (about 22.5% Mg).
The water added to the mixture of waste and calcined dolomite should be sufficient to convert CaO and MgO to their respective hydroxides. The heat of hydration of CaO and MgO raises the temperature of the mixture above 100° C., undesirable microorganisms are destroyed, and ammonia is given off by the mixture. The ammonia is absorbed in a separate vessel in an aqueous solution of an acidic medium, e.g., acetic, citric, nitric, sulfuric or phosphoric acid, or any acid salts such as acid potassium phosphate.
The mixture is brought into contact with carbon dioxide. Calcium hydroxide reacts with the carbon dioxide to form calcium carbonate. Magnesium hydroxide, typically, does not react with carbon dioxide to form its carbonate. A solution of alkali metal stearate, e.g., sodium or potassium stearate, and stearic acid in water is added, forming a coating of calcium and magnesium stearate on the solid particles. Dilute acetic acid is added to selectively dissolve magnesium stearate to make magnesium ion available for the formation of ammonium magnesium phosphate as discussed below. The ammonium salt recovered as described above is now added back into the mixture. The pH is adjusted to 7 to 7.5 with a dilute acidic medium as enumerated above.
The treated mixture now is inoculated with a culture of bacteria such as, for example, a suspension of untreated natural guano in water, or with a small portion of artificial guano produced by the process of this invention in a previous batch. The inoculated mixture is allowed to ferment anaerobically in a closed vessel. Organic nitrogen compounds, primarily proteins, are broken down, releasing ammonia and phosphate to form ammonium magnesium phosphate, which is relatively water-insoluble, thus providing for the slow release of phosphorus and nitrogen to the soil when the artificial guano is used as fertilizer. Carbon dioxide buildup lowers the pH below 7. The partially fermented mixture now is brought in contact with the atmosphere, carbon dioxide gas escapes, and aerobic fermentation takes place with the pH rising to about 8.
The fermented suspension may be dried by evaporation of its water content. Optionally, the suspension may be filtered and the filtercake dried. Filtrate may be combined with the ingredients for the next batch to conserve N and P values in the filtrate.
While this invention has been described in terms of a specific embodiment, it is understood that it is capable of further modification and adaptation of the invention following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains and may be applied to the central features set forth, and fall within the scope of the invention and of the limits of the appended claims.
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High-nitrogen, high-phosphorus fertilizer is produced from animal wastes by mixing the waste with water and soft-burned dolomite, recovering ammonia that is liberated with an aqueous acidic medium, neutralizing the mixture, combining the ammonium salt recovered earlier with the mixture, the adding guano-forming bacteria to the mixture, and allowing the mixture to ferment.
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FIELD OF THE INVENTION
[0001] The present invention relates to diffusing light systems, and in particular, the invention relates to an improved light device having a novel diffusing light collector that provides quite uniform lighting effect of diffusing light guides from a light source.
BACKGROUND OF THE INVENTION
[0002] In general terms, light guides have been used to illuminate panels for general light purposes and for display applications, for example, for illuminating decorative signs, architectural lighting to mark profile of buildings, advertisements to display logos, letters, signs and symbols diffusing light to be seen at various distances, and also for illuminating liquid crystal display panels, among others. Typically, large signage application for illumination systems uses high intensity discharge lamps (HID), neon high-tension tubes or diffusing fiber optic or fluorescent tubes.
[0003] In constructing a diffusing light guide for illumination purposes, achieving a uniform level of brightness and luminance across the signage that is being illuminated, with standard solutions is less than ideal. In other words, it is difficult to maintain the level of luminance at a required consistent level to obtain good uniformity and absence of light interruption on continued light lines.
[0004] Thus, it would be advantageous to produce, comparatively easily and in a cost-effective manner, light guides that would be suitable and flexible for designers to use in a variety of situations for providing continuous illumination effects so that a viewer does not see interruptions of the light lines where the light sources are located.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is an object of the invention to provide an improved light system that provides a quite consistent uniform luminance level at the light source location.
[0006] In particular, the invention provides a light diffusing device for providing illumination along a plurality of segments, where the device includes light diffusing guides extending along the segments; light collectors where each light collector is arranged to supply light into the light diffusing guides; and light sources, where each light source is coupled to at least one of the light diffusing guides via a respective light collector which supplies light from said source into said one of the diffusing guides, and at least one of the light sources is shared by at least two light diffusing guides via respective light collectors configured to allow part of the light emitted from the shared source to leak into a viewing direction transverse to said at least two light diffusing guides.
[0007] One or more of the following features may also be included.
[0008] At least one of the light diffusing guides has two ends fitted with respective light collectors and light sources for propagating light into two opposite directions along the light diffusing guide.
[0009] In another aspect, the light sources include a light emission axis perpendicular to the light diffusing guide. Further, the light diffusing guides are arranged parallel to a surface and where the light sources include substantially point sources disposed to emit light perpendicularly to the surface.
[0010] In yet another aspect, the light sources are mounted on a common support parallel to the surface and the light sources include light emitting diodes.
[0011] Other features of the light diffusing device are further recited in the dependent claims.
[0012] These and other aspects of the invention will become apparent from and elucidated with reference to the embodiments described in the following description, drawings and from the claims, and the drawings are for purposes of illustrating a preferred embodiment(s) of the present invention and are not to be construed as limiting the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic diagram of an exemplary configuration (observer vs. light guide) according to the present invention;
[0014] FIG. 2 is a schematic diagram of an exemplary complete light system having a single output, according to one preferred embodiment of the present invention;
[0015] FIG. 3 is a schematic diagram of another exemplary complete light system having a double output, according to another preferred embodiment of the present invention;
[0016] FIG. 4 is a schematic diagram of another exemplary complete light system having three outputs, according to yet another preferred embodiment of the present invention;
[0017] FIG. 5 is a schematic diagram of another exemplary complete light system having four outputs, according to another preferred embodiment of the present invention;
[0018] FIG. 6 is a schematic diagram illustrating a double output configuration light collector from a perspective view showing the top, according to one preferred embodiment of the present invention;
[0019] FIG. 7 is a schematic diagram illustrating the double output configuration light collector of FIG. 6 , from a perspective view showing the bottom;
[0020] FIGS. 8 and 9 are schematic diagrams illustrating the light collector of FIGS. 6 and 7 in greater detail; and
[0021] FIGS. 10 and 11 are schematic diagrams illustrating hybrid and reflection modes for a light collector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIG. 1 , the radial decrease of luminance due to one light source along the length of a diffusing light guide 10 is exponential due to the fact that current diffusing light guides are made of homogeneous materials. Each light source (e.g., light sources 12 and 14 ) contribute decreasingly in the radial luminance along the light guide.
[0023] For an observer 16 , the length of the light guide 10 which is visible depends on the width of the field of view 18 , the distance between the observer 16 and the light guide 10 , and the direction of view.
[0024] Furthermore, a certain level of luminance (e.g., an average luminance of all the light guides) is required, depending on the application for which the light guide is being used, to adequately view the light guide 10 at certain distances in a direction nearly perpendicular to a light guide axis 20 . At the same time, the luminance level uniformity along the length of the entire light guide must be at least of a minimal value. Also, the light guide system must be sufficiently efficient for cost reasons.
[0025] Accordingly, the diffusing characteristic of the light guide 10 can be selected based on different applications. First, it can consist of a minimal attenuation value for a light guide having greater length, or it can include a maximal attenuation value for more diffusion for a shorter light guide when distance between light sources is short and a more important level of luminance is desired.
[0026] Still referring to FIG. 1 , the luminance uniformity with regards to the total attenuation R(db) of the light guide having only one light source (e.g., 12 ) can be given by the following relation:
[0000] Total attenuation R ( db )=−10×log (minimum radial luminance/maximum radial luminance) [Equation 1]
[0000] R mini ( db )=−10×log(30%/100%) [Equation 2]
[0000] R maxi ( db ))=−10×log(20%/100%) [Equation 3]
[0027] For example, 30% maximum radial luminance or 20% minimum radial luminance represents the radial luminance at half the length of the light guide when the light guide is illuminated by only one light source, as compared to the 100% radial luminance of the light guide at the light input of the light guide ( FIG. 1 ). These maximum and minimum limits affect the operation, efficiency, and uniformity of the light diffusing system.
[0028] With regards to the relation between the length of the light diffusing guide and the attenuation levels, this relation is given by:
[0029] dbU=attenuation by unit length of the light guide
[0000] Minimum ½ length of light guide=log(30%)/(0.1 *dbU ) [Equation 4]
[0000] Maximum ½ length of light guide=log(20%)/(0.1 *dbU ) [Equation 5]
[0000] Minimum distance between two sources=2×log(30%)/(0.1 *dbU )+(length of light collector) [Equation 6]
[0000] Maximum distance between 2 sources=2×log(20%)/(0.1 *dbU )+(length of light collector) [Equation 7]
[0030] First, to design the light diffusing system, a diffusing material is chosen. Thus, by selecting the dbU, which is linked to the light guide aspects and material, the geometry of the light diffusing system is determined. Next, the length of the light guide is determined by the solutions provided by Equations 6 and 7 in order to achieve proper operation of the system. Then, the distance between two light sources can be calculated using Equations 6 and 7.
[0031] In order to estimate the average luminance values, once the length of the light diffusing guide has been satisfied with regards to the attenuation levels desired, the following estimations are possible:
[0032] Maximum average (contribution from one source):
58% from the L max between 100% and 30% length L of light guide 39% from the L max between 100% and 9% length L of light guide
[0035] Minimum average (contribution from one source):
50% from the L max between 100% and 20% length L of light guide 30% from L max between 100% and 4% length L of light guide
[0038] The above maximum and minimum average values correspond to the limits provided by the dbU. If for a given dbU, the light diffusing system does not comply with the lighting specifications, another dbU is selected, i.e., another type of light diffusing guide is to be selected.
[0039] This data is valid in directions outside the numerical aperture of the light guide for materials having a refractive index of approximately 1.5.
[0040] Additionally, the efficiency of the system can be estimated to be in terms of the utilization of the sources flux:
Minimum Configuration=approximately 92% of the flux which has been input in the light guide (minimum distance between 2 sources) Maximum Configuration=more than 95% of the flux which has been input in the light guide (maximum distance between 2 sources)
[0043] In other words, the above values permit good uniformity and good utilization of the light diffusing system, e.g., more than 90% of the flux which has been input in the light guide is used along the length of the light guide.
[0044] Referring now to FIG. 2 , a complete light system 100 is shown. The system 100 has a single output, i.e., a light guide 120 , whose axis is arranged parallel to a surface. A light source 104 (e.g., a Lambertian LED) has an emission axis perpendicular to the light diffusing guide 120 axis and is connected to it via an optical coupling device, namely, a light collector 106 . Moreover, the light source 104 is substantially a point source configured to emit light perpendicularly to the surface. If the light source is an LED, then light source 104 can be mounted on the same plane with the light collector 106 , if necessary.
[0045] As illustrated, the collector 106 includes a massive reflector 107 made of transparent material with an external reflective surface, which has the ability to redirect part of the light coming from the light source 104 inside the light guide 120 , as shown by arrow Y. The light collector 106 also redirects the main part of the light from the source, as shown by arrows X and Z. Y is light which has been slightly refracted by the massive reflector 107 and the collector 106 , Z has been refracted by the collector 106 , and X has been reflected by the collector 106 with an adjustable luminance level in the light guide 120 . The light guide 120 can be rigid, which is often in straight lines, or flexible with curves, for applications which are required for illuminating curved letters and symbols using fiber optics or diffusing cables, for example.
[0046] Referring to FIGS. 3-5 , different configurations of light systems are shown. FIG. 3 illustrates a light system 200 with double output, i.e., two light guide outputs 202 and 204 or two respective segments. FIG. 4 shows a light system 300 with three light guide outputs 302 , 304 , and 306 or three respective segments, and FIG. 5 shows a light system 400 with four light guide outputs 402 , 404 , 406 , and 408 , or four respective segments.
[0047] The characteristics of the light collector 106 will now be described in further detail. The light collector 106 is an optical coupling device made with a refractive material which can reflect the main quantity of light by total reflection, and optionally coated with a reflective additional coating that directs light coming from one common light source towards at least one light diffusing guide that results in giving good radial uniformity throughout the light diffusing guide when connected with the light guides. This configuration provides the effect of continuous and quite uniform light lines wherever the light system has sources placed at equal distances along the light guides.
[0048] The luminance adjustment of the light collector 106 can be obtained by one of following methods. First, adjusting the polishing quality of the surface of the collector, or secondly, adjusting the opacity of the reflective coating or treatment (e.g., a reflective vacuum coating). Further, displacement of the light source 104 provides fine tuning adjustments.
[0049] Referring now to FIGS. 6 , 7 , 8 and 9 , a second embodiment of a light collector is shown.
[0050] In particular, referring to FIGS. 6 and 7 , in a light system 500 , a double output configuration with two diffusing light guides 502 and 504 connected to a light collector 506 is shown from a perspective view showing the top in FIG. 6 and from a perspective view showing the bottom in FIG. 7 . The perspective view showing the top represents the observer direction as indicated by arrow 508 and from the perspective view showing the bottom, a light source 510 can be identified.
[0051] Greater detail is shown in FIGS. 8 and 9 with regards to the light collector 506 . The light collector 506 can be made of a transparent material with its upper part 506 a ( FIG. 8 ) made of a Fresnel lens.
[0052] Internally, the light collector 506 (bottom part 506 b in FIG. 9 ) can be provided with parabolic reflectors to direct the light from the source towards the optical light guide. Then, the number of reflectors would equal the number of light guides connected to it. Thus, the surfaces are vacuum semi-transparent metallized surfaces, which are provided by masks during a metallization process that allows adjustment of the percentage of a hybrid mode and a reflective mode for standard products ( FIGS. 10 and 11 ).
[0053] In an alternative embodiment, the light collector can be made of a transparent material, which works mainly by total reflection. For each direction coming from the source, the tangent of the external surface of the light collector is oriented in such a way that the main direction of light rays coming from the source is reflected by total reflection and is directed to the input of a light guide. The quality of polishing of some surfaces is adjusted in such a way that some light is not reflected but diffuses to give a luminance near the diffuse luminance of the light guide.
[0054] While there has been illustrated and described what are presently considered to be the preferred embodiments of the present invention, it will be understood by those of ordinary skill in the art that various other modifications may be made, and equivalents may be substituted, without departing from the true scope of the present invention.
[0055] Additionally, many advanced light display systems and coupling devices may be made to adapt a particular situation to the teachings of the present invention without departing from the central inventive concept described herein. Furthermore, an embodiment of the present invention may not include all of the features described above. Therefore, it is intended that the present invention not be limited to the particular embodiments disclosed, but that the invention include all embodiments falling within the scope of the appended claims and their equivalents.
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The present invention provides an improved optical light diffusing system for effective and uninterrupted illumination purposes. In particular, the invention is concerned with providing a light collector in the improved diffusing light device that can direct light from a light source to at least one diffusing light guide and can thus prevent the formation of excessively visible or discrete zones within the light guide, resulting in quite uniform and continued lines of light wherein the level of luminance can be flexibly adapted according to different illumination applications.
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FIELD OF THE INVENTION
[0001] This invention relates to antibacterial textiles and, in particular, such textiles treated with polymer particles that consist of polymer cores with chitosan shells.
BACKGROUND OF THE INVENTION
[0002] Compared with man-made fibers, natural textiles, such as those made from cellulose and protein fibers, are much more vulnerable to microbe attack because of their hydrophilic porous structure and moisture transport characteristics. The use of antibacterial agents to prevent or retard the growth of bacteria on textile articles has been becoming a standard finishing method for textile goods, especially for those used in hospitals, hotels, sports and personal care industries. However, there is an increasing public concerns for possible effects of antibacterial finishing on environmental and biological systems. An ideal textile antibacterial finishing should not only kill undesirable microorganisms and stop the spread of diseases, but also be safe and environmentally benign. Furthermore, the antibacterial function should be maintained for as many cycles through a home laundering process as possible.
[0003] Obtained from the shells of crabs, shrimps and other crustaceans, chitosan (CTS) is a non-toxic, biodegradable and biocompatible natural polymer, and has long been used as a biopolymer and natural material in pharmaceutical, medical, papermaking and food processing industries. Because of its polycationic nature, chitosan possesses good antibacterial property against various bacteria and fungi. However, direct coating of chitosan onto textile articles has suffered from four major drawbacks:
1) Chitosan does not dissolve in water but instead only dissolve in acidic aqueous solution. Thus, a considerable amount of acid is used during the chitosan finishing process. This may cause many environmental problems due to the strong odor and corrosive property of acids. 2) The aqueous solution containing dissolved chitosan usually is quite viscous, thus the finishing process is difficult to handle. 3) Chitosan is a rigid material. It affects the fabric hand after coating. 4) Chitosan has strong water-absorption ability due to the presence of many polar groups. Thus the water-repellency of chitosan-treated textile goods is significantly reduced.
[0008] Chitosan-containing particles with core-parts and shell-parts have been reported by Kuwahara et al in two U.S. patents (U.S. Pat. No. 6,359,032 and U.S. Pat. No. 6,252,003) used for other uses such as coloring and deodorizing agents. However, the chitosan molecules on the particle surface are not permanent due to the physical absorption property, thus can be easily released with environmental changes such as pH.
[0009] Thus at present, textiles with chitosan particles have not been able to adequately provide an antibacterial action of any permanence without considerable drawbacks.
OBJECTS OF THE INVENTION
[0010] Therefore, it is an object of this invention to provide an antibacterial textile and method of producing such that may alleviate or ameliorate at least one or more of the problems as set forth in the prior art or, at a minimum, provide the public with a useful choice.
SUMMARY OF THE INVENTION
[0011] Accordingly, in a first aspect the invention may broadly be said to consist in a method of providing an antibacterial finish to a textile including the steps of:
preparing a polymer latex emulsion containing core-shell particles with polymer cores and chitosan shells; and applying said emulsion to a textile.
[0014] Accordingly, in a second aspect, the invention may broadly be said to consist in an antibacterial textile made by the preceding method.
[0015] Accordingly, in a third aspect the invention may broadly be said to consist in an antibacterial textile comprising a textile having a finish comprising a polymer latex emulsion containing core-shell particles with chitosan shells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Preferred embodiments of the present invention will now be explained by way of example and with reference to the accompanying drawings in which:
[0017] FIG. 1 shows core-shell particles that consist of polymer cores and chitosan shells of this invention;
[0018] FIG. 2 shows the Fourier transform infrared (FTIR) spectrum of chitosan-g-poly(n-butyl acrylate) (CTS-PBA) graft copolymer;
[0019] FIG. 3 shows the CTS-PBA particle size and distribution by dynamic light-scattering, D n =number average diameter, D v =volume average diameter, PDI=D v /D n ;
[0020] FIG. 4 shows the pH dependence of the zeta-potential of CTS-PBA particles in a 1 mM NaCl solution at room temperature;
[0021] FIG. 5 shows the transmission electron microscope (TEM) images of CTS-PBA core-shell particles;
[0022] FIG. 6 shows the air resistance of untreated and treated cotton fabrics with CTS-PBA and chitosan-poly(N-isopropyl acrylamide) (CTS-PNIPAM) particles;
[0023] FIG. 7 shows the bacterial reductions of antimicrobial specimens treated with CTS-PBA and CTS-PNIPAM in the presence or absence of crosslinker; and
[0024] FIG. 8 shows the test agar plates from the fabrics before and after the antibacterial treatment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] This invention is now described by way of example with reference to the figures in the following paragraphs. List 1 is a part list so that the reference numerals in the figures may be easily referred to.
[0026] Objects, features, and aspects of the present invention are disclosed in or are obvious from the following description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
[0027] The present invention utilizes the antibacterial properties of chitosan applied to textiles. In doing so, the textile may be coated with particles that consist of polymer cores and chitosan shells.
[0028] The textiles can be natural, synthetic, and regenerated articles, as well as their blends. Examples are cotton, linen, wool, silk, polyester, nylon, polypropylene, cotton/polyester blends, etc., and their fibers.
[0029] In the preparation of this invention, a nanostructured particle may be made containing chitosan in accordance with U.S. Pat. No. 6,573,313 which is incorporated herein by reference.
[0030] In the preferred form of the invention, a synthesis of the polymer core-shell particles based on a surfactant-free emulsion copolymerization is provided. The chitosan shell is covalently grafted onto the polymer core, forming a well-defined core-shell nanostructure.
[0031] Preferably, the chitosan is dissolved in a diluted acetic acid aqueous solution, together with a vinylic monomer and an alkyl hydroperoxide (ROOH) initiator. No surfactant or emulsifier is involved. This one-pot polymerization is based on a graft emulsion copolymerization in which the alkyl hydroperoxide initiation takes place at the amino groups of chitosan. The resulting amino radicals not only are capable of initiating the graft copolymerization of the vinyl monomer, but also forming amphiphilic copolymers that can act like polymeric surfactants to stabilize the resultant particles. Therefore, there are covalent linkages between the chitosan shell and the polymer core due to the grafting of poly(vinyl) chains onto chitosan backbone. Since amphiphilic graft copolymers formed initially self-assemble into micelle-like micro-domain, many small and uniform particles between 100 to 500 nm in diameter can be produced in a high solid content (up to 30%). Such particles may be seen in FIG. 1 .
[0032] Further detail of the preferred embodiment is provided in the following examples and description.
Chitosan
[0033] The chitosan used in the present invention is poly[β-(1→4)-2-amono-2-deoxy-D-glucopyranose], a deacetylated derivative of chitin. Other modified chitosans with various substituted groups and a part of the deacetylated amino groups can also been used. Such materials can have a wide range of molecular weights (M W ) as well as deacetylation degrees (DD). Generally, the antibacterial activity of chitosan increases as the molecular weight and degree of deacetylation of chitosan increase, and decreases over a certain high M W . In the disclosed invention, the M W of chitosan is higher than 10,000 and the DD is in the range of 10% to 100%. It is desirable to have a medium M W of chitosan (50,000 to 100,000) with a relatively DD higher than 70%.
Monomer
[0034] There is no particular restriction on the monomer of the core as long as it has a reactive vinyl group that can be polymerized by free radicals. Hydrophobic monomers with corresponding polymers having low glass transition temperatures (Tg) are good for particles with soft cores. Hydrophilic monomers can also be used. Depending on the water solubility of core polymers, a crosslinking agent may be needed. A possible core monomer may be vinylic monomer such as an acrylate monomer, an acrylamide monomer, polymerizable nitrile, chloride and fluoride monomers, a styrenic monomer and a diene monomer. It is preferable to monomer with low water solubility under reaction conditions. It is also preferable to a monomer mixture with more than one of the mentioned monomers.
[0035] Examples of vinylic monomers include those with one or two carbon-carbon double bonds and substitution groups of hydrogen, alkyl, aryl, heteroaryl, halo, cyano, or other suitable groups.
[0036] Examples of acrylate and methacrylate monomers include those of esters which contain vinyl groups directly attached to the carbonyl carbon. They have formula of CH 2 ═CH—COOR and CH 2 ═C(CH 3 )—COOR, where R is alkyl or substituted allyl or other suitable hydrophobic group. Preferred groups for R include C 1 -C 16 , more preferably C 1 -C 12 alkyl which may be straight or branched chains, and such groups substituted with one or more substituents chosen from unsubstituted amino, monosubstituted amino or disubstituted amino, hydroxy, carboxy, fluorine atoms, siloxane, or other usual acrylate substituents. Particular acrylate monomers comprise butyl acrylate, ethyl acrylate, isopropyl acrylate, methyl methacrylate, lauryl methacrylate, stearyl methacrylate, and more of these monomers may be used.
[0037] Example of (meth)acrylamide monomers includes those of formula CH 2 ═CH—CONHR and CH 2 ═C(CH 3 )—CONHR, where R is as defined above.
Hydroperoxide Initiator
[0038] Alkyl hydroperoxides are suitable initiating agents to induce the graft copolymerization of vinyl monomers from chitosan amino groups. Among them, tert-butyl hydroperoxide, cumene hydroperoxide, p-isopropyl cumene hydroperoxide, p-menthane hydroperoxide and pinane hydroperoxide are preferred. The most preferred initiator is the water-soluble tert-butyl hydroperoxide.
Process for Preparing the Polymer Emulsion
[0039] The polymer core-shell particles are prepared from a surfactant-free emulsion copolymerization. Chitosan is dissolved in a dilute acetic acid aqueous solution with a chitosan concentration of 0.1 to 10%, preferably in the range of 0.5 to 2% to overcome the high viscosity. Filtration may be necessary to remove any insoluble impurities. Before the polymerization, nitrogen or argon purge may be necessary to remove oxygen in the solution and reaction container. Reaction temperature is in the range of 50 to 100° C., preferably at 80° C. There is no particular limitation for the weight ratio between the monomer and chitosan, preferably at 0.5-50 to 1 (w/w), and ideally at 4-10 to 1 (w/w). The polymerization occurs after the addition of initiator and a white polymer latex emulsion is observed. Concentration of alkyl hydroperoxides can be varied from 0.02 mM to 5.0 mM, preferably with a small amount of ROOH (≦0.2 mM). The polymerization is allowed to react for 24 hours. Normally much shorter time is needed, for example, less than 5 hours.
[0040] The core-shell particles prepared from the described emulsion copolymerization are quite uniform, having sizes less than 1 μm, preferably less than 500 nm in diameter. In our invention, the average particle size and the size distribution are measured with a laser diffraction device (Coulter LS-230 Particle Size Analyzer). Scanning Electron Microscopy (SEM) (Leica Stereoscan 440 SEM) is used to image the particle morphology. The particle internal core-shell structure is revealed by an FEITACNAIR scanning transmission electron microscope (STEM).
Process for Antibacterial Treatment
[0041] The polymer emulsion prepared as disclosed can be applied to various textile materials by padding, coating or spray, preferably by padding at room temperature. It is preferred that the material wet pick-up is around 80˜100 wt %. A further drying or curing process may be necessary and the conditions depend on the nature of the textile. For example, padded cotton needs 5-min drying in an oven at 100° C., followed by 4-min curing at 150° C. For nonwoven polypropylene (PP), 3-min drying at 100° C. is enough after padding. Rinsing with water is recommended for all finished samples. Crosslinking agents may or may not be added in the padding solution, depending on the requirement. The treatment is suitable for natural and synthetic fabric, including cotton, linen, wool, silk, polyester, nylon, polypropylene, and cotton/polyester blends, etc., as well as their fibers. It is reasonable to assume that the disclosed invention is also useful for coatings on a solid surface, such as toys and furniture, for antimicrobial purpose.
Antibacterial Test
[0042] The antibacterial mechanism of chitosan is a non-leaching type, which means that chitosan cannot be released from the substrate to the medium during inhibition. Therefore, it is recommended that the Shake Flask Method (Corporate Test Method 0923) and the ASTM-E-2148-01 are preferable to evaluate the antibacterial activity. Both methods are specially designed for non-releasing antibacterial treated specimens under dynamic contact conditions. The test determines the reduction in the number of bacterial cells in one hour (or several hours) shaking flask containing treated specimen to provide quantitative data. A gram positive bacterium, S. aureus (ATCC 6538), commonly found on the human body, may be used as the testing bacterium. The antimicrobial efficacy of tested fabrics can be expressed as percentage bacterial reduction calculated from to the following equation:
[0000] R =( B−A )/ B× 100,
[0000] where R is the percentage bacterial reduction, B and A are the number of live bacterial cells in the flask before and after shaking.
EXAMPLES
[0043] The following examples are provided in order to illustrate the practice of the invention, but are not to be constructed to limit the scope of the invention.
Example 1
Synthesis of Chitosan/Poly(n-Butyl Acrylate) (CTS-PBA) Particles
[0044] A 500 mL round-bottomed, three-necked flask equipped with a magnetic stirring bar, a condenser, and a nitrogen inlet was immersed in an oil bath. In a typical run, 100 mL of 0.6% acetic acid in solution was added into the flask, followed by the addition of 0.5 g chitosan. The flask was then heated to 60° C. and the solution was stirred continuously. After the dissolution of chitosan was completed, filtration might be necessary to remove any residues. Then the solution was heated to 80° C. under a nitrogen purge. Purified monomer (2 g) was added, followed by a quick addition of 1 mL of TBHP initiator solution (20 mM). Within minutes, the reaction medium became aggressively white and was finally stabilized as milky-white latex solution under stirring. Polymerization was held at 80° C. for 5 hours, and a slow nitrogen purge was maintained throughout the reaction. After completion, the white latex dispersion was cooled down to room temperature and stored for finish procedure. Monomer conversion was determined gravimetrically.
Example 2
Synthesis of Chitosan/Poly(N-isopropylamide) (CTS-PNIPAM) Particles
[0045] For the preparation of CTS-PNIPAM particles, the procedure is similar to Example 1 except 1% of N—N′-methylenebisacrylamide crosslinker (MBA, based on the weight of NIPAM) was added as a crosslinking agent for polyNIPAM core.
Characterization of CTS-PBA Particles
[0046] The poly(n-butyl acrylate) homopolymer and the chitosan-g-poly(n-butyl acrylate) graft copolymer were isolated using Soxhlet extraction with 1% acetic acid solution followed by chloroform. The PBA core comprises 67% grafted poly(n-butyl acrylate) and 33% poly(n-butyl acrylate) homopolymer. The FTIR spectrum ( FIG. 2 ) of the graft copolymer shows strong carbonyl peaks at 1735 cm −1 , and amino peak at 3451 cm −1 , indicating the presence of both poly(n-butyl acrylate) and chitosan.
[0047] Measurements of particle size and distribution as shown in FIG. 3 indicate that the average number particle diameter of CTS-PBA particles was 320 nm, with narrow particle size distribution (polydispersity index, D v /D n =1.16).
[0048] Particle surface charge was determined by ξ-potential measurement. FIG. 4 shows the ξ-potential of CTS-PBA latex as a function of pH in a 1 mM NaCl solution at 25° C. As pH increased, the positive value of the particles decreased, indicating the labile cationic chitosan coated on the particle surfaces.
[0049] With careful staining of the CTS-PBA particles, the nanostructure of the particles was clearly revealed with TEM images. FIG. 5 shows that the CTS-PBA particles are spherical and have well-defined core-shell morphology where poly(n-butyl acrylate) cores are coated with chitosan shells. It also shows that the CTS-PBA particles are so soft that particles are deformed when they are contact with each other ( FIG. 5 b ).
Example 3
Preparation of Antibacterial Cotton Fabrics
[0050] The antibacterial finish is based on the conventional pad-dry-cure method. Each fabric sample (˜20×40 cm) was washed with nonionic detergent before finishing, then immersed into CTS-PBA or CTS-NIPAM emulsions with or without a crosslinker dimethylolhydroxyetheneurea (DMDHEU, 0.3 wt % with a catalytic amount of magnesium chloride) for 3˜5 minutes, and padded through a laboratory pad machine (Rapid Vertical Padder, Taiwan) under a nip pressure of 1 kg/cm 2 for a wet pick-up of ˜100%. The dip-pad procedure was repeated one more time, then the twice-padded samples were dried in an oven at 100° C. for 5 minutes and subsequently cured at 150° C. for 4 minutes. After rinsing with running tap water, the treated samples were dried and ready for further tests.
[0051] Fabric mechanical properties, such as air permeability, handling, and tensile strength, are shown in FIG. 6 , Table 1 and Table 2, respectively. The results suggest that all particles-treated samples have improved air permeability regardless of the DMDHEU binder. In both warp and weft directions the cotton fabric tensile strength decreased after the latex modification. Nevertheless, the change was not significant. All fabrics still maintained at least 75% of their original tensile strength. The addition of the crosslinker DMDHEU could weaken the fabric tensile property as when a small amount of DMDHEU was added, more decreases in fabric tensile strength along both warp and weft directions were observed (Table 2).
[0052] Results on fabric hand (Table 1) showed that the latex finish could increased the values of fabric bending rigidity (B) and hysteresis of bending moment (2HB) in both machine (warp) and cross (weft) directions. Depending on the core flexibility and the padding solution with or without a crosslinker, the increase in fabric stiffness was quite different. While fabrics became much stiffer after finishing with the hardcore CTS-PNIPAM latexes, the soft CTS-PBA treated cotton had relatively small changes in both bending rigidity and bending hysteresis. Moreover, we found that the CTS-PBA padded sample had a better fabric hand than the fabric padded from 0.5 wt % chitosan solutions (Table 1).
Example 3
Antibacterial Test
[0053] In this procedure, sample fabrics (1±0.1 g), cut into around 0.5×0.5 cm, were dipped into a test flask containing 50 mL of 0.5 mM PBS (monopotassium phosphate) culture solution with a S. aureus (ATCC 6538) cell concentration of 1.0-1.5×10 4 /mL. The flask was then shaken at 250 rpm on a rotary shaker at 37° C. for 1 h. Before and after the shaking, 1 mL of the test solution was extracted, diluted and spread onto an agar plate. After 24 h of incubation at 37° C., the number of colonies formed on the agar broth was counted and the number of bacterial cells (A or B) in the testing flask was calculated. FIGS. 7 & 8 are the results of antibacterial tests on cotton fabrics before and after the treatment. Besides cotton, antibacterial test on other modified textiles is summarized in Table 3. All results indicated that the core-shell particles with chitosan antibacterial shells had excellent antimicrobial activity on textile materials.
Example 4
Washfastness
[0054] To check the durability of antimicrobial treatment, accelerated wash fastness was evaluated based on the AATCC Test Method 61-1996. An AATCC standard wash machine (Atlas Launder-Ometer) and detergent (AATCC Standard Detergent WOB) was used. Samples were cut into 5×15 cm swatches and put into a stainless steel container with 150 mL of 0.15 w/v % WOB detergent solution and 50 steel balls (0.25 in. in diameter) at 49° C. for various washing time to mimic 5, 20 and 50 wash cycles of home/commercial launderings. Results of antibacterial durability of cotton fabric after different laundry cycles are summarized in Table 4. All samples maintained high antibacterial efficacy (>90%) after 50 times of wash regardless of the DMDHEU crosslinker.
[0055] Thus it can be seen that the description and examples give rise to a textile coated or treated with chitosan in which the chitosan-based core-shell particles once applied to a textile offer the following advantages:
1) The particle consists of a well-defined core-shell nanostructure where the polymer core can be flexible material. Thus the polymer core can provide a flexible coating with a good water-repellency. 2) Since the chitosan is covalently bounded on the polymer core, not dissolved, viscosity of the particle dispersion is low even with high content of chitosan. Thus the coating is more uniform and the finishing process is much easier to handle. 3) The particles are in nano-sized range, and form ultra-thin film on textile surface. Therefore, the fabric hand and appearance are not affected very much by the coating. 4) The chitosan shell functions not only as an antibacterial agent, but also provides functional groups to strongly bind with textile material. Thus the coating is enduring.
[0060] The core-shell particles may also be used as antibacterial coatings or additives in a wide variety of applications that may have fabric on them or are similar to textiles in nature such as cotton balls. They may include items such as toys, furniture, interior textiles, medical/hospital materials, and cosmetic/personal care products. Examples of such applications include the following:
[0000] Solid objects: toys, containers, furniture and the like;
Interior textiles: drapes, curtains, carpets, air filters and the like;
Medical/hospital materials: surgical gowns, masks, sutures, hospital sheets, pillows and the like;
Personal care/cosmetic products: diapers, feminine products, deodorants, cotton balls, cotton swabs and the like.
[0061] While the preferred embodiment of the present invention has been described in detail by the examples, it is apparent that modifications and adaptations of the present invention will occur to those skilled in the art. Furthermore, the embodiments of the present invention shall not be interpreted to be restricted by the examples or figures only. It is to be expressly understood, however, that such modifications and adaptations are within the scope of the present invention, as set forth in the following claims. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the claims and their equivalents.
[0000]
TABLE 1
Bending rigidity (B) and bending hysteresis
(2HB) of untreated and treated cotton fabrics
Fabric Direction
Warp
Weft
B-MEAN
2HB-MEAN
B-MEAN
2HB-MEAN
[gf ·
[gf ·
[gf ·
[gf ·
Sample
cm 2 /cm]
cm/cm]
cm 2 /cm]
cm/cm]
Untreated
0.0353
0.0360
0.0720
0.0658
CTS-PBA
0.0604
0.0310
0.1756
0.0796
CTS-PNIPAM
0.1375
0.0916
0.3754
0.2314
CTS-PBA
0.0878
0.0518
0.2576
0.1396
(DMDHEU)
CTS-PNIPAM
0.1425
0.1191
0.3620
0.2835
(DMDHEU)
CTS
0.0783
0.0508
0.2860
0.1361
CTS (DMDHEU)
0.1436
0.1007
0.3294
0.2195
[0000]
TABLE 2
Break tensile strength and elongation
of treated and untreated cotton fabrics
WARP
WEFT
Tensile
Break
Strength
Break
Break
Strength
Break
Direction
force
maintained
strain
force
maintained
strain
Sample
(N)
(%)
(%)
(N)
(%)
(%)
Untreated
377.5
—
17.8
219.2
—
15.0
CTS-PBA
364.6
96.6
20.7
168.6
76.9
12.3
CTS-PNIPAM
361.8
95.8
19.5
210.6
96.1
14.1
CTS-PBA
305.1
80.8
16.9
164.4
75.0
13.5
(DMDHEU)
CTS-PNIPAM
356.8
94.5
18.6
197.9
90.3
13.9
(DMDHEU)
[0000]
TABLE 3
Antibacterial reductions (%)* of various fabrics after
the modification with CTS-PBA and CTS-PNIPAM particles
CTS-BA
CTS-NIPAM
Fabric
untreated
treated
treated
silk
2.9
100.0
95.9
polypropylene
0.0
94.4
100.0
linen
0.0
90.6
99.2
polyester
4.4
91.2
98.8
nylon
0.0
94.9
99.9
Polyester/cotton, 65/35
2.6
97.1
96.9
diacetate
4.2
97.1
100.0
wool
3.8
99.4
n/a
*Antibacterial reductions with standard deviation of ±4.5%
[0000]
TABLE 4
Antibacterial activity of treated cotton after different laundering
cycles (%: bacterial reduction, with ±5% error bar)
wash cycles
0
5
20
50
CTS-PBA
99.0
89.2
92.6
98.7
CTS-PNIPAM
100
98.3
98.3
98.7
CTS-PBA
100
100
99.8
96.7
(DMDHEU)
CTS-PNIPAM
100
97.7
99.8
97.9
(DMDHEU)
|
The present invention describes a novel antibacterial treatment on textile materials using polymeric core-shell particles dispersing in water. These particles are prepared from a surfactant-free emulsion polymerization according to the method of U.S. Pat. No. 6,573,313 and have average particle sizes in the range of 100 to 1000 nm in diameter. When applied to a textile article, the particles form a uniform coating, which prevents the growth of bacteria and microbes. The treatment does not affect the fabric mechanical properties, hand feeling and appearance. Antibacterial activity on cotton is maintained even after 50 times of home laundering.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrophotographic photosensitive member. More particularly it relates to an electrophotographic photosensitive member having a photosensitive layer containing a resin with a specific structure. The present invention is also concerned with an electrophotographic apparatus, a device unit and a facsimile machine that have such a photosensitive member.
2. Related Background Art
Electrophotographic photosensitive members are, of course, required to be endowed with given sensitivity, potential characteristics and optical properties in accordance with electrophotographic processes applied. In particular, in the case of electrophotographic photosensitive members repeatedly used, they are required to have a durability to the electrical and mechanical external forces that act during electrostatic charging, developing, transfer and cleaning.
Specifically stated, they are required to have a durability against a decrease in sensitivity or dark portion potential caused by O 3 or NO x generated during corona charging, an increase in residual potential, and wear and scratches caused on their surfaces as a result of sliding friction.
In the case of electrophotographic photosensitive members making use of an organic photoconductive material, their surface layers usually contain resins, and hence the properties of resins are one factor having a great influence on the performance of photosensitive members.
As resins hitherto used in electrophotographic photosensitive members, a bisphenol-A type polycarbonate resin (hereinafter "polycarbonate-A") and a modified polycarbonate resin as disclosed in U.S. Pat. No. 2,999,750 or Japanese Patent Application Laid-open No. 62-187353 have been proposed. These resins, however, have the problems as shown below.
(1) The resins have such poor solubility that they exhibit good solubility only in a few kinds of halogenated aliphatic hydrocarbons, such as dichloromethane and 1,2-dichloroethane. These halogenated aliphatic hydrocarbons have a low boiling point. Hence, photosensitive members manufactured by the use of a coating solution prepared using any of these solvents tend to have whitened coating surfaces. In addition, use of such solvents requires troublesome process management such that the solid's content in coating solutions must be kept constant.
(2) With regard to solvents other than the halogenated aliphatic hydrocarbons, the resins are partly soluble in tetrahydrofuran, dioxane, cyclohexane, or a mixed solvent of these. The solutions obtained, however, have poor stability with time such that they may gel in a few days.
Use of bisphenol-Z type polycarbonate resins (hereinafter "polycarbonate-Z") has settled these problems. However, in recent years, as image quality, durability and productivity are increasingly made higher in the field of electrophotography, resins are being studied which can satisfy the required properties at a much higher level.
SUMMARY OF THE INVENTION
The objects of the present invention are to solve the problems as discussed above, involving conventional polycarbonate resins, and to provide an electrophotographic photosensitive member having superior mechanical properties such as lubricity and wear resistance, capable of stably giving images with a high image quality even after repeated use, and also achieving cost reduction and easy manufacture.
The present invention provides an electrophotographic photosensitive member comprising a conductive support and a photosensitive layer provided thereon, wherein said photosensitive layer contains a random copolymer having a structural unit represented by the following Formula (I): ##STR3## wherein R 1 to R 8 each represent a hydrogen atom, a halogen atom, a hydroxyl group or an alkyl group having 1 to 4 carbon atoms; and a structural unit represented by the following Formula (II): ##STR4## wherein A represents a straight-chain, branched or cyclic alkylidene group having 1 to 10 carbon atoms, an aryl-substituted alkylidene group or an arylene group; and R 9 to R 16 each represent a hydrogen atom, a halogen atom, a hydroxyl group or an alkyl group having 1 to 4 carbon atoms.
The present invention also provides an electrophotographic apparatus, a device unit and a facsimile machine each having the above electrophotographic photosensitive member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a TEM photograph of the random copolymer used in the present invention.
FIG. 2 is a TEM photograph of a copolymer having a non-uniform structure.
FIG. 3 schematically illustrates an electrophotographic apparatus having the electrophotographic photosensitive member of the present invention.
FIG. 4 is a block diagram of a facsimile machine having the electrophotographic photosensitive member of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electrophotographic photosensitive member comprises a photosensitive layer containing a random copolymer having structural units, represented by the following Formulas (I) and (II) respectively: ##STR5## wherein R 1 to R 8 each represent a hydrogen atom, a halogen atom, a hydroxyl group or an alkyl group having 1 to 4 carbon atoms; and ##STR6## wherein A represents a straight-chain, branched or cyclic alkylidene group having 1 to 10 carbon atoms, an aryl-substituted alkylidene group or an arylene group; and R 9 to R 16 each represent a hydrogen atom, a halogen atom, a hydroxyl group or an alkyl group having 1 to 4 carbon atoms.
The random copolymer used in the present invention can be obtained by subjecting a bisphenol having a structure represented by the following Formula (III): ##STR7## wherein R 1 to R 8 are as defined above; and a bisphenol having a structure represented by the following Formula (IV): ##STR8## wherein A and R 9 to R 16 are as defined above; to interfacial polymerization in the presence of phosgene, carbonic acid ester or chloroformic acid ester.
In the present invention, the component unit represented by Formula (I) is introduced for the purpose of imparting suitable flexibility to the polycarbonate resin, and is presumed not to prohibit free rotation of phenol groups and, at the same time, impart flexibility inherent in ether bonds to enable improvement of mechanical properties and durability.
Preferred examples of the bisphenol represented by Formula (III) are shown below. Examples are by no means limited to these. ##STR9##
Bisphenol represented by (III-1) is particularly preferred among these compounds.
In the present invention, the structural unit represented by Formula (II) is presumed to impart a suitable mechanical strength to the polycarbonate resin.
Preferred examples of the bisphenol represented by Formula (IV) are shown below. Examples are by no means limited to these. ##STR10##
Among these compounds, bisphenols (IV-3), (IV-4), (IV-16), (IV-19) and (IV-20) are particularly preferred, and bisphenol (IV-3) is more preferred.
However, the generation of gels that may cause faulty images in electrophotography, which is concerned with storage stability of solutions, can not be well prevented if only a copolymer is formed, and can be well prevented when the copolymer is formed particularly as a random copolymer so that the crystallinity of polymer segments themselves can be lowered. That is, in the present invention, the copolymer formed as a copolymer in which monomers are randomly copolymerized can greatly lower the speed of gelation and enables prevention of faulty images such as black spots. Moreover, introduction of non-bulky groops into the structure of structural units is particularly preferred since it is presumed that the mutual overlap of polymers is thereby improved to give a highly sensitive electrophotographic photosensitive member. If, on the other hand, the copolymer can not retain its randomness (uniformity), gelation thereof may occur from its part comprised of block segments to tend to cause faulty images such as black spots.
Such randomness (uniformity) of the copolymer can be evaluated by observation, using a transmission electron microscope (TEM), of the structure of a coating formed by applying the copolymer dissolved in a suitable solvent, to a suitable substrate such as an aluminum substrate or a glass substrate. More specifically, if the copolymer is the random compolymar, even a slight non-uniformity can not be recognized on observation with a TEM (see FIG. 1). If, on the other hand, the copolymer even slightly has block segments, non-uniform structure is seen on the observation (see FIG. 2). Such microscopic non-uniform structure is presumed to cause the gel generation which results in image defects.
The proportion of the aforementioned structural units contained in the copolymer must be selected taking account of anti-scratch properties and hardness required according to electrophotographic processes. Taking account of the capability of stable formation of the random copolymer, and the mechanical properties, electrical properties and environmental stability of these properties, the structural unit represented by Formula (I) and structural unit represented by Formula (II) may preferably be in a proportion of (I):(II)=5:95 to 95:5, particularly preferably (I):(II)=20:80 to 70:30, and more preferably (I):(II)=35:65 to 65:35, in the ratio of copolymerization (molar ratio).
The reason therefor can be considered to concern various factors. As stated above, the randomness of the copolymer and polymerization composition are important factors for the mechanical properties and electrophotographic images, and hence it is presumed that the copolymer can not retain the randomness of its segments if any one of the components is in large excess.
A synthesis example of the random copolymer used in the present invention is shown below.
Synthesis Example
In 42 lit. of water, 3.7 kg of sodium hydroxide was dissolved. While the solution was maintained at 20° C., 3.65 kg of bisphenol-A (IV-3) and 3.23 kg of 4,4'-dihydroxydiphenyl ether (III-1) and 8 g of hydrosulfite were dissolved therein.
To the resulting solution, 28 lit. of methylene chloride was added, and 48 g of p-t-butylphenol was further added with stirring, followed by blowing of 3.5 kg of phosgene over a period of 60 minutes. After the blowing of phosgene, the reaction mixture was vigorously stirred to effect emulsification, taking good care not to cause crystallization. After the reaction mixture was well emulsified, 8 g of triethylamine was added thereto, followed by stirring for about 1 hour to effect polymerization.
The polymerization mixture was separated into an aqueous phase and an organic phase, and the organic phase was neutralized with phosphoric acid, and thereafter repeatedly washed with water until the pH of the wash liquid became neutral, followed by addition of 35 lit. of isopropanol to precipitate the polymerization product. The precipitate obtained was filtered and thereafter dried to give a white powdery polycarbonate resin.
The random copolymer used in the present invention may preferably have a solubility of not less than 1 g, and particularly preferably not less than 5 g, in 100 cc of solvent. This is because, if its solubility is less than 1 g/100 cc, the solution tends to have a low viscosity when, for example, a charge transport layer coating solution is prepared, making it impossible to give a layer thickness suited for the charge transport layer.
As to the molecular weight of the copolymer, the copolymer may preferably have a viscosity average molecular weight (Mv) ranging from 10,000 to 150,000, and particularly preferably from 40,000 to 100,000, taking account of the durability, i.e., wear resistance and anti-scratch properties, and the viscosity required when the copolymer is produced, i.e., productivity.
In the present invention, the copolymer used in the present invention may have two or more kinds of copolymerization components having the structure represented by Formula (I). Similarly, it may have two or more kinds of copolymerization components having the structure represented by Formula (II).
In the present invention, the copolymer used in the present invention may be used in the form of a mixture of two or more kinds. The copolymer used in the present invention may also be used in a mixture thereof with a different type of resin. Such a different type of resin may include polyester resins, acrylic resins, polyethylene resins, polypropylene resins, polyvinyl carbazole resins, phenoxy resins, polycarbonate resins, polyvinyl butyral resins, polystyrene resins, polyvinyl acetate resins, polysulfone resins, polyacrylate resins, and polyvinylidene-acrylonitrile copolymer resins.
The photosensitive layer in the present invention may be a single layer type, in which a charge-generating material and a charge-transporting material are contained in the same layer, or a lamination type, in which the layer is functionally separated into a charge generation layer containing a charge-generating material and a charge transport layer containing a charge-transporting material. In the present invention, the lamination type is preferred, and the type in which the charge transport layer is formed on the charge generation layer is particularly preferred.
The charge generation layer can be formed by coating a solution prepared by dissolving a charge-generating material in a binder resin, followed by drying. Such a charge-generating material may include azo pigments such as Sudan Red and Dian Blue, quinone pigments such as pyrene quinone and anthanthrone, quinocyanine pigments, perylene pigments, indigo pigments such as indigo and thioindigo, azulanium salt pigments, and phthalocyanine pigments such as copper phthalocyanine. As the binder resin, at least the copolymer of the present invention is used when the charge generation layer is a surface layer. When it is not a surface layer, a different type of resin may be used, without use of the copolymer of the present invention. Such a different type of resin may be the same as those previously described.
The charge-generating material and the binder resin may preferably in a proportion of from 1:5 to 5:1, and particularly preferably from 1:2 to 3:1, in weight ratio. The charge generation layer may preferably have a layer thickness of not more than 5 μm, and particularly preferably from 0.05 to 2 μm.
The charge-transporting material contained in the charge transport layer may include polycyclic aromatic compounds such as biphenylene, anthracene, pyrene and phenanthrene, nitrogen-containing cyclic compounds such as indole, carbazole, oxazole and pyrazoline, hydrazone compounds, and styryl compounds.
In general, because of poor film forming properties, the charge-transporting material is dissolved in a suitable binder resin and then put into use. As the resin, the copolymer of the present invention is used when the charge transport layer is a surface layer. When it is not a surface layer, a different type of resin may be used, without use of the copolymer of the present invention. Such a different type of resin may be the same as those previously described.
The charge transport layer can be formed by coating a solution prepared by dissolving a charge-transporting material and a binder resin in a suitable solvent, followed by drying. The charge-transporting material and the binder resin may preferably be mixed in a proportion of from 3:1 to 1:3, and particularly preferably from 2:1 to 1:2 in weight ratio.
The charge transport layer may preferably have a layer thickness of from 5 to 40 μm, and particularly preferably from 10 to 30 μm.
In the case where the photosensitive layer is of the single layer type, it can be formed by coating a solution prepared by dispersing and dissolving the charge-generating material and charge-transporting material as described above into a binder resin, followed by drying.
As the binder resin, at least the copolymer of the present invention is used when the photosensitive layer is a surface layer. When it is not a surface layer, a different type of resin may be used, without use of the copolymer of the present invention. Such a different type of resin may be the same as those previously described.
The photosensitive layer may preferably have a layer thickness of from 5 to 40 μm, and particularly preferably from 10 to 30 μm.
In the present invention, a surface protective layer may further be provided on the photosensitive layer so that the photosensitive layer can be protected from mechanical, chemical or electrical adverse influences externally exerted. The protective layer contains at least the copolymer of the present invention, which may be used in a mixture thereof with a different type of resin. Such a different type of resin may be the same as those previously described. The protective layer may be solely comprised of the resin, or may also contain the charge-transporting material previously described or a conductive material such as a conductive powder. The conductive powder may include powders of metals such as aluminum, copper, nickel and copper, scaly metal powders, metal short fibers, conductive metal oxides such as antimony oxide, indium oxide and tin oxide, polymeric conductive agents such as polypyrrole, polyaniline and polymeric electrolytes, and conductive powders such as carbon black, carbon fiber and graphite powder, and organic or inorganic electrolytes or the conductive powder of particles whose surfaces are coated with such conductive materials.
In the present invention, the protective layer is defined to be also included in the photosensitive layer.
The thickness of the protective layer is selected taking account of electrophotographic performances and durability. The protective layer may preferably have a layer thickness of from 0.2 μm to 15 μm, and particularly preferably from 0.5 μm to 15 μm.
In the present invention, a subbing layer endowed with a barrier function and an adhesive function may be provided between the conductive support and the photosensitive layer.
Materials for the subbing layer may include casein, polyvinyl alcohol, nitro cellulose, an ethylene-acrylic acid copolymer, polyvinyl butyral, phenol resin polyamides such as nylon 6, nylon 66, nylon 610, copolymer nylon and alkoxymethylated nylon, polyurethane, gelatin, and aluminum oxide. The subbing layer may preferably have a layer thickness of from 0.1 to 10 μm, and particularly preferably from 0.1 to 5 μm.
In the present invention, between the support and the photosensitive layer or the support and the subbing layer, a coating may be formed for the purpose of compensating any surface faults, or a conductive layer may be provided for the purpose of preventing interference bands which occur especially when the image input is carried out using laser light. This conductive layer can be formed by coating a solution prepared by dispersing metal particles or conductive metal oxide powder in a suitable binder resin, followed by drying. The conductive layer may preferably have a layer thickness of from 5 to 40 μm, and particularly from 10 to 30 μm.
All the layers describe above can be formed by coating methods such as dip coating, spray coating, spin coating, bead coating, blade coating and beam coating.
The conductive support used in the present invention may be comprised of a support which is electrically-conductive in itself, as exemplified by aluminum, aluminum alloy, copper, zinc, stainless steel, vanadium, molybdenum, chromium, titanium, nickel, indium, gold or platinum. Besides these, it may also include a plastic or paper having a conductive layer formed by vacuum deposition of aluminum, aluminum alloy, indium oxide, tin oxide or indium oxide-tin oxide alloy, a support comprising a plastic or paper impregnated with conductive particles, and a plastic having a conductive polymer.
The support may have the form of a drum, a sheet or a belt, and may have any form according to electrophotographic apparatus used.
The photosensitive member of the present invention can be commonly used in electrophotographic apparatus such as copying machines, laser printers, LED printers and liquid crystal shutter type printers. It may also be widely used in display, recording, light printing, lithographic and facsimile apparatus which electrophotography is applied to.
FIG. 3 schematically illustrates an example of the structure of an electrophotographic apparatus in which the photosensitive member of the present invention is used.
In FIG. 3, reference numeral 1 denotes a drum photosensitive member serving as an image bearing member, which is rotated around a shaft la at a given peripheral speed in the direction shown by an arrow. In the course of rotation, the photosensitive member 1 is uniformly charged on its periphery, with positive or negative given potential by the operation of a charging means 2, and then photoimagewise exposed to light L (slit exposure, laser beam scanning exposure, etc.) at an exposure zone 3 by the operation of an imagewise exposure means (not shown). As a result, electrostatic latent images corresponding to the exposure images are successively formed on the periphery of the photosensitive member.
The electrostatic latent images thus formed are subsequently developed by toner by the operation of a developing means 4. The resulting toner-developed images are then successively transferred by the operation of a transfer means 5, to the surface of a transfer medium P fed from a paper feed section (not shown) into the part between the photosensitive member 1 and the transfer means 5 in the manner synchronized with the rotation of the photosensitive member 1.
The transfer medium P on which the images have been transferred is separated from the surface of the photosensitive member and led through an image-fixing means 8, where the images are fixed and then delivered to the outside as a transcript (a copy).
The surface of the photosensitive member 1 after the transfer of images is brought to removal of the toner remaining after the transfer, using a cleaning means 6. Thus the photosensitive member is cleaned on its surface, further subjected to charge elimination by a pre-exposure means 7, and then repeatedly used for the formation of images.
The charging means 2 for imparting uniform charge on the photosensitive member 1 includes corona assemblies, which are commonly put into wide use. As the transfer means 5, corona transfer assemblies are also commonly put into wide use.
The electrophotographic apparatus may be constituted of a combination of plural components joined as one device unit from among the constituents such as the above photosensitive member, developing means and cleaning means so that the unit can be freely mounted on or detached from the body of the apparatus. For example, the photosensitive member 1 and at least one of the charging means, developing means and cleaning means may be joined into one device unit so that the unit can be freely mounted or detached using a guide means such as a rail provided in the body of the apparatus. Here, the above device unit may be so constructed as to be joined together with the charging means and/or the developing means.
In the case when the electrophotographic apparatus is used as a copying machine or a printer, the photosensitive member is exposed to optical image exposing light L by irradiation with light reflected from, or transmitted through, an original, or by the scanning of a laser beam, the driving of an LED array or the driving of a liquid crystal shutter array according to signals obtained by reading an original with a sensor and converting the information into signals.
When used as a printer of a facsimile machine, the optical image exposing light L serves as exposing light used for the printing of received data. FIG. 4 illustrates an example thereof in the form of a block diagram.
As shown in FIG. 4, a controller 11 controls an image reading part 10 and a printer 19. The whole of the controller 11 is controlled by CPU 17. Image data outputted from the image reading part is sent to the other facsimile station through a transmitting circuit 13. Data received from the other station is sent to a printer 19 through a receiving circuit 12. Given image data are stored in an image memory 16. A printer controller 18 controls the printer 19. The numeral 14 denotes a telephone.
An image received from a circuit 15 (image information from a remote terminal connected through the circuit) is demodulated in the receiving circuit 12, and then successively stored in an image memory 16 after the image information is decoded by the CPU 17. Then, when images for at least one page have been stored in the memory 16, the image recording for that page is carried out. The CPU 17 reads out the image information for one page from the memory 16 and sends the decoded image information for one page to the printer controller 18. The printer controller 18, having received the image information for one page from the CPU 17, controls the printer 19 so that the image information for one page is recorded.
The CPU 17 receives image information for next page in the course of the recording by the printer 19.
Images are received and recorded in this way.
The present invention will be described below in greater detail by giving Examples.
The TEM observation in the present invention was made in the following way: Coatings were cut into pieces with a thickness of about 0.1 μm using a microtome (Ultracut-N, Reihelt Nissei Co.), which were steam-dyed using ruthenium tetraoxide to produce samples. The observation was made under the following conditions.
(1) TEM: JEM2000EXa, manufactured by Nippon Denshi
(2) Accelerating voltage: 200 kV
(3) Magnification: 10,000x
In the following, "part(s)" refers to "part(s) by weight".
EXAMPLE 1
In a sand mill making use of glass beads of 1 mm in diameter, 50 parts of conductive titanium oxide powder whose particle surfaces were coated with tin oxide containing 10% of antimony oxide, 25 parts of phenol resin, 20 parts of methyl cellosolve, 5 parts of methanol and 0.002 part of silicone oil (a polydimethylsiloxane-polyoxyalkylene copolymer; average molecular weight: 3,000) were dispersed for 2 hours to give a conductive layer coating composition. This coating composition was applied onto an aluminum sheet by Mayar bar coating, followed by drying at 140° C. for 30 minutes to form a conductive layer with a layer thickness of 20 μm.
Next, 5 parts of N-methoxymethylated nylon was dissolved in 95 parts of methanol to give an intermediate layer coating composition. This coating composition was applied onto the above conductive layer by Meyer bar coating, followed by drying at 100° C. for 20 minutes to form a subbing layer of 0.6 μm thick.
Subsequently, in a sand mill making use of glass beads of 1 mm in diameter, 3 parts of disazo pigment as a charge-generating material, represented by the formula: ##STR11## 2 parts of polyvinyl benzal (benzalation ratio: 80%; weight average molecular weight: 11,000) and 35 parts of cyclohexane were dispersed for 12 hours, followed by addition of 60 parts of methyl ethyl ketone to give a dispersion for charge generation layer. This dispersion was coated on the above intermediate layer by Meyer bar coating, followed by drying to form a charge generation layer with a layer thickness of 0.2 μm.
Next, 10 parts of hydrazone compound as a charge-transporting material, represented by the formula: ##STR12## and 10 parts of random copolymer represented by the formula: ##STR13## (viscosity average molecular weight: 2.16×10 4 ; having a uniform structure as confirmed by TEM observation of its coating; the numerals indicates copolymerization ratio in molar ratio and the same applies hereinafter) were dissolved in a mixed solvent comprised of 20 parts of dichloromethane and 40 parts of monochlorobenzene. The resulting solution was coated on the above charge generation layer by Meyer bar coating, followed by drying at 120° C. for 60 minutes to form a charge transport layer with a layer thickness of 18 μm.
On the photosensitive member thus produced, its wear resistance and electrophotographic performance were evaluated. The wear resistance was tested using an abrasion tester No.101 T-bar type, manufactured by Yasuda Seiki Co. As an abrasive material, commercially available copy paper was used. The electrophotographic performance was evaluated by measuring light-discharge characteristics using a conductive glass sheet of 10 cm 2 .
Results obtained are shown in Table 1.
EXAMPLE 2
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR14## (viscosity average molecular weight: 2.51×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
EXAMPLE 3
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR15## (viscosity average molecular weight: 9.56×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
EXAMPLE 4
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR16## (viscosity average molecular weight: 3.28×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
EXAMPLE 5
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR17## (viscosity average molecular weight: 2.35×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
COMPARATIVE EXAMPLE 1
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using polycarbonate-A (viscosity average molecular weight: 3.2×10 4 ).
Results obtained are shown in Table 1.
COMPARATIVE EXAMPLE 2
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using polycarbonate-Z (viscosity average molecular weight: 3.6×10 4 ).
Results obtained are shown in Table 1.
COMPARATIVE EXAMPLE 3
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a copolymer represented by the formula: ##STR18## (viscosity average molecular weight: 2.57×10 4 ; having a fine non-uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
COMPARATIVE EXAMPLE 4
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a copolymer represented by the formula: ##STR19## (viscosity average molecular weight: 2.05×10 4 ; having a fine non-uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
COMPARATIVE EXAMPLE 5
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge transport layer was formed using a copolymer represented by the formula: ##STR20## (viscosity average molecular weight: 2.8×10 4 ; having a fine non-uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 1.
TABLE 1______________________________________Electrophotographicperformance Liquid*Sensitivity Residual Abrasion storageμJ/cm.sup.2 potential wear (mg/ Black stabil-(778 nm) (V) 1,000 rap) spots ity______________________________________Example:1 0.68 31 0.62 AA AA2 0.75 28 0.71 AA AA3 0.61 25 0.65 AA AA4 0.65 33 0.73 AA AA5 0.70 29 0.52 AA AACompar-ativeExample:1 1.32 45 4.9 C C2 1.20 43 4.5 C A3 0.92 38 1.2 C C4 0.80 34 0.87 C C5 0.78 37 0.98 C C______________________________________ *(monochlorobenzene; 90 days) Remarks: AA: Excellent, A: Good, C: Failure
EXAMPLE 6
A photosensitive member was produced and evaluated in the same manner as in Example 1 except that the charge generation layer was formed using a disazo pigment represented by the formula: ##STR21## and the charge transport layer was formed using a random copolymer represented by the formula: ##STR22## (viscosity average molecular weight: 2.23×10 4 ; having a uniform structure as confirmed by TEM observation of its coating) and as a charge-transporting material a compound represented by the formula: ##STR23##
Results obtained are shown in Table 2.
EXAMPLE 7
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR24## (viscosity average molecular weight: 2.98×10 4 ; having a uniform structure as confirmed by TEM observation of its coating). Evaluation was also made similarly.
Results obtained are shown in Table 2.
EXAMPLE 8
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR25## (viscosity average molecular weight: 2.34×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 2.
EXAMPLE 9
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR26## (viscosity average molecular weight: 4.10×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 2.
EXAMPLE 10
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR27## (viscosity average molecular weight: 2.86×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 2.
COMPARATIVE EXAMPLE 6
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using polycarbonate-A (viscosity average molecular weight: 3.2×10 4 ).
Results obtained are shown in Table 2.
COMPARATIVE EXAMPLE 7
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using polycarbonate-Z (viscosity average molecular weight: 3.6×10 4 ).
Results obtained are shown in Table 2.
COMPARATIVE EXAMPLE 8
A photosensitive member was produced and evaluated in the same manner as in Example 6 except that the charge transport layer was formed using a copolymer represented by the formula: ##STR28## (viscosity average molecular weight: 2.05×10 4 ; having a fine non-uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 2.
TABLE 2______________________________________Electrophotographicperformance Liquid*Sensitivity Residual Abrasion storageμJ/cm.sup.2 potential wear (mg/ Black stabil-(778 nm) (V) 1,000 rap) spots ity______________________________________Example:6 0.48 22 0.50 AA AA7 0.45 28 0.61 AA AA8 0.51 25 0.58 AA AA9 0.55 30 0.63 AA AA10 0.51 29 0.52 AA AACompar-ativeExample:6 1.10 41 4.3 C C7 0.87 35 4.4 C A8 0.70 37 0.67 C C______________________________________ *(monochlorobenzene; 90 days) Remarks: AA: Excellent, A: Good, C: Failure
EXAMPLE 11
A conductive layer, a subbing layer and a charge generation layer were formed in the same manner as in Example 1 except that the support was replaced with an aluminum cylinder and the coating was carried out by dip coating, and provided the charge-generating material as used in Example 6 was used.
Next, 10 parts of butadiene compound represented by the formula: ##STR29## and 10 parts of random copolymer represented by the formula: ##STR30## (viscosity average molecular weight: 2.05×10 4 ; having a uniform structure as confirmed by TEM observation of its coating) were dissolved in a mixed solvent comprised of 20 parts of dichloromethane and 40 parts of monochlorobenzene. The resulting solution was coated on the above charge generation layer by dip coating, followed by drying at 120° C. for 60 minutes to form a charge transport layer with a layer thickness of 18 μm.
Then, using the resulting photosensitive member in a commercially available laser printer, electrophotographic performance was evaluated. As a result, no black spots were seen and also good images were obtained substantially without scratches, even after running on 10,000 sheets.
EXAMPLE 12
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR31## (viscosity average molecular weight: 2.51×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 3.
EXAMPLE 13
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR32## (viscosity average molecular weight: 9.56×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 3.
EXAMPLE 14
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR33## (viscosity average molecular weight: 3.28×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 3.
EXAMPLE 15
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using a random copolymer represented by the formula: ##STR34## (viscosity average molecular weight: 2.35×10 4 ; having a uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 3.
COMPARATIVE EXAMPLE 9
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using polycarbonate-A (viscosity average molecular weight: 3.2×10 4 ).
Results obtained are shown in Table 3.
COMPARATIVE EXAMPLE 10
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using polycarbonate-Z (viscosity average molecular weight: 3.6×10 4 ).
Results obtained are shown in Table 3.
COMPARATIVE EXAMPLE 11
A photosensitive member was produced and evaluated in the same manner as in Example 11 except that the charge transport layer was formed using a copolymer represented by the formula: ##STR35## (viscosity average molecular weight: 2.57×10 4 ; having a fine non-uniform structure as confirmed by TEM observation of its coating).
Results obtained are shown in Table 3.
Then, using the photosensitive member obtained in Comparative Examples 9-11 in a commercially available laser printer, electrophotographic performance was evaluated. As a result, black spots were seen even at the initial stage. After running on 10,000 sheets, deep scratches occurred on the surface layer to cause faulty images.
TABLE 3______________________________________ Electrophotographic performance Sensitivity Residual Liquid* μJ/cm.sup.2 potential Black storage (778 nm) (V) spots stability______________________________________Example:11 0.28 21 AA AA12 0.25 23 AA AA13 0.21 22 AA AA14 0.25 25 AA AA15 0.31 32 AA AAComparativeExample:9 0.95 54 C C10 0.92 43 C A11 0.50 35 C C______________________________________ *(monochlorobenzene; 90 days) Remarks: AA: Excellent, A: Good, C: Failure
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There is disclosed an electrophotographic photosensitive member comprising a conductive support and a photosensitive layer provided thereon, wherein the photosensitive layer contains a random copolymer having a structural unit represented by the following Formula (I): ##STR1## and a structural unit represented by the following Formula (II): ##STR2##
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention is directed to novel organosilicon compounds containing functional groups including an ethylene double bond, and methods of preparing them.
2. Description of the Prior Art:
The use of organosilicon compounds in preparing thermoplastic elastomers is well recognized in the art. For example, in Belgian Pat. No. 834,046, published Mar. 30, 1976, polysiloxane thermoplastic elastomers are formed from recurrent groups of silicon bonded to oxygen upon which other functional groups may be attached to form complex, branched chain thermoplastic polymers.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide novel organosilicon compounds containing functional groups which include carbon-carbon double bonds. Such compounds are useful in the production of thermoplastic elastomers.
Another object of the invention is to provide a process for the preparation of the novel organosilicon compounds.
Other objects and advantages of the present invention will become evident to those of skill in the art after reading the detailed description which follows.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the present invention are organosilicon compounds of the formula:
(R-Si(R.sub.1).sub.2 --G--Y--.sub.n Q (I)
in which:
The symbol n is equal to 2 or 3;
The symbol R represents a monovalent hydrocarbon radical containing as many as 10 atoms of carbon and including a carbon-carbon double bond;
The symbol R 1 represents a monovalent hydrocarbon radical, which has been selected from among linear or branched alkyl radicals with at the most 10 carbon atoms--radicals which can be replaced by one or several halogen atoms or cyano groups; cycloalkyl radicals with 3 to 6 carbon atoms in the cycle; aryl radicals. The cycloalkyl or aryl radicals can be replaced by one or several halogen atoms;
The symbol G represents an aromatic carbocyclic radical or a heterocyclic radical. These radicals can be mono- or polycyclic, when polycyclic can be condensed or combined by a simple bond or by an atom or group such as --O--, --CH 2 --, --C(CH 3 ) 2 --, --C(CH 3 ) 2 --, --SO 2 --, --CONH--;
The symbol Q represents a radical of n valence, selected from the group consisting of aliphatic radicals with up to 13 carbon atoms, cycloaliphatic radicals with 5 or 6 carbon atoms in the cycle, heterocyclic radicals, aromatic radicals containing one or several benzene nuclei. When there are several benzene nuclei they can be condensed or related by a simple bond or by an atom or group such as --CH 2 --, --C(CH 3 ) 2 , --O--, ##STR1## --CONH--;
The symbol Y represents a group selected from the group consisting of --CONH-- and --COO--. The radicals represented by the symbols R, R 1 , G, and Y may be different from one motif [R--Si(R 1 ) 2 --G--Y] to another.
According to a preferred embodiment of the present invention, the symbols referred to above are given the following meaning:
n is an integer equal to 2 or 3;
R represents a radical selected from the group consisting of vinyl, allyl, dichloro-2, 2 vinyl, trichloro-1,2,2 vinyl, butene-2 yl, propene-1 yl, butene-1 yl, methyl-2 propene-1 yl;
R 1 represents a radical selected from the group consisting of methyl, ethyl, trifluoro-4,4,4 butyl, phenyl, o-, m- or p-tolyl, xylyl, p- or m-chlorophenyl, dichloro-3,5 phenyl, trichlorophenyl, tetrachlorophenyl, β-cyanoethyl and γ-cyanopropyl;
G represents a radical selected from the group consisting of: ##STR2## wherein a is equal to 1 or 2 and T represents a simple bond or O, CH 2 , C(CH 3 ) 2 or SO 2 ;
Q represents a divalent radical selected from the group consisting of pentamethylene, hexamethylene, cyclohexylene, one of the radicals illustrated above in defining G and radicals containing up to 5 benzene nuclei related to each other by simple bonds or one of the following groups: O, CH 2 , C(CH 3 ) 2 , SO 2 , COO, or CONH.
Alternatively, Q may be a trivalent radical corresponding to the divalent radicals listed above.
The following formulas represent organosilicon compounds which are within the scope of the present invention: ##STR3##
The compounds of the present invention can be prepared by reacting a silane of the formula:
R--Si (R.sub.1).sub.2 --G--Y.sub.1 (II)
with a compound of the formula:
(Y.sub.2).sub.n Q (III)
In these two formulas, the symbols R, R 1 , G, Q and n have the meaning recited above. Y 1 and Y 2 represent groups which, as a result of the reaction, form the various groups represented by Y in formula I. Ordinarily, to obtain a group represented by Y, Y 1 is a radical selected from the group consisting of COOH, COOR 2 , COCl, and COOM in which M represents sodium, potassium, or lithium and R 2 represents a linear or branched alkyl radical containing up to 4 carbon atoms. In such cases, Y 2 is either a NH 2 or OH radical, making the compounds of formula III polyols, polyphenols, polyamines, amino alcohols and aminophenols.
The quantities of the two reactants are initially chosen so that there is n moles of the silane of formula II per mole of the second reactant. The silane reactant is not required to be one particular product but may be a mixture of silanes corresponding to formula II. These silanes are prepared from other silanes having the formula:
R--Si (R.sub.1).sub.2 --G--Cl (IV)
by application of conventional methods, such as, carbonation or esterification.
The silanes of formula IV are prepared by a reaction scheme utilizing an organomagnesium halide complex (Grignard reagent) according to the following process:
Step (a) Condensation of a dichlorinated Grignard reagent containing the radical G with a dichlorosilane:
Cl-G-MgCl+(R.sub.1).sub.2 SiCl.sub.2 →Cl-G-Si (R.sub.1).sub.2 Cl+MgCl.sub.2 (A)
Step (b) Condensation of product (A) with Grignard reagent, RMgCl:
(A)+RMgCl→Cl-G-Si (R.sub.1).sub.2 -R+MgCl.sub.2
Illustrative of the compounds represented by formula II which are useful as reactants in forming the compounds of the present invention are:
vinyldimethylsilyl-4 benzoic acid
chlorocarbonyl-1 vinyldimethylsilyl-4 benzene
divinylmethylsilyl-4 benzoic acid
methoxycarbonyl-1 vinyldimethylsilyl-4 benzene
ethoxycarbonyl-1 vinyldimethylsilyl- 4 benzene
ethoxycarbonyl-3 vinyldimethylsilyl-4 pyridine
vinyldimethylsilyl-4 methoxycarbonyl-4' diphenylmethane
vinyldimethylsilyl-4 methoxycarbonyl-4' diphenylether
Exemplary of compounds represented by formula III which comprise the second reactant in preparing the compounds of the present invention are: (A) polyamines such as:
hexamethylenediamine
bis(amino-4 cyclohexyl)-2,2 propane
m-phenylenediamine
p-phenylenediamine
triamino-1,2,4 benzene
m-xylylenediamine
p-xylylenediamine
bis(amino-4 phenyl) methane
diamino-4,4' phenyl oxide
diamino-4,4' benzophenone
diamino-4,4' benzoate of phenyl
N,N'bis(p-aminobenzoyl)diamino-4,4' diphenylmethane
bis p-(amino-4 phenoxy) benzene
diamino-2,6 pyridine
(B) polyols or polyphenols such as:
ethylene glycol
propanediol-1,3
butanediol-1,4
pentanediol-1,5
hexanediol-1,6
heptanediol-1,7
bis(δ hydroxybutyl)1,4 cyclohexane
bis(β hydroxyethyl)-1,4 benzene
hydroquinone
resorcinol
dihydroxy-1,5 naphthalene
dihydroxy-4,4' biphenyl
bis(hydroxy-4 phenyl) methane
bis(hydroxy-4 phenyl) sulfone
(C) amino alcohol or aminophenols such as:
ethanolamine
amino-3 propanol-1
amino-4 butanol-1
amino-5 pentanol-1
amino-6 hexanol-1
amino-6 methyl-5 hexanol-1
amino-10 decanol-1
p-aminophenyl-4 cyclohexanol
p-hydroxymethylbenzylamine
hydroxymethyl-4 aminomethyl-4' biphenyl
(p-amino)phenethyl alcohol
The reaction between the silane of formula II and the compound of formula III is brought about as a general rule at a temperature between about -20° and 200° C., and preferably between about -10° and 100° C. Usually, one of the reagents is introduced in the reactive environment containing the other reagent. Depending on the particular groups which are present, the reactive environment may additionally contain an acceptor of hydrochloric acid or a catalyzer of transesterification. As a general rule, the reaction occurs in the environment of a solvent, such as, N-methylpyrrolidone, dimethylacetamide, chloroform, methylene chloride, tetrahydrofurane, dioxane, ethyl ether, or isopropyl ether. After the reaction, the compounds of formula I can be isolated from the reactive environment by applying known methods, such as, precipitation, recrystallization.
The polyethylene silicon compounds which are the subject of the present invention can take part in many reactions because of the presence of unsaturated groups. In particular, they can allow reticulation of polyolefines or organosiloxanes in the presence of peroxides or radiation. They may also allow addition of mono- or bis-hydrogenated silanes or siloxanes with hydrolyzable or non-hydrolyzable function in order to prepare resins or elastomers, or they may lead to homopolymers by heating in the presence of a "radicalary initiator" or a source of radiation.
The following examples are provided to further illustrate the subject matter of the present invention, it being understood that in no way are they intended to limit the scope of the invention.
In the following examples, the silanes which were used as initial silanes (product of formula II) were dimethylvinylsilyl-4 benzoyl chloride (z). This product was prepared by action of thionyl chloride on the corresponding benzoic acid (y); the acid (y) was itself prepared from the corresponding chlorophenylsilane (x). These various products were prepared as follows:
PREPARATION OF P-CHLOROPHENYLSILANE DIMETHYL VINYL (X)
Forty cubic centimeters (0.33 mol) of dimethyldichlorosilane at 20° C. were placed in a three-neck balloon-flask swept by a flow of nitrogen. Eighty cubic centimeters of toluene were added while agitating the mixture. The temperature was changed to 5° C., then 0.33 mol of p-chlorophenylmagnesium chloride was added in 30 mn in the form of a solution in tetrahydrofurane (140 cubic centimeters). Twenty cubic centimeters of toluene were added and shaken for 2 hours 30 minutes. Them 0.36 mol of vinylmagnesium chloride was added in 20 mn in the form of a solution in tetrahydrofurane (120 cubic centimeters), with the temperature being maintained at 25° C. Then the temperature of the reactive environment was raised to 80° C. and maintained at that temperature for 2 hours. The reactive environment was cooled, the product was washed twice in 120 cubic centimeters of water acidified by 5 cubic centimeters of HCl. Then, after decantation, neutralization by means of bicarbonate of soda, drying, 42 grams of a product was collected containing (chromatography in gaseous phase) 80 percent by weight of p-chlorophenyldimethylvinylsilane (yield 51.3 percent as compared to dimethylchlorosilane.)
PREPARATION OF VINYLDIMETHYLSILYL-4 BENZOIC ACID (Y)
Twelve and one-half grams of magnesium in the form of shavings were packed in a three-neck balloon-flask under flow of nitrogen, then 10 cubic centimeters of "magnesian (a)" product (obtained from the previous operation) were poured in. The mixture was heated to 70° C., then 99 grams of dimethylvinylchlorophenylsilane as prepared above in the form of a solution in 150 cubic centimeters of THF were added. The pouring of chlorophenylsilane was completed in 2 hours. It was kept boiling (reflux of tetrahydrofurane THF) during 12 hours in order to complete the reaction, then the environment containing p-(dimethylvinylsilyl) phenylmagnesium chloride (a) was withdrawn. Two hundred cubic centimeters of THF were poured in a balloon-flask and cooled by a bath of ice/acetone and saturated with CO 2 by stirring. Then the magnesian product was poured in the balloon-flask while CO 2 was kept in excess and the temperature of the reactive environment was maintained around 10° C. This reactive environment was then poured in 2 liters of ice cold water acidified by 55 cubic centimeters of a solution of HCl 10 N. Two hundred-fifty cubic centimeters of toluene were added in order to stimulate the decantation of the resulting paste.
After washing, treatment in a basic environment, precipitation, 62 grams of a white product with a melting point of 82° C. were collected and identified as vinyldimethylsilyl-4 benzoic acid (yield of 61 percent as compared to dimethylvinylchlorophenylsilane).
PREPARATION OF DIMETHYLVINYLSILYL-4 BENZOYL CHLORIDE (Z)
The acid prepared in accordance with the preceding paragraph was used.
This acid (815 grams=3.75 mol) was placed in a balloon-flask and heated to 90° C. The product after shaking became a pasty liquid. In this environment, 595 grams (5 mols) of thionyl chloride were introduced in 1 hour 30 minutes. The reaction was endothermic. The reactive environment was maintained at 45° C. for 1 hour 20 minutes.
Dimethylvinylsilyl-4 benzoyl was obtained with a yield of 90.5 percent (as compared to dimethylvinylsilyl-4 benzoic acid). (Boiling point 98.5°-100° C. under pressure of 3 millimeters of mercury).
EXAMPLE 1
In a balloon-flask kept in an atmosphere of nitrogen and equipped with an agitation system, a condenser, a tap vial and a thermometer, 24.8 grams (0.125 m) of diamino-4,4' diphenylmethane and 150 millimeters of N-methylpyrolidone (NNP) were introduced. Fifty-seven and one-half grams (0.25 m) of dimethylvinylsilyl-4 benzoyl chloride was poured over a period of 1 hour in the solution which had been cooled to 5° C. The homogeneous reactive environment was kept for 3 hours at room temperature, then precipitated in 1 liter of ice cold water while being shaken energetically. After several washings, bis(dimethylvinylsilyl-4 benzamido-4' phenyl) methane was recrystallized in toluene. A white product was obtained. The yield was 57 percent as compared to dimethylvinyl-4 benzoyl chloride.
The infrared spectrum showed bands which were characteristic of the compound having the following formula: ##STR4## The instant melting point was 152° C.
The centesimal analysis with regard to C, H, and N gave the following results:
C%: 73.06-73.23
H%: 6.72-6.65
N%: 4.61-4.85
Chromatographic analysis of thin layer did not detect any impurity.
EXAMPLE 2
According to the operational conditions of Example 1, 45 grams (0.1 m) of bis(amino-4 benzamido-4' phenyl) methane and 250 millimeters of NMP were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the suspension cooled to 5° C.
The homogeneous reactive environment was kept for 2 hours at room temperature, then precipitated in 1.5 liters of ice cold water. The bis(dimethylvinylsilyl-4 dibenzamido-4',4" phenyl) methane was recrystallized in a mixture at the rate of 90/10 of DMF/water (volume/volume).
The infrared spectrum showed characteristic bands of the product of the following formula: ##STR5##
This white solid, which was obtained with a yield of 91 percent, had an instant melting point of 250° C.
Chromatographic analysis of a thin layer did not detect any impurities.
The centesimal analysis indicated the following:
C%: 70.27-70.32
H%: 5.86-6.04
N%: 7.50-7.33
EXAMPLE 3
In accordance with Example 1, 35 grams (0.1 m) of bis-(amino-4 phenyl) terephthalate and 300 millimeters of NMP were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were poured over a period of 1 hour in the solution which had been cooled to 5° C. The heterogeneous paste-like reactive environment was kept for 4 hours at room temperature, then precipitated in 1 liter of ice cold water. The bis(dimethylvinylsilyl-4 benzamido-4' phenyl) terephthalate was recrystallized in dimethylformamide. The crystallized product was white. The yield was 81.5 percent. The instant melting point was 330° C.
The infrared spectrum corresponded to the product of the following formula: ##STR6##
Chromatographic analysis of a thin layer did not detect any impurities.
The centesimal analysis indicated the following:
C%: 69.16-69.29
H%: 5.62-5.65
N%: 4.03-4.00
EXAMPLE 4
In accordance with Example 1, 24 grams (0.1 m) of amino-4 benzoate of 'amino-4' phenyl and 150 millimeters of NMP were introduced. Dimethylvinylsilyl-4 benzoyl chloride was added over a period of 1 hour in the solution which was cooled to 5° C. The homogeneous reactive environment was kept for 2 hours at room temperature, then precipitated in 1 liter of ice cold water. The dimethylvinylsilyl-4 benzamido-4' benzoate of (dimethylvinylsilyl-4" benzamido-4'") phenyl was recrystallized in alcohol.
A white amorphous product was collected with a yield of 73 percent. The instant melting point was 225° C.
The infrared spectrum corresponded to the product of the following formula: ##STR7##
Chromatographic analysis of a thin layer detected the presence of a small quantity of aromatic impurity.
Centesimal analysis indicated the following:
C%: 69.10
H%: 5.98-6.10
N%: 4.24-4.50
EXAMPLE 5
In accordance with Example 1, 21.6 grams (0.2 m) of p-phenylene diamine and 200 millimeters of NMP were introduced. Ninety grams (0.4 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the suspension which was cooled to 5° C. The homogeneous reactive environment became heterogeneous when half of it was poured in, and paste-like at the end of the pouring. It was kept for 4 hours at room temperature, then precipitated in 1 liter of cold water. The p-phenylene bis(dimethylvinylsilyl-4 benzamide) was recrystallized in dioxane.
The product obtained with a yield of 82 percent was a white, crystalline compound. The instant melting point was 180° C.
The infrared spectrum showed the characteristic bands of the product of the following formula: ##STR8##
Chromatographic analysis of a thin layer detected the presence of a small quantity of aromatic impurity.
Centesimal analysis indicated the following:
C%: 69.33-69.30
H%: 6.46-6.52
N%: 5.74-5.63
EXAMPLE 6
In accordance with Example 1, 12.1 grams (0.1 m) of hexamethylene diamine and 200 millimeters of NMP were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the solution which was cooled to 5° C. The heterogeneous reactive environment was kept for 3 hours at room temperature, and then precipitated in 1 liter of ice cold water. The hexamethylene bis(dimethylvinylsilyl-4 benzamide) was recrystallized in cyclohexane.
The product obtained with a yield of 40 percent was white and crystalline in the form of flakes. The melting point was 128° C.
The infrared spectrum corresponded to the product of the following formula: ##STR9##
Chromatographic analysis of a thin layer did not detect any impurity.
Centesimal analysis indicated the following:
C%: 69.17-68.86
H%: 8.26-8.20
N%: 5.48-5.70
EXAMPLE 7
In accordance with Example 1, 10.9 grams (0.1 m) of m-phenylene diamine and 200 millimeters of NMP were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the solution which was cooled to 5° C. The homogeneous reactive environment was kept for 2 hours at room temperature, and then precipitated in 1 liter of ice cold water. The m-phenylene bis(dimethylvinylsilyl-4 benzamide) was recrystallized in a mixture of 75 25 alcohol/water (volume/volume).
A translucid, crystalline product in the form of flakes was collected with a yield of 77.5 percent.
The product had an instant melting point of 178° C.
The infrared spectrum showed the characteristic bands of the product of the following formula: ##STR10##
Chromatographic analysis of a thin layer detected the presence of an impurity which did not contain any amine.
Centesimal analysis indicated the following:
C%: 69.28-69.16
H%: 6.58-6.65
N%: 6.00-5.80
EXAMPLE 8
In accordance with Example 1, 25.08 grams (0.1 m) of p-terphenyl diamine and 200 millimeters of NMP were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the suspension which was cooled to 15° C. The heterogeneous reactive environment was heated for 2 hours to 75° C. The solution was precipitated in 1 liter of ice cold water. The p-terphenylene bis(dimethylvinylsilyl-4 benzamide) was recrystallized in acetophenone.
A white product in the form of prismatic crystals was obtained with a yield of 89.5 percent. The melting point was 338° C.
The infrared spectrum corresponded to the product of the following formula: ##STR11##
Chromatographic analysis of a thin layer did not detect any impurity.
Centesimal analysis indicated the following:
C%: 76.41-76.33
H%: 6.41-6.51
N%: 4.27-4.50
EXAMPLE 9
In accordance with Example 1, 15.25 grams (2/30th m) of triamino-3,4,4' diphenyl ether and 150 millimeters of pyridine were introduced. Forty-five grams (0.2 m) of dimethylvinylsilyl-4 benzoyl chloride were added over a period of 1 hour in the solution which was cooled to 5° C. The homogeneous reactive environment was kept for 2 hours at room temperature, then precipitated in 1 liter of ice cold water. By dissolving the product in hot hexane and cooling it, tri-(dimethylvinysilyl-4 benzamido) 3',4',4" diphenyl ether was obtained.
The product obtained with a yield of 62 percent was beige in color and amorphous. The melting point was 162° C.
The infrared spectrum showed characteristic bands of the product of the following formula: ##STR12##
Chromatographic analysis of a thin layer detected the presence of a small quantity of impurities which did not contain any amines.
EXAMPLE 10
In accordance with Example 1, 40 grams (0.2 m) of diamino-4,4' diphenyl ether to dissolve in 100 cubic centimeters of NMP were introduced, then 93.48 grams of dimethylvinylsilyl-4 benzoyl chloride were added in the solution which was cooled to 0° C. over a period of 1 hour. The reactive environment was kept under agitation for 2 hours at room temperature, then precipitated in 1 liter of distilled water while the product was shaken energetically. The p-bis-(dimethylvinyl)silyl-N,N' benzamido-4,4' diphenyl ether was recrystallized in toluene.
A white product with a melting point of 185° C. was obtained with a yield of 68.2 percent.
The infrared spectrum corresponded to the product of the following formula: ##STR13##
Centesimal analysis indicated the following:
C%: 71.00-71.23
H%: 6.36-6.36
N%: 4.77-4.88
While the invention has now been described in terms of certain preferred embodiments and exemplified with respect thereto, the skilled artisan will readily appreciate that various modifications, substitutions, changes and omissions, may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the invention be limited solely by that of the following claims.
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Novel organosilicon compounds and processes for their preparation are disclosed. The compounds are di- and trisilanes of the formula
(R--Si (R.sub.1).sub.2 --G--Y--.sub.n Q
in which R represents a radical containing one double ethylene bond, R 1 represents a hydrocarbon radical, G represents a carbocyclic aromatic or heterocyclic radical, Y represents CONH or COO, Q represents an organic radical and n is an integer equal to 2 or 3. The compounds are useful in preparing thermoplastic elastomers.
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to an error control method to replace the conventional transport protocol which brings about a bottleneck phenomenon in a communication between computers mutually communicating by accessing a network in comparison with a performance of a network being super-high-speedified and a computing speed of a computer in multimedia computer communication and, in particular, to an error control method for guaranteeing a multiparty reliable data transmission in a transport protocol which supports a many-to-many communication model.
2. Information Disclosure Statement
A recent tendency of persisting the globalization of the world brings many areas in a state and states all over the world close to each other through communication and information processing. These requirements are not simply satisfied through conventional usual mail, telephone and faximile but require a variety of multimedia application services such as group wares which support a group joint work which facilitates a concurrent face-to-face dialogue through application services such as remote lecture, remote medical treatment and remote video conference, etc.
One approach for sharing an application service which persist high speed and diversification is to develop transport protocols for multiple users. However, most of them are 1:1 transport protocol modes which share a single user which supports participating users with only existing user-system interaction. As one of the efforts to solve such problem, the field of communication network and application service highlights the transport protocol as an important research area, and the high speed transport protocol appears to be a new research field for a multimedia application in different machines high speed networks. Existing OSI TP(Transport Protocol) 4 stack or TCP/IP is a protocol provided to transmit a general text data and has many disadvantages in that it is not appropriate to provide a real time communication required in multimedia environment and a communication to reliably process a lot of data. In addition, these protocols are not appropriate for a communication protocol which can satisfy requirements accompanying an increase in a variety of computer communication networks, an increase in transmission rate according to development of communication technology and transmission apparatus, a development of computer technology and an extension of new application service area including a varietymedia. Furthermore, since these protocols were developed in the time when the bandwidth of network was narrow, the network had high error occurrence rate and there was lack of system resources, the main object of the protocols was an efficient use of bandwidth and an efficient performance of error detection and recovery. However, to solve the performance degradation due to the structural problem of the existing protocol, the existing high speed communication environment uses a method of revising or extending the function of existing protocol and minimizing the protocol processing time and a method of designing a new protocol structured to be appropriate to the existing high speed network environment. Since the extension of existing protocol among the methods can not be a long term solution, a research on the design of new protocol is vigorously carried out.
The error control is to reliably provide the data transmission necessary for multimedia application such as collaborative work in inter-multi-user transport protocol environment of multimedia computer communication. Since the existing error control methods have been used mainly for document-oriented text data in the time when the network was unsafe due to jitter and delay, etc., and the performance such as speed was poor, they present too many disadvantages to be used as an error control method required in the super high speed information communication environment based on the existing multimedia and super high speed transmission network.
To guarantee the inter-multi-user reliable data transmission, the reliability of data packet transmission and of group membership of subscriber of communication must be guaranteed. To provide the reliability of this type, the problem of acknowledge implosion and scalability of group membership which does not occur in the protocol based on end-to-end or peer-to-peer communication such as Transmission Control Protocol (TCP) must be considered.
A real conference wants to have the guaranty of strict transmission delay service instead of reliable transmission service. On the other hand, the collaborative application such as common editor or distribution of medical image information absolutely requires the transmission service guaranteeing the reliability. Recently, reliable multicast transmission protocols of various types have been developed to accommodate the requirement of application program requiring the quaranty of reliability, and there are results of research which compares and analyses the protocols, however, such protocols have not efficiently solved the problem of salability of group size and reliability.
In the conventional end-to-end communication in which a transmitter and a receiver establish a 1:1 connection, after the receiver receives the data from the transmitter, the receiver acknowledges the state of the received data according to the method of reliably transmitting and receiving the data. The error control is the function of detecting and solving the errors occurring at the time of data transmission between the transmitters and receivers. The errors that can occur in the procedure of transmission and reception are deformation of packet content, change in the order of packet arrival, duplication of packet arrival and loss of packet, etc. These error control functions are three functions such as error detection, error reporting and error recovery (correction), and the following researches are carried out on them.
The error detection function is to check whether the packets arrive in the order of transmission without deformation of packet contents. The error detection has a procedure of receiving a message by using the information such as sequence number, packet length and data checksum, checking the messages and receiving next message.
The error reporting function is to transfer to the transmission side the informations about the arrival of wrong packet or the loss of packet, and for the error reporting function, a Negative Acknowledge (NACK) mode of selecting the packet to which the error occurred and acknowledging is well known rather than Acknowledge (ACK) mode of acknowledging whenever the packet arrives. In general, since the existing protocol does not have such error exporting function but frequently detects the error based on the arrival or not of packet by using a Positive Acknowledge (PACK) mode in which the receiver securely acknowledges to the transmitter within a predetermined period, if the existing protocol is applied to a many-to-many communication, it causes an overload at the time of data transmission.
The error recovery (correction) function is to recover a reported error by retransmitting the packet corresponding to the reported error. A method of retransmitting all packets after the packet to which the error occurred is used, and the method is easy to implement so that it can be easily applied to a communication network having high error rate, therefore, the method is adopted and used in the existing protocol, however, nowadays a revised method is required in the super high speed network environment in which the reliability of the network is improved and a great amount of data must be transmitted a short time period.
The functions described above is a method of controlling errors occurring in the end-to-end communication composed simply of one transmitter and one receiver and is not appropriate to solve the errors occurring concurrently and in a bundle between one or some transmitters and many receivers in the many-to-many multiple points, multiple user communication such as multimedia environment.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an error control method which can satisfy requirements for various multimedia application services in a multiple points, multiple user communication environment by improving the reliable transmission and reception of data by using error control techniques appropriate to multimedia computer communication environment.
The present invention to accomplish the object described above is characterized in that it comprises the steps of: a first step in which the rereceiver receives the data and heartbeat from the source, analyzes them and checks whether the error occurred to the data reception; a second step in which in case where the error occurred to the data reception as a result of check at first step, the receiver re-receives the data and heartbeat from the source, and in case where the error did not occur, the receiver checks whether it received the data packet outside the sequence number zone; a third step in which in case of having received the data packet inside the sequence number zone, as a result of sheck at second step the receiver shifts to the step for analyzing the data and heartbeat, and in case where the receiver received the data packet outside the sequence number zone, the receiver actuates the error correction mechanism; a fourth step in which in case where the receiver receives any message within the threshold for retransmission request from the source after actuation of said error correction mechanism, the receiver shifts to the step of analyzing the received data and heartbeat, and in case where the receiver did not receive anything, the receiver sends the query message to the multicast group to query the status of source ; and a fifth step in which the source transmits the heartbeat to respond to the query, and in case where there is an error in the data packet received from the source, the receiver shifts to the step of receiving the data and heartbeat from the source, and in case where there is no more error to the data packet, the procedure is terminated.
BRIEF DESCRIPTION OF THE DRAWINGS
The above object, and other features and advantages of the present invention will become more apparent by describing the preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is a status flow diagram in a transport control according to the present invention;
FIG. 2 is a status flow diagram for error detection and retransmission request according to the present invention;
FIG. 3 is a status flow diagram for error correction according to the present invention;
FIG. 4 is a structural drawing of the upper and lower portions of protocol in a multimedia communication system to which the present invention is applied;
FIG. 5 is a process flow diagram of error detection and retransmission request according to the present invention; and
FIG. 6 is a process flow diagram of error correction according to the present invention.
Similar reference characters refer to similar parts in the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
A communication group is composed of a small number of sources and a large number of receivers which are users participating in the communication, and a connection for communication between them is established to transmit and receive data. During the transmission of data, errors occur due to the loss (this means a damage and a loss) of transmitted message and an abrupt change in environment of system established between two terminals such as a network traffic implosion, failure and system down, and therefore, procedures of detection, correction and recovery of errors are required. In the present invention, these procedures are classified into an error detection mode an error correction mode as follows.
1. Error Detection Mode
For the error detection mode, there are data packet error control method and host system error control method.
A. Data Packet (Message failure) Error Control Method
This method only deals with the error of messages transmitted between sources and receivers. The sources recognize data transmitted and received by using sequence number of messages. The sequence number starts with a number, is sequentially increased for identification of each data packet and is independently maintained by each source. The receiver detects the loss of packet by checking the gap between sequence numbers and finds out the damage of packet by checking the checksum of data packet.
A heartbeat message is used for indication of presence and status of a source host. The heartbeat message which is sent first after the start of communication is transmitted only be the source host and is included in the sequence number of last packet.
The cases in which the heartbeat is generated are as follows. The heartbeat is generated when the source does not send the data, makes the receiver recognize the generation of data loss of source, and represents the time of stop of source and the activity of source. The heartbeat is used when the source is momentarily sloped for a certain period of time. When the source stops the transmission for a certain period, the heartbeat is regularly transmitted until the source normally transmits.
The receiver uses the heartbeat message sent by the source as an indication for responding to an arbitrary request. In the case although the connection between the source and receivers is not interrupted but still established, the source restrains the data transmission due to some reason, then constants such as amount of NACK, flow control parameter and time period taken in a return delivery are calculated after elapse of certain period and before start of heartbeat message.
Most of conference participants transmit small amount of message and, in fact, occasionally transmit during multicast session duration, an at this time the heartbeat transmission time is limited. After the source transmits about 10 messages for a certain period, it declares that it no longer is a source.
The receivers internally refers to a source reference state, and if the receiver fails to obtain the messages and requests the source to improve the status, then the source again repeats the information. The host shifts from the source to the receiver after elapse of certain duration, where the data synchronization of the receiver is the responsibility of the layers of session and application, and the source no more transmits the heartbeat message.
The source maintains all informations on the receivers in the group, and the receiver continues to maintain the information on status of source. The source transmits the heartbeat message by the multicast to maintain the information about the receiver, and the receiver periodically transmits the heartbeat message to the source to inform the source of the last received message. The heartbeat information sent by the receiver can be received only by the source and can not be received by other receivers, and the receiver send the heartbeat to the source by the unicast. The heartbeat includes the receiver ID and a port number of connection and also includes the sequence number of the last message which the receiver received. The source uses the randomized method of periodically selecting only one receiver as a method of avoiding an implosion of heartbeats coming from various receivers.
The source uses the heartbeat sent by the receiver to maintain the trace of status of receiver, collects the status information of the receiver by using the heartbeat received from various other receivers with reduced overhead by using the randomized method, and makes a list of group member on a status table of its own. All the receivers in the group also install a status table about the source by using the first heartbeat message sent by the source. The informations about the status thus obtained are notified to upper layers. The source maintains the state tables which is the base for insuring the reliability on all of the communication such as subscribing procedure, leaving procedure, flow control and error control, etc., If the receiver stops the dialogue, the source informs it to the application layer. If the source once determines that the receiver left, the source removes the receiver form the receiver list and informs the charge to the application layer.
The heartbeat of the source includes the source ID, sequence number of last message and the port number. The receiver uses the sequence number of the first data packet to trace the message sent by the source. The receiver transmits the heartbeat message to the source to the unicast address to respond to the first message is periodically repeated, since there is no secured ACK from the source except the heartbeat. The source sends the heartbeat when there is no data packet to send, and requests the receiver to respond within the heartbeat period.
After the source receives the first data, the use of heartbeat message by the receiver is necessary for providing the reliability to application layer and making a state table to maintain the state of receiver.
In summary, the heartbeat of receiver received by the source is randomized and received by the source to avoid the saturation of network by the heartbeat send by the entire receivers.
The heartbeat of receiver is sent to source by unicast, notifies the last message sent by source, and provides the information with which the source can manage membership of the group of entire receivers.
This heartbeat message is periodically repeated, since there is no secured ACK of source except this heartbeat. The source sends this heartbeat when there is no data packet to send, and requests the receiver to respond within the heartbeat period.
B. Host System (Site failure) Error Control Method
This method is an error control method about the status of source and receivers. In case where the reception of data including the heartbeat message if source is interrupted, the receiver must send a specific message to source to grasp the status of source and it sends the message directly to the multicast group or host. The advantage is that since the multicast tree is used, other hosts can continue to work.
In case where the source can not sense the retransmission request for a certain period, it must be confirmed whether it is due to interrupt from receivers or whether there is no more receiver listening. Therefore, the source transmits the status request to receivers. One of the receivers responds to the status request and if the source multicasts the response to all groups on the multicast address, other receivers cancel their responses. If the source once receives the response to status request, the source can know that at least one receiver exists and continues to receive the data. In case where the source hears no response, it is assumed that the response of receiver is lost or there is no receiver in the group.
To remove the possibility of loss of message, the source must repeat this status request several times before making a decision that there is no receiver in the group.
When the source recovers from the site failure, a resynchronization is required since the source has a new sequence number and the receiver has an old decency number. If the source sends a new START message having the new sequence number the receiver receives the new START message. And forcingly performs the resynchronization. At the time of data transmission, the source makes all receivers receive the START message by repeating the START three times. The receivers checks the START message of a header, and when the START message is lost, the receivers inform the source with NACK that the error has occurred.
2. Error Correction Mode
The transport protocol detects and corrects the error occurring during the data transmission to guarantee the reliability. This guarantees the reliable data delivery to each participant, and each receiver anticipates and is responsible for the loss and damage of data.
If the source hears nothing from the receiver, it decides that there is no abnormality in reception of data by the receiver. If the connection of receiver is interrupted, although the source has a method of retransmission, the source can not take any action for error correction. A countermeasure against this is that the receiver reestablishes a connectivity to the group and retransmits the data. Since the source recognizes the loss of data only when the receiver requests the lost data, the receiver is solely responsible for the error detection.
If the receiver finds out and confirm the damage of one or more data among the message, it can request the retransmission of necessary data and here the NACK is used for that. NACK is transmitted through IP-Multicast group, and other host notices the request and prevents the transmission for the same request by using the damping technique.
In case where the source can not retransmit, other host retransmits the data. The host capable of retransmission shall have sufficient buffers for data to carry our the retransmission process.
The source has a large buffer to satisfy the data retransmission requirement, and the data is removed from the buffer if once the data is discarded. Since the buffer is used for new data, the discarded data can no longer be kept in the buffer. This structure is a model used as an example since the buffer management is not determined.
The use of damping technique reduces the possibility of message implosion occurring when many receivers concurrently respond, the receiver immediately transmits the NACK at the time of detection of lost data to reduce the implosion, and other receivers listen to the NACK. In case where the receiver senses the NACK (retransmission request), the receiver does not hade to send the NACK of its own. However, if the local receiver did not receive other NACK or the supplement of lost data is not sufficient, the local receiver have the necessity of sending the NACK. If all receivers have to wait for same period, the damping technique has no meaning. In general, the time spacings for which the receivers wait are different. Each receiver calculates the random time value for listening before carrying out the retransmission request. The advantage of damping technique is that it reduces the repetition and limits the saturation of packet of source and network.
The partial loss or damage of data occurs at the time of data transmission processing. The receiver requests the retransmission of them, and one of source and peer-hosts retransmits them. When the source does not transmit data for a certain period, it transmits the heartbeat message instead.
Two models for data retransmission is a method in which the source is responsible for retransmission and a method in which all hosts are responsible for retransmission. The former is a method in which the source responds to all retransmission requests and if the source can not retransmit for some reason, the peer-hosts take charge of retransmission.
The latter is a method in which the hosts (including the source itself) listen to the source and take charge of retransmission.
There are two solutions for the excessive retransmission responses. In the first method, the retransmission response is carried out by the source itself, and although it is simple, the host takes charge of responding to the retransmission request and the peer host does not respond. However, this method must be selectively used. For example, if the source host is overloaded with other works, the retransmission delivery in time is impossible, and therefore, the method must be selectively used.
In the second method, the retransmission response is carried by the agent of the source, and the retransmission processing is slow, and in case where the source has a problem of connectivity, the retransmission response of peer hosts is delayed. The advantage in case where all hosts have potential retransmission points is that the processing for reduction of overload of source is possible. This method can give the efficiency to other host (dealing with response) which is capable of fast response. There is no method for other host which is overloaded. The host carries out the retransmission in case where the source is more overloaded than the host.
In case of using a model in which the source is given a priority, the requirement for the retransmission is satisfied even in a case where the source has no room for retransmission. In case where other host retransmits instead of the source due to the overload, the host must be a receiver of the source data to perform the function and the host can respond to the retransmit request in the same way as the source host.
The source can not avoid the response to the retransmission of data, it responds to the retransmission. In case where the source can not respond to the retransmission request, the peer host responds. In some cases, the peer host can better deal with the retransmission request than the source and decide the sufficient time for response to the retransmission request on behalf of the source. This can be performed by using a timer or a specific number for the retransmission request.
The peer hosts can prevent by using the damping technique a lot of response to the requests occurring even after the retransmission of requested data. All peer-hosts trying to respond to the retransmission request wait for a certain period for listening to respond to the request from other host.
In a case where the source or receiver uses a method other than a predetermined procedure due to a special situation, if the receiver does not receive a retransmission after ten times of attempt nor hear a heartbeat from the source in that time period, the receiver decides that the source host is no longer available, that is, the receiver considers that the source has already left the group. Both of the case where the receiver does not know the status of the source which left the group and the case where the connection to the source is lost are a case where there is no peer-receiver to satisfy the retransmission request or the peer-receivers do not have the required data. At this time, the transport protocol notifies the error occurrence to the application layer. The application layer considers this and decides next operation according to the situation of application layer. The receiver does not note the leave of the source. That is, the receiver is set to regularly receive data or heartbeat.
In case where the receiver does not receive any message from the source for a predetermined period, the receiver decides the status of the source. This is important since the receiver updates the moment it listens to the source for the last. At that time, the receiver does not know whether the source transmitted other data.
The receiver obtains the status of source through an explicit request. If, although the source is still in the multicast group, it is a receiver, then the previous source host notifies that it is no longer a source.
The previous source can no longer keep the last segment of data so that it sends the last lacked with a sequence number to the source. This makes the receiver decide the loss of data or not, If the receiver notifies this to the application layer, the processing by the source shift is completed when the data of source is no longer valid, and the data is discarded by all receivers.
In case where the source is no longer in the multicase group (when it left), the receivers (status requesters) respond to the peer-hosts since the receivers consider that the peer-hosts still keep the information about the source.
The receiver having the data and heartbeat of the source can not request the termination of retransmission. This is because of a network error that the path to the source return to the receiver itself In this case, the peer-receiver can perform the retransmission on behalf of the source. If there is no peer-receiver listening to the retransmission request, the receiver terminates the error state and notifies this to the application layer.
Being different from a 3-way handshake method in which the reansmitter of conventional transport protocol requests a connection to the receiver, the receiver receives an indication of connection and respond to the transmitter, the error control method according to the present invention is a method in which a source and a plurality of receivers participate in a cession according to a predetermined rule. In that method,
The present invention will be described below in detail with reference to the accompanying drawings.
FIG. 1 is a status flow diagram inside the transport protocol to which the present invention is applied, wherein the change in the statuses of connection, leave, error control and data transmission between transmitters and receivers is illustrated.
A CLOSED status 104 is a step before all sources and receivers start communication from an application layer.
A SENDING status 101 is a status in which if the source receives a source open command form the application layer, the source substantially transmits data after transmitting a START packet to the receivers.
A WAIT-1 status 105 is a status in which the sources and receivers in SENDING status 101 or RECEIVING status 109 respond to error request. When the host such as source or receiver receives an error message, it returns to the WAIT-1 status 105, responds to the error message and provides recovered correction data. The WAIT-1 status 105 is used in damping with which the peer host responds to error message. The host generates correction data, operates the timer and waits checking whether other peer-host responds to correction data, and if no other peer-host transmits within the waiting tamer period, the host moves to a SEND-REPAIR status 106 and then transmits correction data to the multicast group. However, in case where other peer-host responds to correction data, the host returns to the original SENDING status 101 or RECEIVING status 109.
In WAIT-2 status 110, the receiver detects the damage of packet by checking the checksum value of packet and detects the lost packet by tracing the packet sequence number, and if the receiver knows that although a data was transmitted, it was not received, then the receiver invokes the timer. The receiver moves to the WAIT-2 status 110 after the end of timer. In this status, the receiver detects the error and sends the NACK to the mulitcast group. If the receiver is waiting in this status for damping for reducing the number of NACKs, other host in the multicase group listens to the NACKs. If the timer is exhausted in WAIT-2 status 110, the receiver generates error message, sends it to the multicast group and moves to WAIT-3 state 111. If there is no response to error message from other host (source or other receiver), the receiver returns to WAIT-2 status 110 and generates error message again. This back-and-forth shift between WAIT-2 status 110 and WAIT-3 status 111 is performed only five times. If there is no progress after five timers are exhansted, the host assumes that there has occurred an abnormality to the connection establishment between the source and receiver and notifies to the application layer that error occurred.
If other host detects error, the receiver in WAIT-2 status 110 moves to WAIT-3 status 111, waits for response to error message and moves to normal RECEIVING status 109 when it receives the correction data.
In case where there is an error to the data packet which the receiver receives from the source or in case where the receiver does not receive the data packet, the source searches the data having the sequence number form the data stored in the buffer of its own and retransmits the data packet relevant to the receiver before the timer attached to the data packet is exhausted thereby recovering the data packet.
In a CLOSING state 103, if the source shifts from the SENDING status 101 to HEARTBEATS status 102 and a given time is elapsed, the source sends to the receiver six heartbeat messages according to the timer and notifies to the receiver the intention that it no longer sends the data packet and then changes to the position of receiver or to a state of terminating the communication.
In the HEARTBEATS status 102, the source sends the heartbeat instead of data to inform the receivers of the status of source in the idle status in which the source momentarily stop the data transmission according to the status of application layer after the source sends the data packet.
The RECEIVING status 109 is a status in which the receiver receives an open command from the application layer and shifts to a LISTEN status 107, and thereafter the receiver substantially receives the data packet.
The LISTEN status 107 is a status in which if the receiver receives the open command from the application layer, the transport protocol of the receiver side prepares for receiving the START packer from the source.
A START MISSED status 108 is a case in which the receiver does not receive the START packet send by the source in the LISTEN status 107, wherein the receiver is treated as a normal join status in case it receives the START packet and is treated as a Late Join status.
FIG. 2 is a status process diagram of error detection and retransmission request according to the present invention. In the RECEIVING status 21, the receiver traces the sequence number, detects the error occurring in the message delivery procedure, and invokes the timer necessary for recovery period. Here, the object of detection is the received data.
The receiver moves to WAIT-2 status 22 after the termination of timer. In this status, the receiver detects the error and sends the NACK to multicast group. If the receiver waits in this status for damping which reduces the number of NACK, other host in multicast group listens to the NACKs.
If other host already detected the error, the receiver moves to WAIT-3 status 23, waits for response to error message, and moves to a normal RECEIVING state 21 in case of receiving the correction data.
If the timer is exhausted in WAIT-2 status 22, the receiver generates the error message, sends it to multicast group and moves to WAIT-3 status 23. If there is no response to error message from other host (source or other receiver), the receiver returns to WAIT-2 status 22 and generates the error message again. This back-and-forth shift between WAIT-2 status 22 and WAIT-3 status 23 is performed only ten times. If there is no progress after ten timers are terminated, the host decides that a serious obstruction occurred to the connection establishment between source and receiver and notifies the error condition to application layer.
FIG. 3 is a status transition diagram for error correction according to the present invention. The host in SENDING status 31 or RECEIVING state 32 respond to the error request via other peer-host. In case of receiving error message, the host enters the WAIT-1 status 33, responds to the error message and provides the correct correction data. The peer host uses the WAIT-1 status 33 in damping for responding to the error message. The host generates the correction data and operates the timer, and thereafter, if the timer period for which the host waits to the whether other host responds to the correction data is over, the host moves to SEND REPAIR status 34 and sends the correction data to the multicast group. However, In case where other peer-host responded to the correction data, the host returns to the original SENDING status 31 or RECEIVING status 32.
The heartbeat message is used in indicating the presence and status of the source host, The heartbeat message which is sent first is sent only by the source host and is included in the sequence number of the last packet.
The heartbeat is generated in the idle status in which an idea exchange is interrupted for a while during a conference in the application layer or the source does not send the data, and the heartbeat makes the receiver recognize the intention that the source does not send the data and indicates the stop time and activity status, etc. When the source stops sending for a certain period, it regularly sends the heartbeat until it normally sends the data. In case where the source does not send the data, the time taken for bask-and-forth delivery of the amount of NACK, flow control parameter and constants is calculated after the elapse of certain time.
The receiver also regularly sends the heartbeat message to the source so as to inform the source of the final message which the receiver received. The heartbeat information sent by the receiver can be requested only by the source but not by other receiver, and the receiver send the heartbeat to the source by the unicast. The heartbeat includes the receiver ID and the port number of connection, and also the sequence number of the final message which the receiver received. The source uses the randomized method of periodically selecting one receiver as a method of avoiding the implosion of the heartbeat coming from various receivers.
FIG. 4 shows a condition in which the transport protocol is loaded inside the system, wherein the portion which takes charge of flow control in a status processor in which the transport protocol exists is shown.
As shown in the drawing, the transport protocol 401 is situated in the center, the upper side of the transport protocol 401 is connected to an application interface (API) 402 and the lower side of the transport protocol 401 is connected to a network 404.
The application layer constitutes a queue list by using a shared buffer 405 to communicate with API 402 and transmits the constituted queue list to a queue 406 of the protocol 401.
The protocol perform the communication procedure by using the status processor, and a format means 407 formats the data packet to be transmitted and sends it to a Transport Protocol (TP) system interface 408. The formatted data packet of the TP system interface 408 is sent to the network 404 through the kernel 403. The formatted data packet send to the network side 404 is sent to various receivers. The receiver side is constructed in such a way that it resolves the formatted data packet at a parse means 409, performs a procedure according to status process such as a connection management means 410, flow control means 411, error control means 412, timers 414 and a buffer management means 415 inside the protocol if the resolved data packet is sent up to the upper level transport protocol, and makes a queue list and transmits it to the application layer through the queue 406. The connection management means 410, flow control means 411 and error control means 412 constitute a finite state machine 413.
As a procedure of previous step for connection establishment, the API which connects the application layer to the inside of protocol is performed in three procedures.
The initialization of protocol brings the multicast address and port number from the application layer to initialize the protocol. The application layer provides a unique ID to confirm the source. The order of read and write uses a shared buffer between an application layer and API to exchange the data. The API write procedure copies the data from the application layer buffer to the buffer of transport protocol. The flow control method has many relations with the timer and buffering.
FIG. 5 is a process flow diagram for error detection and retransmission request according to the present invention, and is a drawing which integrates the partial illustration of FIG. 1 through 3.
The receiver receives 51 the data and heartbeat from the source, analyzes 52 them and decides 53 whether the error occurred to the data reception. In case where the error occurred to the data reception, the receiver re-receives the data and heartbeat from the source, and in case where the error did not occur, the receiver checks 54 whether it received the data packet outside the whether it received the data packet outside the sequence number zone. In case of having received the data packet inside the sequence number zone, the receiver shifts to the step 52 for analyzing the data and heartbeat. In case where the receiver received the data packet outside the sequence number zone, the receiver actuates 55 the error correction mechanism for correcting the error. In case where the receiver receives 56 any message within the threshold for retransmission request from the source, the receiver shifts to the step 52 of analyzing the received data heartbeat, and in case where the receiver did not receive 56 anything, the receiver sends the query message to the multicast group to query 57 the status of source. The source transmits the heartbeat to immediately respond 58 to the query about the status. In case there is an error in the data packet received from the source, the receiver shifts to step 51, and in case where there is no more error to the data packet, the procedure is terminated.
FIG. 6 is a process flow diagram for error correction according to the present invention and is to illustrate in detail the step 55 in FIG. 5.
The presently embodied protocol is designed in such a way that only the source responds to the retransmission. The source stores 61 the packet to its own buffer for retransmission at the time of sending the data packet. After discarding the data, the buffer manger discards the data from the buffer.
It is checked 62 whether there was retransmission request from the receiver, and in case where there is retransmission request, the source discriminates a round trip delay (RTD) time for the retransmission request packet from the receiver and calculates 63 an optimum response to the request of the receiver. In case where there is no retransmission request as a result of checking at step 62, the source proceeds to step 69. The source discriminates 64 whether the retransmission of data is necessary, and when the source retransmits the data, the source withdraws 65 the data packet from the buffer and resends it. The error correction method is go-back-N method. Therefore, all incidentital data packets are withdrawn from the buffer and resent. As a result of the step 64, if the data is not retransmitted, it is checked 66 whether the source can not satisfy the retransmission request of the receiver. If the source does not satisfy the retransmission request of the receiver, the source sends 67 the sequence number of the oldest data packet and error message on the multicast address.
In case that the retransmission request is satisfied at step 65 and 66, after performing the step 67, it is checked 68 whether the receiver received the corrected data from the source by using the retransmission. In case where the receiver did not receive the corrected data from the source, the procedure shifts to the step 66, and in case where the receiver received the corrected data, it is checked 69 whether there is no error to the data packet received from the source. In case where there is an error to the data packet, the procedure shifts to the step 62, and if there is no error, the procedure is terminated.
As described above, the present invention is an error control method for transmitting the multimedia data between multiple points and multiple users with high reliability and can be used in various application fields.
As described above, the algorithm according to the present invention can be used in the transport protocol of computer communication so as to not only facilitate the reliable multimedia data transmission between multiple users but also minimize the loss of data.
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The present invention relates to the error control method in inter-multi-user multimedia communication. There are error detection, error reporting and error recovery functions in the conventional error control method which finds out and solve the error occurring at the time of data transmission between transmitter and receiver, however, these functions are an error control method occurring in end-to-end communication consisting of one transmitter and one receiver and are not appropriate to solving errors occurring concurrently and in a bundle between one or some transmitters and many receivers in many-to-many multiple points inter-multi-user communication such as multimedia communication. Therefore, the present invention uses the damping technique to minimize the number of error control packets of which all the receiver having sensed the error concurrently request the resend based on the NACK.
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FIELD
The present embodiments generally relate to remotely controlled equipment that removes and installs withdrawable motor control center components.
BACKGROUND
A need exists for a rollable, repositionable tool that prevents harm to humans in a facility which has electrical equipment that needs replacing and is susceptible to arcing during testing, maintenance or switching out of equipment on a piece by piece basis.
A need exists for a tool that can be remotely operated by a human and used for performing maintenance or switching out of equipment such as in a circuit breaker room on a piece by piece basis without shutting down power to the entire facility. A need not to shut down a hospital is particularly important for hospitals, but also has an impact on other facilities, such as hotels which have 24 hour, 7 day a week occupation by at least one resident.
It is common for a large facility, such as a hospital or a hotel, to have to shut down all power in the facility for 1 and ½ hours to replace circuit breakers and do other manual electrical maintenance in a switching room. Typically, a hotel has to shut off power, typically between 3:00 am and 4:30 am at least once a year to replace used or worn equipment. A hotel often has pilots staying with them, and these customers, who typically need to be up at 4:00 am, will not stay at the hotel that night, causing a loss of revenue. In a time of recession, loss of customers is to be avoided, and a need has existed for a device to replace this equipment without shutting down the facility.
More importantly, hospitals that need to perform the same shut down and prevent arcing in their switch rooms, do not desire a total shut down even for 1 hour. A hospital prefers to stay “on line,” that is, fully powered, otherwise it needs to provide back up power to its emergency room, life support facilities, and intensive care units, where patients are on breathing machines. The time of shut down, scheduling, and costs involved are large, and if something goes wrong it can mean loss of a patient's life.
If no shut down is performed, and the equipment is worked on by hand, the switching room can generate “arcs” of electricity that can cause first and second degree burns to an operator manually swapping out or otherwise working on the equipment.
A need has existed for a tool that can be operated remotely by a human that is low cost and prevents the shut down of a facility to swap out circuit breakers or similar “electric arc” producing equipment.
The present embodiments meet these needs.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description will be better understood in conjunction with the accompanying drawings as follows:
FIG. 1A is a left side view of the remotely operable tool which is also referred to herein as “a bucket extractor.”
FIG. 1B is a right side view of the remote operable tool from a side opposite that shown in FIG. 1A .
FIG. 2 is a front view of an embodiment of a bucket extractor.
FIG. 3 is a back view of an embodiment of a bucket extractor.
FIG. 4 is a detail of the magnetic supports used to hold the bucket extractor to the equipment of interest.
FIG. 5 is an open lid version of a remote-switch operator usable with the bucket extractor.
FIG. 6 is a diagram of the components under the face plate of the remote-switch operator of FIG. 5 .
FIG. 7 is a detail of a linear actuator usable in the invention.
The present embodiments are detailed below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Before explaining the present system in detail, it is to be understood that the system is not limited to the particular embodiments and can be practiced or carried out in various ways.
The present embodiments relate to a remotely operated tool termed herein “a bucket extractor” for removing equipment in a facility, such as removing circuit breakers or other withdrawable electrical apparatus, such as those commonly found in a switch room of a hospital.
The moveably, relocatable tool enables an operator to no longer need to wear the typical inch thick full body arc flash hazard suit when operating the tool.
The tool allows an owner to more easily maintain equipment in an electric room, clean it up and lube it up, without needing to shut down the entire facility during such maintenance because there is a remote-control for operating the tool.
The invention can be operated by a user without detailed training. An unskilled worker can use this tool in less than 1 hour from seeing the tool for the first time.
The tool enables a wide variety of plant personnel, trained and untrained, to perform the maintenance function safely.
The embodiments can prevent explosions and arcing fires of electricity from reaching a person, as the operator, because the operator can be in a different room while the tool is operating.
This tool is easy to move, enabling men and women, strong or frail, to move, install, and remotely operate the device.
The equipment prevents an arc explosion from harming people during live switching, live switch testing, or live maintenance of electric equipment. This device allows one circuit breaker to be shut down and replaced while an entire bus of circuit breakers remains live and operational.
This tool can roll up and down stairs easily for use in many places in a facility.
The tool is extraordinarily effective in saving time and money during maintenance, as no power shut down is needed.
The tool saves humans from harm, by enabling operation of the device from a safe distance away from the circuit breakers or similar electrical equipment devices.
The invention includes in an embodiment a first riser and a second riser extending from a base support. The base support provides a first load-supporting wheel and a second load-supporting wheel.
The tool can use at least one floor lock to prevent movement of the base support.
A high-lift support rail is fixed to a first and second high-lift rail bracket connected between the first and second risers.
A first high-lift support rail bracket and a second high-lift support rail bracket are connected between the first and second risers for supporting the high-lift support rail.
A first high-lift moveable slide is connected to the first high-lift support rail and a second high-lift moveable slide is connected to the first high-lift support rail.
A moveable high-lift rail is connected to the first and second high-lift moveable slides. A first moveable slide engages the moveable high-lift rail and a second moveable slide is connected to the moveable high-lift rail.
A moveable mounting brace with at least one moveable magnetic pad is installed on the bucket extractor tool for engaging a metal surface proximate to electrical equipment of interest. The moveable mounting brace is telescopically connected to the second moveable slide.
A linear actuator with a detachable push-pull unit engages electrical equipment of interest for removing or inserting a portion of the electrical equipment while adjacent electrical equipment is operating with a voltage. The linear actuator is connected to the first moveable slide.
A remote-switch operator connected to the linear actuator remotely controls and powers the linear actuator.
The tool is made up of a first riser and a second riser extending from a base support.
The first and second risers can be rounded tubulars connected to the base support in a “U” shape.
The base support can be made from plate steel that is reinforced. The base support engages a first load-supporting wheel and a second load-supporting wheel. The load-supporting wheels can be rubberized, electric isolating wheels on rigid wheel centers.
To the base support, can be attached at least one floor lock to prevent movement of the base support. The floor lock can be foot operated pedal designs which provide a suction type connection to concrete or smooth floor, or can be another type of foot lock that locks the load-supporting wheels and prevents them from turning, enabling the device to be stable.
A high-lift support rail is fixed to and connected between the first and second risers. The high-lift support rail can be made of aluminum. The high-lift support rail, in an embodiment, is centered between the first and second riser using a first horizontal brace at about a 90 degree angle to the high-lift support rail that engages the first and second riser on each end. The horizontal brace for the high-lift support rail can be mounted over the braces used between the first and second risers to provide a sturdy frame to the tool.
The moveable high-lift rail is connected in parallel to the high-lift support rail in a sliding engagement that can be raised or lowered and fixed into place, and then moved again. The moveably high-lift rail can create a telescoping effect adjacent the high-lift support rail.
The moveable mounting brace operates at about a 90 degree angle to the moveable high-lift rail. The brace is secured on one end to the moveable high-lift rail and on the other end has at least one moveable magnetic pad for engaging a metal surface proximate to electrical equipment of interest. The brace can have two moveable magnetic pads that move in and out of a housing, in an embodiment. Other versions of the moveable magnetic pads are also contemplated herein.
Parallel to the moveable mounting brace is the linear actuator with a detachable one push-pull unit for engaging electrical equipment of interest and removing or inserting a portion of the electrical equipment while adjacent electrical equipment is operating with a voltage.
The linear actuator has a motor and can be a variable speed motor adapted to run on about 110 volt current or on about a 12 volt DC current.
A remote operated switch is mounted between the risers and is connected to the linear actuator for remotely controlling and powering the linear actuator while distanced from possible arc flashing during equipment removal, installation or maintenance.
A holding basket can be used between the risers and even extending from the risers opposite the linear actuator for supporting the remote operated switch that powers the linear actuator. The basket can be made of steel, such as ¼ diameter solid tubular steel.
The high-lift support rail can be between about 6 feet to about 12 feet in length. The high-lift rail can have the same length, but twice the width of the high-lift support rail. The high-lift support rail and the high-lift rail can be configured to both be made from a generally hollow, lightweight, strong aluminum alloy.
The high-lift support rail in an embodiment has a first and second high-lift slider slidably connected to the high-lift support rail for moveably and fixedly supporting the high-lift rail. These devices are generally rectangular and act as a stop as well as a support for the sliding high-lift rail.
The high-lift rail in an embodiment has a first channel about 1 inch in depth and a second channel having the same depth parallel to the first channel in the same rail.
A front axle in an embodiment is connected to the base support and a first front wheel is on one end of the axle and a second front wheel is on the other end of the axes. This gives a 4 point support to the risers and linear actuator for good stability with no rocking, no vibration, and a rigid stance for insertion of the electrical equipment or removal of the electrical equipment and dealing with the weight of the electrical equipment by the tool.
It can be noted that in an embodiment the first and second front wheels have a diameter less than about 25 percent the diameter of the load-supporting wheels.
A power supply mount can be positioned and fastened, such as with bolts or similar fasteners, or even welded, between the first and second risers on at least one brace for supporting an AC/DC power supply at least engagaeble with about 110 volts of AC current from a power grid.
An embodiment can contemplates that a quick-disconnect can be used with the linear actuator to quickly install and replace push-pull units having different shapes, different features as needed.
At least two high-lift stops are mounted to the high-lift rail to prevent excessive movement of the high-lift rail in an embodiment.
Turning now to the Figures, FIG. 1A shows a left side view of an embodiment of a bucket extractor 10 .
The bucket extractor 10 can have a base support 12 with a first extension 13 and a second extension 15 , which is shown in FIG. 1B , connected to a back side 17 .
A first front wheel 78 and a second front wheel 80 , which is shown in FIG. 1B , can be attached to a front axle 74 . In another embodiment, the wheels can be attached directly to the first and second extensions.
In a similar fashion, a first load-supporting wheel 22 and a second load-supporting wheel 24 , which is also shown in FIG. 1B , can be attached to a load-supporting axle 20 .
The first load-supporting wheel 22 can be positioned proximate to a first riser 14 , and the second load-supporting wheel 24 can be positioned proximate to a second riser 16 , also shown in FIG. 1B .
In an embodiment the first riser 14 can attach to the first extension 13 , and the second riser 16 can attach to the second extension 15 , which is shown in FIGS. 1A and 1B .
Braces 31 , 32 , 33 , 34 and 35 , shown in FIG. 2 , can be configured for use between the risers to ensure a sturdy, non-deforming bucket extractor.
A first floor lock 28 and a second floor lock 30 can be connected to the back side 17 of the base support 12 . The first and second floor locks can be used to lock the base support 12 to a cement floor or similar stable surface. One foot lock can be used, but this embodiment is configured to use two. The foot locks can be configured to be pedal depressing types for engaging the floor with suction.
FIG. 1A shows a first high-lift support rail 40 which can be positioned between the first and second risers 14 and 16 . The first high-lift support rail 40 can be mounted to a first high-lift support bracket 42 and a second high-lift support bracket 44 that can be connected to the first and second risers 14 and 16 .
The first high-lift support rail 40 can be between 4 feet and 10 feet in length and can be made from very durable high strength aluminum. The rail can be generally hollow and light weight. In another embodiment the rail can be made from an aluminum alloy.
A moveable high-lift rail 56 can connect to the first high-lift support rail 40 using a first high-lift moveable slide 48 and a second high-lift moveable slide 50 . The moveable high-lift rail 56 can have a first channel 58 and a second channel 60 which can be used for engaging the first and second high-lift moveable slides 48 and 50 .
The first high-lift moveable slide 48 can have a first handle 49 and the second high-lift moveable slide 50 can have a second handle 52 . First and second handles 49 and 52 can lock the first and second high-lift moveable slides 48 and 50 into a position along the second channel 60 of the moveable high-lift rail 56 .
A first moveable slide 61 , with a third handle 65 , can connect a moveable mounting brace 64 to the moveable high-lift rail 56 . The third handle 65 can lock the first movable slide 61 into a position along the first channel 58 of the movable high-lift rail 56 .
A second moveable slide 63 , with a fourth handle 66 , can connect a linear actuator 62 to the moveable high-lift rail 56 . The forth handle 66 can lock the second movable slide 63 into a position along the first channel 58 of the movable high-lift rail 56 .
It can be contemplated that in an embodiment two or more linear actuators can be used simultaneously.
The moveable mounting brace 64 can have a cross brace 68 , which is shown in FIG. 2 , which can secure to a first and second moveable magnetic pad 70 and 72 , which is shown in FIG. 1B . The first and second moveable magnetic pads 70 and 72 can be used to connect to a metal surface surrounding electrical equipment to be installed, removed or maintained while associated electrical equipment is operating at full electrical capacity. The moveable mounting brace 64 can be a solid brace, a telescoping brace, or combinations thereof.
A magnetic brace quick-disconnect 100 can be used to remove the first and second moveable magnetic pads 70 and 72 from the moveable mounting brace. A quick-disconnect can have a first extension that engages a second receptacle for a latching engagement that can be thumb released for fast break down.
A linear actuator 62 with a detachable push-pull unit 96 can be used to engage the electrical equipment to be installed, removed or maintained. The detachable push-pull unit 96 can be used to pull out an electric bucket while the adjacent electrical equipment is operating without fear of harm to an operator running the bucket extractor. The detachable push-pull unit 96 can be used to push in a bucket of metal with electrical equipment for maintenance or installation while adjacent electrical equipment that can arc is still running and operating.
The linear actuator 62 can be supported by a linear actuator bracket 92 for supporting the weight of the linear actuator and for connecting the linear actuator to first moveable slide 61 .
The linear actuator can be made by CBS ARCSAFE of Denton, Tex. The linear actuator can be connected to the first moveable slide 61 . A quick-disconnect 99 can be used with the linear actuator for quickly and easily removing or reinstalling push-pull units 96 of different sizes and configurations. The quick-disconnect 99 can be the same types as quick-disconnect 100 , which can also be made by CBS ARCSAFE of Denton, Tex.
The high-lift rail 56 , with first and second channels 58 and 60 , which can be attached to the first and second high-lift moveable slides 48 and 58 , can enable the moving mechanism of the bucket extractor to be raised to a height greater than the height of the risers for operation of the linear actuator. The first channel and second channel are formed in the rail, so that the rail is a one piece structure for a more secure sliding engagement than other types of support devices.
A remote-switch operator 38 a can be removably secured in a holding basket 36 a . The holding basket 36 a can be made of steel tubing, aluminum tubing, aluminum alloy tubing or combinations thereof. The holding basket can be welded to the first and second risers and can provide a container to safely support the remote-switch operator 38 a.
In FIG. 1A , two remote-switch operators 38 a and 38 b are shown in holding baskets 36 a and 36 b.
It can be contemplated in an embodiment that one holding basket can be used to hold two remote-switch operators. It is contemplated that each remote-switch operator can provide power to and control signals to different individual linear actuators mounted to the moveable high-lift rail.
A first high-lift stop 47 and second high-lift stop 54 can be mounted in the second channel 60 of the moveable high-lift rail 56 for stopping motion up and down the rail. The first and second high-lift stops 47 and 54 can be rubber stops or metal stops.
It is contemplated that in another embodiment additional high-lift stops can be mounted in the first channel 58 of the moveable high-lift rail 56 , to stop the movement of the first and second moveable slides 61 and 63 along the moveable high-lift rail 56 .
A power supply mount 82 can be mounted on at least one brace that is mounted between the first and second risers 14 and 16 . The power supply mount 82 can support an AC/DC power supply 84 that can plug into a wall socket with 100 volts of AC current. The power supply mount can be an insulated metal plate such as those that can be purchased from Fisher Scientific.
FIG. 1B shows a right side view of an embodiment of a bucket extractor 10 .
The bucket extractor 10 can have a base support 12 with a first extension 13 , which is shown in FIG. 1A , and a second extension 15 connected to a back side 17 .
A first front wheel 78 , shown in FIG. 1A , and a second front wheel 80 can be attached to a front axle 74 . In another embodiment the wheels can be attached directly to the first and second extensions.
In a similar fashion, a first load-supporting wheel 22 , which is shown in FIG. 1A , and a second load-supporting wheel 24 can be attached to a load-supporting axle 20 .
The first load-supporting wheel 22 can be positioned proximate to a first riser 14 , shown in FIG. 1A , and the second load-supporting wheel 24 can be positioned proximate to a second riser 16 .
In an embodiment the first riser 14 can attach to the first extension 13 , which is shown in FIG. 1A , and the second riser 16 can attach to the second extension 15 .
Braces 31 , 32 , 33 , 34 and 35 , shown in FIG. 2 , can be configured for use between the risers to ensure a sturdy, non-deforming bucket extractor.
A first floor lock 28 , shown in FIG. 1A , and a second floor lock 30 can be connected to the back side 17 of the base support 12 . The first and second floor locks can be used to lock the base support 12 to a cement floor or similar stable surface. One foot lock can be used, but this embodiment contemplates using two. The foot locks can be configured to be pedal depressing types for engaging the floor with suction.
FIG. 1B shows a first high-lift support rail 40 which can be positioned between the first and second risers 14 and 16 . The first high-lift support rail 40 can be mounted to a first high-lift support bracket 42 and a second high-lift support bracket 44 that can be connected to the first and second risers 14 and 16 .
The first high-lift support rail 40 can be between 4 feet and 10 feet in length and can be made from very durable high strength aluminum. The rail can be generally hollow and light weight. In another embodiment the rail can be made from an aluminum alloy.
A moveable high-lift rail 56 can connect to the first high-lift support rail 40 using a first high-lift moveable slide 48 and a second high-lift moveable slide 50 . The moveable high-lift rail 56 can have a first channel 58 and a second channel 60 which can be used for engaging the first and second high-lift moveable slides 48 and 50 .
A first moveable slide 61 can connect a moveable mounting brace 64 to the moveable high-lift rail 56 .
A second moveable slide 63 can connect a linear actuator 62 to the moveable high-lift rail 56 .
It can be contemplated that in an embodiment two or more linear actuators can be used simultaneously.
The moveable mounting brace 64 can have a cross brace 68 , shown in FIG. 2 , that can secure to a first and second moveable magnetic pad 70 and 72 , which are shown in FIG. 1A . The first and second moveable magnetic pads 70 and 72 can be used to connect to a metal surface surrounding electrical equipment to be installed, removed or maintained while associated electrical equipment is operating at full electrical capacity. The moveable mounting brace 64 can be a solid brace, a telescoping brace, or combinations thereof.
A magnetic brace quick-disconnect 100 can be used to remove the first and second moveable magnetic pads 70 and 72 from the moveable mounting brace. A quick-disconnect can have a first extension that engages a second receptacle for a latching engagement that can be thumb released for fast break down.
A linear actuator 62 with a detachable push-pull unit 96 can be used to engage the electrical equipment to be installed, removed or maintained. The detachable push-pull unit 96 can be used to pull out an electric bucket while the adjacent electrical equipment is operating without fear of harm to an operator running the bucket extractor. The detachable push-pull unit 96 can be used to push in a bucket of metal with electrical equipment for maintenance or installation while adjacent electrical equipment that can arc is still running and operating.
The linear actuator 62 can be supported by a linear actuator bracket 92 for supporting the weight of the linear actuator and for connecting the linear actuator to first moveable slide 61 .
The linear actuator can be made by CBS ARCSAFE of Denton, Tex. The linear actuator can be connected to the first moveable slide 61 . A quick-disconnect 99 can be used with the linear actuator for quickly and easily removing or reinstalling push-pull units 96 of different sizes and configurations. The quick-disconnect 99 can be the same types as quick-disconnect 100 which can be made by CBS ARCSAFE of Denton, Tex.
The high-lift rail 56 , with first and second channels 58 and 60 , which can be attached to the first and second high-lift moveable slides 48 and 58 , can enable the moving mechanism of the bucket extractor to be raised to a height greater than the height of the risers for operation of the linear actuator. The first channel and second channel are formed in the rail, so that the rail is a one piece structure for a more secure sliding engagement than other types of support devices.
A remote-switch operator 38 a can be removably secured in a holding basket 36 a . The holding basket 36 a can be made of steel tubing, aluminum tubing, aluminum alloy tubing or combinations thereof. The holding basket can be welded to the first and second risers and can provide a container to safely support the remote-switch operator 38 a.
In FIG. 1B , one remote-switch operators 38 a is shown in holding baskets 36 a.
It can be contemplated in an embodiment that one holding basket can be used to hold two remote-switch operators. It is contemplated that each remote-switch operator can provide power to and control signals to different individual linear actuators mounted to the moveable high-lift rail.
A first high-lift stop 47 and second high-lift stop 54 can be mounted in the second channel 60 of the moveable high-lift rail 56 for stopping motion up and down the rail. The first and second high-lift stops 47 and 54 can be rubber stops or metal stops.
It is contemplated that in another embodiment additional high-lift stops can be mounted in the first channel 58 of the moveable high-lift rail 56 to stop the movement of the first and second moveable slides 61 and 63 along the moveable high-lift rail 56 .
A power supply mount 82 can be mounted on at least one brace that is mounted between the first and second risers 14 and 16 . The power supply mount 82 can support an AC/DC power supply 84 that can plug into a wall socket with 100 volts of AC current. The power supply mount can be an insulated metal plate such as those that can be purchased from Fisher Scientific.
It can be contemplated in an embodiment that stair climber holders 110 and 111 can be formed in the risers. Brackets (not shown) can be commercially purchased and secured to these stair climber holders enabling the risers to smoothly move over stairs with only one person moving the bucket extractor.
FIG. 2 provides a front view of the bucket extractor 10 with the base support 12 .
Front axle 74 , which can be supported by a front axle tube 76 , and first and second front wheel 78 and 80 can be seen in FIG. 2 , along with first and second load-supporting wheels 22 and 24 .
It is contemplated that each of the wheels can be made of a durable polymer like a polyamide or nylon, or possibly an elastomeric. The front wheels can have a diameter less than 25 percent of the diameter of the load-supporting wheels. For example, the front wheels can have a diameter of 4 inches and the load-supporting wheel can be 12 inches.
The first and second extensions 13 and 15 of the base support 12 which can be connected via the back side 17 can be seen in FIG. 2 . The back side and first and second extensions can be made of steel, aluminum, an aluminum alloy, or combinations thereof.
The first load-supporting wheel 22 is shown along with the second load-supporting wheel 24 .
The two moveable high-lift support brackets 42 and 44 can be viewed between the first and second risers 14 and 16 .
Braces 31 , 32 , 33 , 34 and 35 are shown engaging the first and second risers 14 and 16 .
The moveable high-lift rail 56 can be viewed engaging the first movable high-lift slider 48 with handle 49 and the second moveable high-lift slider 50 with handle 52 .
In this embodiment one remote-switch operator 38 a is shown. The power supply mount 82 which can hold the power supply 84 is shown attached to brace 34 .
Also viewable in this FIG. 2 is the push-pull unit 96 engaged with the linear actuator 62 . The linear actuator 62 is shown supported by linear actuator bracket 92 which can attach to the second moveable slide 63 with fourth handle 66 .
The first and second moveable magnetic pads 70 and 72 , of the moveable mounting brace, are shown secured to the crossbeam 68 . The moveable mounting brace can be attached to the first moveable slide 61 with third handle 65 .
FIG. 3 depicts a back view of the bucket extractor 10 .
The first high-lift support rail 40 and the moveable high-lift rail 56 can be seen located between the first and second risers, 14 and 16 .
The high-lift support brackets 42 and 44 are can be seen fastened between the first and second risers 14 and 16 . In this embodiment the brackets 42 and 44 are bolted to the risers, but the brackets, which can be made of aluminum, can be welded to the bracket as well.
Braces 31 , 32 , 33 , 34 and 35 and also be seen positioned between the first and second risers 14 and 16 .
The first and second load-supporting wheels 22 and 24 can be viewed in this embodiment. The load-supporting wheels can be about 4 inches to about 12 inches in diameter and can have rubberized wheels over steel inserts, or be made of a 100% rubberized material.
In contrast, in an embodiment the front wheels can be polyamide wheels with a diameter of about 2 inches to about 4 inches, and mainly used for turning the tool easily while moving and providing a 4 point support frame, unlike others in the industry which provides both high stability and ease of movability simultaneously.
The load-supporting wheels can be attached to the load-supporting axle 20 . The load-supporting axle 20 can be supported by a load-supporting axle tube 19 .
Also shown in this view are first and second floor locks 28 and 30 which can be attached to the back side 17 of the base support 12 . First floor lock 28 , can be positioned adjacent first extension 13 and second floor lock 30 can be positioned adjacent the second extension 15 . The floor locks can be pedal operated floor locks wherein a plate of the floor lock engages the ground, providing a secure platform for the bucket extractor 10 .
The power supply mount 82 is shown connected to brace 34 , which can in turn support the AC/DC power supply 84 .
A holding basket 36 a can also be seen holding a remote-switch operator 38 a.
Moveable high-lift rail 56 can be seen with the first movable slide 61 attached. The First movable slide 61 can have third handle 61 . First and second moveable magnetic pads are shown attached to the crossbeam 68 .
The second moveable slide 63 with fourth handle 66 can be seen along with a portion of the push-pull unit 96 .
FIG. 4 shows a top view of the moveable mounting brace 64 having a crossbeam 68 supporting a first moveable magnetic pad 70 and a second moveable magnetic pad 72 .
The magnetic pads can be contained within housings. The magnetic pads can be extendable or retractable in their housing. The magnetic pads can each have a face that is usable for engaging metal around electrical equipment to be maintained or repaired or switched out with the push-pull device 96 .
FIG. 5 shows an embodiment of a remote-switch operator usable with the bucket extractor.
A remote-switch operator 38 a can have a body 88 and a lid 86 which can be hinged to the body. In this view, the lid is in an open position.
The body can have a face plate 89 . The face plate 89 can have an on/off switch 93 , an install momentary push button 95 , a remove momentary push button 104 , and a circuit breaker 97 .
An actuator cord 90 can provide power and signals to the linear actuator 62 , shown in FIG. 1A .
A wireless remote transmitter/receiver 101 can be connected by a cable 113 to a plug 103 in the face plate.
A wireless remote controller 104 can be in communication with the wireless remote transmitter/receiver 101 .
The wireless remote controller 104 can have a remote-on button 105 , a remote-off button 106 , a remote-install button 107 , a remote-remove button 108 , and an antenna 109 .
An AC/DC power plug 99 can also be located in the face plate 89 . The AC power plug 99 can receive power from the AC/DC power supply 84 or another AC/DC power source 114 .
FIG. 6 is a diagram of the components under the face plate of the remote-switch operator of FIG. 5 .
The install momentary push button 95 mounted to the face plate can be connected to a relay 120 and circuit board 122 disposed beneath the face plate 89 . A remove momentary push button 104 can be mounted to the face plate and connected to the relay 120 and circuit board 122 .
A circuit breaker 97 can be connected between a battery 118 and the relay 120 .
An AC/DC power plug 99 can be located in the face plate 89 and can receive power from an AC/DC source 114 that is outside the housing.
A charger power supply 116 can engage the AC/DC power plug in the body beneath the face plate and the battery.
Additionally, FIG. 6 shows that a second side 124 of the face plate can connect to the face plate for ensuring a watertight connection around the battery and circuit board. The first battery and a second battery 109 can be secured to the body with a mounting bracket 111 .
FIG. 7 shows the linear actuator 62 in more detail as well as the magnetic mounting brace 64 .
The linear actuator 62 can be mounted to a linear actuator support bracket 92 . The linear actuator can connect with a linear actuator quick-disconnect 99 that in turn can engage a “push-pull” mechanism 96 .
The push-pull mechanism can be one of a variety of shapes and sizes, but must function to pull out a bucket such as a bucket of circuit breakers or push in the bucket, such as a bucket of circuit breakers in one stroke.
The push-pull mechanism 96 shown in this embodiment is triangular in shape with a ridge and a first hook on one end and a second hook on the other end and can be quickly engaged and disconnected form the linear actuator at the quick-disconnect 99 .
The magnetic brace 64 is shown with a magnetic brace quick-disconnect 100 . The Figure shows the first moveable magnetic pad 70 that can be extendable to connect with metal around the electric equipment, which can be a bucket for circuit breakers.
While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.
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A motor control bucket replacement tool, such as for circuit breakers, that is portable, and rugged for providing electrically operated controlled insertion and removal of electrical equipment by an operator from a remote location using an easily detachable magnetic coupling device for engagement with the electrical equipment and using a linear actuator.
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REFERENCE TO COPENDING APPLICATION
Reference is made to our copending application Ser. No. 628,727 filed on even date entitled "Centrifugal Blood Pump with Tapered Shaft Seal".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to centrifugal blood pumps.
2. Description of the Prior Art
Centrifugal pumps have been used for many years to pump a wide variety of different fluid materials. In general, a centrifugal pump includes a pumping chamber with an inlet aligned with a rotational axis of the pump, an outlet adjacent the periphery of the pumping chamber, and an impeller mounted within the pumping chamber for rotation about the axis. The impeller in such pumps can be mounted on a drive shaft which extends outside the pumping chamber to a rotational drive source or the shaft can be mounted within the pumping chamber as a spindle about which the impeller rotates (rotatably driven by means other than the rotation of the shaft, such as a magnetic drive arrangement). In any case, as the impeller is rotated, it imparts centrifugal force and velocity to the fluid, thus pumping the fluid from the pump inlet to the pump outlet.
In recent years, centrifugal pumps have been used extensively for pumping blood during open heart surgery. Examples of centrifugal blood pumps are shown in the following U.S. patents: Rafferty et al U.S. Pat. No. Re. 28,742; Dorman et al U.S. Pat. No. 3,608,088; Rafferty et al U.S. Pat. No. 3,647,324; Kletschka et al U.S. Pat. No. 3,864,055; Rafferty et al U.S. Pat. No. 3,957,389; Rafferty et al U.S. Pat. No. 3,970,408; Rafferty et al U.S. Pat. No. 4,037,984; and Reich et al U.S. Pat. No. 4,135,253.
The pumping of blood requires great care to avoid any damage to the red corpuscles, or any of the other constituents of blood. Any practical blood pump useful as part of heart/lung bypass equipment during open heart surgery must deliver the requisite flow volumes under pressure, without damaging the blood being pumped.
In a centrifugal pump, and in particular in a centrifugal pump for pumping liquids such as blood, a fluid tight seal between the drive shaft and the housing is an important factor in the performance of the pump. Friction at the seal produces heat which can damage both the components of the pump and the blood being pumped if not dissipated.
In prior art centrifugal pumps, the rotation of the impeller can lead to generation of an air bubble surrounding the shaft. This air bubble tends to seek the smallest shaft diameter, which is adjacent the drive shaft seal. In prior art centrifugal pumps, the area adjacent the drive shaft seal has also been a relatively stagnant or low flow area in terms of fluid flow within the pumping chamber. The air bubble tends to insulate the seal from the flow of the fluid within the pump chamber, thus decreasing the dissipation of heat generated by friction at the seal interface.
SUMMARY OF THE INVENTION
The present invention is an improved centrifugal blood pump which has a seal between the pump housing wall and the hub of the impeller for providing a fluid tight seal interface which surrounds the shaft at an intermediate position between the wall and the hub. The impeller has a plurality of first blades which are attached to and extend outward from the hub. Each of these blades has a rear edge which is closer to the wall than is the seal interface, and has an inner edge which extends from the rear edge to the hub and which is generally parallel to the seal. This arrangement of the plurality of first blades causes the seal interface to be located in a high flow area, thus enhancing the dissipation of heat generated by friction at the seal interface.
In preferred embodiments the impeller includes an annular blade support ring which is supported by the first blades at a position which is spaced radially outward from the hub and the seal. A plurality of second shorter blades are supported by the blade support ring at positions between the longer first blades. The short blades increase the pumping efficiency, while maintaining a small hub diameter since the short blades are not attached to the hub.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the centrifugal pump of the present invention.
FIG. 2 is a side view of the centrifugal pump.
FIG. 3 is a sectional view of the centrifugal pump along section 3--3 of FIG. 1.
FIG. 4 is an exploded perspective view of the centrifugal pump.
FIG. 5 is a view of the rotor along view 5--5 of FIG. 3.
FIG. 6 is a view of the drive plate along view 6--6 of FIG. 3.
FIG. 7 is an exploded view, partially in section, of the tapered shaft seal of the centrifugal pump.
FIG. 8 is a sectional view of the shaft seal along section 8--8 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred embodiment shown in the Figures, centrifugal pump 10 of the present invention includes a three-part housing 12 formed by front housing section 14, center wall housing section 16, and rear housing section 18. Front and center sections 14 and 16 are sealed to define pumping chamber 20. Center and rear sections 16 and 18 are sealed to define rotor chamber 22.
Front housing section 14 (which is preferably transparent so that operation of the pump can be visually monitored) includes axially aligned pump inlet 24 and tangential pump outlet 26. Blood or other biological fluid is received at inlet 24 from inlet tubing 27 and is pumped to outlet 26 and outlet tubing 28 by rotation of impeller 30 within pumping chamber 20.
Impeller 30 is mounted on a threaded outer end 32A of shaft 32, and is rotated about an axis defined by shaft 32. Impeller 30 includes a conical shaped impeller hub 34 (with internal threads 34A for engaging threaded outer end 32A), a plurality of long blades 36, a plurality of short blades 38, and circular flange 40.
Long blades 36 are attached at their inner ends to impeller hub 38. Flange 40 is attached to and is supported by long blades 36. Short blades 38 are supported by flange 40. In the particular embodiment shown in the Figures, long and short blades 36 and 38 are alternatively spaced about the circumference of impeller 30.
Large diameter impellers require a greater number of blades in order to achieve pumping efficiency. By use of short blades 38 supported by flange 40, impeller 30 achieves pumping efficiency while retaining a small hub diameter, since only long blades 36 are attached to hub 34.
Shaft 32 is mounted for rotation by a pair of axially aligned ball bearings 42 and 44. Ball bearing 42 is press fitted into center wall section 16, while ball bearing 44 is press fitted into rear housing section 18.
Rotor 46 is connected to shaft 32, so that as rotor 46 rotates within rotor chamber 22, shaft 32 and impeller 30 are rotated. In the particular embodiment shown in the Figures, pump 10 is a magnetically driven pump. Rotor 46 carries a plurality of small magnets 48. Each magnet 48 has the same pole orientation (which in the particular embodiment shown has the north (N) pole closest to drive console 50). Magnets 48 are equally spaced around the circumference of rotor 46 and, in the particular embodiment shown in FIG. 3, five magnets 48 spaced at 72° intervals (center-to-center) from one another are carried by rotor 46.
Drive console 50 includes drive plate 52 which is rotated by motor 54 about an axis which is aligned with the axis of shaft 32. Clip 55 and spring-loaded latch 56 engage flange 18A of rear housing section 18 to hold pump housing 12 in position adjacent drive console 50. Pump housing 12 can be quickly removed from engagement with drive console 50 by lifting latch 56.
Drive plate 52 carries five equally spaced south (S) pole magnets 58 and five equally spaced north (N) pole magnets 60. Magnets 58 and 60 are arranged alternatively (as shown in FIG. 6). This gives both attractive and repelling force to magnets 48 carried by rotor 46. This magnetic drive allows the use of small, discrete magnets in pump 10, rather than a single large magnet with multiple poles. This provides a significant cost reduction which is of particular advantage since pump housing 12, when used for pumping blood or other biological fluids, must be disposed of or resterilized after a single use.
In the present invention, leakage of fluid from pumping chamber 20 into rotor chamber 22 is prevented by a tapered shaft seal 62 formed by seal stator 64, seal rotor 66, and resilient elastomer spring 68. Tapered seal 62 is tapered to conform to the taper of impeller hub 34 so that an air bubble (which seeks the smallest shaft diameter within pumping chamber 20) will not insulate the seal interface edges from fluid flow. Tapered seal 62 provides a seal interface 70 between seal stator 64 and seal rotor 66 which is generally perpendicular to the axis of shaft 32 and which is located at an intermediate position between wall 16 and hub 34. The location of the seal interface 70 is in a high fluid flow area, which increases cooling effects and improves dissipation of heat caused by friction at seal interface 70.
In the preferred embodiment of the present invention shown in FIG. 1, seal stator 64 is fixed to center wall section 16, seal stator 64 is a high thermal conductivity material (such as nickel-plated aluminum). Seal stator 64 has a central passage 72 which is axially aligned with shaft 32 and is of sufficient diameter so that shaft 32 does not contact seal stator 64. Front face 74 of seal stator 64 defines the location of seal interface 70 and is, in the preferred embodiment shown in FIGS. 1 and 2, generally perpendicular to the axis of shaft 32.
Seal stator 64 has a flange 64A at its rear end which extends outward in a radial direction and generally conforms to the surface of wall 16 at the rear end of pumping chamber 20. Flange 64B provides a large surface area for seal stator 64, thus increasing the ability of seal stator 64 to transfer heat generated at seal interface 70.
Seal rotor 66 is positioned on shaft 32 adjacent to seal stator 64. Rear face 76 of seal stator 66 engages front face 74 of seal stator 64 to provide seal interface 70. Front face 78 of seal rotor 66 faces and is engaged by spring 68. Seal rotor 66 has a pair of inwardly projecting keys 80 which engage axially extending keyways 82 on shaft 32 so that seal rotor 66 can move in the axial direction and yet rotates with shaft 32. Such a keyed arrangement may not be necessary if, by friction fit or bonding, the seal rotor 66 is driven by the spring 68 to rotate therewith. In a preferred embodiment, seal rotor 66 is a low friction polymer material such as nylon.
Spring 68 is an elastomer (such as silicone rubber) ring which is mounted coaxially on shaft 32 between impeller hub 34 and seal rotor 66. Rear face 84 of spring 68 engages front face 78 of seal rotor 66, and front face 86 of spring 68 engages rear face 88 of hub 34. Elastomer spring 68 is maintained under compression by hub 34, which is threaded on outer end 32A of shaft 32, so that it urges seal rotor 66 in an axial direction into engagement with seal stator 64. Spring 68 preferably has an annular rib 90 which is positioned in annular groove 92 in front face 78 of seal rotor 66 and has an annular rib 94 which is positioned in annular groove 96 in the rear face 88 of hub 34. Ribs 90 and 94 help to maintain an axial alignment of spring 68 so that an essentially uniform axial force is applied to seal rotor 66. In another embodiment (not shown), the resilient elastomer spring is positioned between the seal stator and wall section with which it is mounted (rather than between the seal rotor and hub) and the seal rotor is fixed to the hub to effectuate the sealing of the pumping chamber about the shaft.
To increase fluid flow in the area of seal interface 70, each of the long blades 36 of impeller 30 has a rear edge 36A which is closer to center wall 16 than are impeller hub 34 and seal interface 70. Each long blade 36 has an inner edge 36B which extends from rear edge 36A to impeller hub 34, and which is closely spaced and generally parallel to the outer surface of tapered seal 62.
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. For example, although the particular embodiment of pump 10 shown in the Figures utilizes a synchronous magnetic drive, the shaft seal is equally applicable to pumps in which other forms of coupling (including direct coupling) between shaft 32 of pump 10 and motor 54 of console 50 are provided. In addition, where the shaft is a fixed spindle about which the impeller is rotated by other means such as a magnetic drive arrangement wherein magnets are mounted directly on the impeller), the shaft seal seals the pumping chamber from the bearings and lubricants between the shaft and impeller hub.
As a further example, although as shown in the Figures flange 40 is attached to long blades 36 near their rear edges, in other embodiments flange 40 is connected to long blades 36 at other points such as their front edges or a location between the front and rear edges.
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A centrifugal blood pump has an impeller with a hub, a blade support ring and alternating long and short blades. A tapered seal between a pump housing wall and a hub of an impeller which provides a fluid tight seal interface surrounding a shaft. The long blades of the impeller have rear edges which are closer to the wall than is the seal interface and inner edges which extend from the rear edges to the hub. This provides high flow in the vicinity of the seal interface to enhance heat dissipation from the seal interface.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application No. 61/488,855, filed May 23, 2011, entitled VISCOSITY MODIFIER COMPOSITIONS AND METHODS, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Viscosity modifiers comprising amine-acid adducts are described in US patent publication 2005/0276924. Application of such viscosity modifiers to compositions comprising conductive nanomaterials is described in US patent publication 2009/0035707.
SUMMARY
[0003] Some embodiments provide compositions comprising at least one conductive nanomaterial, at least one first compound comprising at least one carbamic acid or carbamate moiety and at least one second compound comprising at least one ester linkage and at least one hydroxyl moiety, where the at least one first compound is more volatile than the at least one second compound. The at least one conductive nanomaterial may, for example, comprise one or more nanowires, nanocubes, nanopyramids, nanotubes, or the like. The at least one conductive nanomaterial may, for example, comprise at least one coinage metal or at least one silver nanowire. In at least some embodiments, the at least one first compound comprises ten or fewer carbons, or it comprises a single carbamic acid or carbamate moiety, or it may, for example, comprise (butan-2-yl)carbamic acid. In at least some embodiments, the at least one second compound comprises four or more carbon atoms, or it comprises at least one lactate moiety, or it may, for example, comprise ethyl lactate.
[0004] Other embodiments provide methods comprising introducing dry ice to a vessel, forming in the vessel at least one first compound comprising at least one carbamic acid or carbamate moiety, and contacting the at least one first compound with a conductive nanomaterial and at least one second compound comprising at least one ester linkage.
[0005] These embodiments are other variations and modifications may be better understood from the brief description of figures, description, figures, exemplary embodiments, examples, and claims that follow. Any embodiments provided are given only by way of illustrative example. Other desirable objectives and advantages inherently achieved may occur or become apparent to those skilled in the art.
BRIEF DESCRIPTION OF FIGURES
[0006] FIG. 1 shows a transmission micrograph at 400 power of the coating of Example 1.
[0007] FIG. 2 shows a reflection micrograph at 400 power of the coating of Example 1.
[0008] FIG. 3 shows a reflection micrograph at 80 power of the coating of Example 1.
[0009] FIG. 4 shows a reflection micrograph at 400 power of the coating of Example 3.
[0010] FIG. 5 shows a transmission micrograph at 400 power of the coating of Example 3.
DESCRIPTION
[0011] All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference.
[0012] U.S. provisional application No. 61/488,855, filed May 23, 2011, entitled VISCOSITY MODIFIER COMPOSITIONS AND METHODS, is hereby incorporated by reference in its entirety.
[0013] Compositions comprising conductive nanoconductors, such as, for example, silver nanowires, may be applied to substrates as coatings. In order to provide conductive coatings, the nanoconductors may be distributed throughout the coating, such as, for example, in a uniform manner. Such distribution may be enhanced by providing one or more binders in one or more carriers. Such binders may have sufficient viscosity and be present in high enough concentration to reduce or prevent settling of the nanoconductors during or subsequent to coating the substrates. However, such binders should not be present in high enough concentration in the final coating to reduce its conductivity so as to render the coating unfit for use in, for example, an electronic device.
[0014] Binders may comprise viscosity modifiers that are capable of being volatilized during or subsequent to coating the substrates. An example of such viscosity modifiers are compositions comprising one or more carbamic acid or carbamate moieties, such as, for example, (butan-2-yl)carbamic acid. Such compositions may be formed by reaction of amines, such as, for example, secondary amines, with carbon dioxide, provided in, for example, gaseous or solid form. Such viscosity modifiers may be used in sufficient concentration to address coating needs and then may be partially or wholly removed from the coating layer by volatilization, thereby improving the coating conductivity.
[0015] The Applicant has discovered that binders comprising such viscosity modifiers may provide coatings that are hazy, or coatings that lack uniformity, or coatings that lack mechanical strength. The use of compounds comprising at least one ester linkage and at least one hydroxyl moiety, such as, for example, ethyl lactate, in combination with these viscosity modifiers, can provide conductive coatings with improved clarity, uniformity, and mechanical strength.
EXEMPLARY EMBODIMENTS
[0016] U.S. provisional application No. 61/488,855, filed May 23, 2011, entitled VISCOSITY MODIFIER COMPOSITIONS AND METHODS, which is hereby incorporated by reference in its entirety, disclosed the following 11 non-limiting exemplary embodiments:
[0000] A. A composition comprising:
[0017] at least one conductive nanomaterial,
[0018] at least one first compound comprising at least one carbamic acid or carbamate moiety, and
[0019] at least one second compound comprising at least one ester linkage and at least one hydroxyl moiety,
[0020] wherein the at least one first compound is more volatile than the at least one second compound.
[0000] B. The composition according to embodiment A, wherein the at least one conductive nanomaterial comprises one or more nanowires, nanocubes, nanorods, nanopyramids, or nanotubes.
C. The composition according to embodiment A, wherein the at least one conductive nanomaterial comprises at least one coinage metal.
D. The composition according to embodiment A, wherein the at least one conductive nanomaterial comprises at least one silver nanowire.
E. The composition according to embodiment A, wherein the at least one first compound comprises ten or fewer carbon atoms.
F. The composition according to embodiment A, wherein the at least one first compound comprises a single carbamic acid or carbamate moiety.
G. The composition according to embodiment A, wherein the at least one first compound comprises (butan-2-yl)carbamic acid.
H. The composition according to embodiment A, wherein the at least one second compound comprises four or more carbon atoms.
J. The composition according to embodiment A, wherein the at least one second compound comprises at least one lactate moiety.
K. The composition according to embodiment A, wherein the at least one second compound comprises ethyl lactate.
L. A method comprising:
[0021] introducing dry ice to a vessel;
[0022] forming in the vessel at least one first compound comprising at least one carbamic acid or carbamate moiety; and
[0023] contacting the at least one first compound with a conductive nanomaterial and at least one second compound comprising at least one ester linkage and at least one hydroxyl moiety.
EXAMPLES
Example 1
[0024] In a vial, 2.0 g ethyl lactate, 2.0 g sec-butyl amine, and 1.0 g water were mixed. 3.6 g dry ice was added slowly to the vial with mixing. The viscous mixture was allowed to come to room temperature, aided by an exotherm, after which 4.0 g isopropanol and 0.5 g of a 2.7 wt % suspension of silver nanowires in isopropanol were added. The resulting coating composition was wire coated on a polyethylene terephthalate substrate using a #14 wire-wrapped rod. The coated substrate was oven dried to give a hazy coating with a surface resistivity that ranged from 50 to 100 ohms/square, as measured with an R-CHEK™ RC2175 four-point surface resistivity meter. Examination of the coating with an optical microscope showed a network of nanowires, as illustrated in FIGS. 1-3 . The coating was easily wiped off of the substrate.
Example 2
[0025] To a 2.81 g sample of the coating composition of Example 1, 2.0 g of ethyl lactate and 0.8 g of a 2.7 wt % suspension of silver nanowires in isopropanol were added. The resulting composition was coated on a polyethylene terephthalate substrate using a #16 wire-wrapped rod. The resulting coating was more uniform than the coating of Example 1 and had fewer visible patterns.
Example 3
[0026] To a vial filled with dry ice were slowly added 4.0 g ethyl lactate, 2.0 g sec-butyl amine, 1.0 g water, and 4.0 g isopropanol. The mixture was allowed to increase in temperature, due to an exotherm, then cool due to an excess of dry ice being present, and then warm to room temperature over the course of about 50 min. 1.3 g of a 2.7 wt % suspension of silver nanowires in isopropanol was then added and mixed into the mixture. The resulting composition was coated on a polyethylene terephthalate substrate using a #9 wire-wrapped rod. The resulting coating was dried for 1 min at 110° C. to give a uniform coating with surface resistance that ranged from 200 to 400 ohms/square. The resulting coating was more uniform and the wires more uniformly distributed than the coating of Example 1, as shown in FIGS. 4-5 .
[0027] The invention has been described in detail with reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.
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Disclosed are conductive coatings that exhibit improved clarity, uniformity, and mechanical strength. Such coatings comprising volatile viscosity modifiers are useful for electronics applications.
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RELATED APPLICATIONS
The present invention was first described in a notarized Official Record of Invention on Sep. 7, 2007, that is on file at the offices of Montgomery Patent and Design, LLC, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to the manipulation of wires and cable assemblies, and more particularly, to a specialty device to aid the twisting or separation of up to six (6) individual wires for a cable assembly.
BACKGROUND OF THE INVENTION
The field of electrical devices and systems, and in particular the design, arrangement, and manipulation of electrical wires and cable assemblies, is of great importance in the modern world. The twisting of multiple wires into cable assemblies and the corresponding separation of those cable assemblies into its constituent wires are important processes in this field of work. While these processes may be accomplished through a variety of means, including the use of the hands, dealing with such assemblies can be dangerous, difficult, and time consuming. This disadvantage is especially apparent in cases where the desired work area is difficult to access in some manner.
Various attempts have been made to provide for a means to more efficiently work with cable assemblies or a plurality of wires simultaneously. Examples of these attempts can be seen by reference to several U.S. patents. U.S. Pat. No. 1,324,583, issued in the name of Carlson, describes a wire twisting tool adapted to hold free adjacent wire ends. The Carlson tool provides a particular special relationship to allow for uniform twisting. U.S. Pat. No. 3,092,152, issued in the name of Neff, describes a wire twisting and cutting tool that grips a plurality of wires for twisting in a perpendicular manner. The Neff tool provides a cutting edge to trim the wires once the cable assembly is achieved. U.S. Pat. No. 7,124,786, issued in the name of Gowhari, describes linesman type pliers with a wire splice twister. The jaws provide a tapered recess to allow for wire insertion and a twisted splice when the pliers are manually rotated.
Additionally, ornamental designs for a wire twisting tool exist, particularly, U.S. Pat. Nos. D 485,146 and D 494,032. However, none of these designs are similar to the present invention.
While these devices fulfill their respective, particular objectives, each of these references suffer from one (1) or more disadvantages. Many of these devices are unfit to manipulate a plurality of wires. Those devices which are suited for manipulating a plurality of wires are not suited for the process of separating such cable assemblies. Furthermore, such devices are designed to grip a plurality of wires in a manner which is not perpendicular to the axis of twisting, thereby limiting the accessibility of use. Accordingly, there exists a need for a wire twisting device without the disadvantages as described above. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for a wire twisting device that is suitably adapted to manipulate a plurality of wires in a manner which is suitable for the processes of both assembling and separating cable assemblies and in a manner which is best suited for use in a variety of situations, particularly those situations in which access is limited in some manner. Thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.
To achieve the above objectives, it is an object of the present invention to provide upper and lower jaw members wherein the aforementioned wires and cable assemblies may be inserted and manipulated. The jaws function in the manner of pliers inasmuch as their purpose is to secure a firm grip upon wires and cable assemblies.
Another object of the present invention is a plurality of pivoting members coupled to the upper and lower jaws. The pivoting members couple to the jaw members in a way such that the device functions in the manner of pliers, wherein the user may close the jaw members by manually gripping the pivoting members.
Yet still another object of the present invention is to provide a locking mechanism that is connected to the upper and lower jaw members. It is the purpose of the locking mechanism to allow the user to maintain the closed position of the upper and lower jaw members, once achieved, without continuous application of manual force.
Yet still another object of the present invention is to provide a plurality of channels formed within and between the upper and lower jaws, wherein these channels are linear and adapted to grip the electrical wires. The channels are oriented in a direction which is perpendicular to the pivoting axis.
Yet still another object of the present invention is a one-way fixture formed at the lower jaw and oriented perpendicular to the aforementioned channels. This one-way fixture is designed to bend downward when the upper and lower jaws are pressed together, in a manner which allows the wire to be guided freely along the channels.
Yet still another object of the present invention is to provide a method of utilizing the device that provides a unique means of assembling and separating a plurality of wires and cable assemblies in a manner which allows the user to do so quickly and easily and in cases in which access is limited in some way.
Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is an in-use view of a twisting device for a plurality of wires 10 , according to a preferred embodiment of the present invention;
FIG. 2 is a side view of the twisting device for a plurality of wires 10 , according to a preferred embodiment of the present invention;
FIG. 3 is a perspective view of the twisting device for a plurality of wires 10 depicting an open state, according to the preferred embodiment of the present invention; and,
FIG. 4 is a side cut-away view of the twisting device for a plurality of wires 10 depicting a wire placement, according to the preferred embodiment of the present invention.
DESCRIPTIVE KEY
10
twisting device for a plurality of wires
20
upper jaw
21
upper mouth
22
first upper jaw anchor
23
second upper jaw anchor
25
lower jaw
26
lower mouth
27
lower jaw pivot point
28
spring aperture
29
spring
30
upper channel
31
lower channel
35
one-way fixture
40
upper member
45
lower member
46
lower member pivot point
47
adjustable link
48
adjustable link pivot point
49
adjusting screw
50
unlocking lever
55
unlocking lever pivot point
70
electrical wire
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 4 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a twisting device for a plurality of wires (herein described as the “device”) 10 , which provides a means for separating or twisting of up to six (6) individual electrical wires 70 preferably for a cable assembly. The device comprises an upper jaw 20 , lower jaw 25 , a pair of pivoting members, a locking mechanism, and a plurality of channels 30 . This specialty portable hand tool possesses a similar body to that of pliers and would be utilized in many electrically dexterous trades and occupations.
Referring now to FIG. 1 , an in-use view and FIG. 2 , a side view of the device 10 , according to the preferred embodiment of the present invention, are disclosed. The device 10 is depicting as comprising a conventional locking pliers-style style body comprising common features for illustration purposes only, it is known that other bodies may be utilized without limiting the scope of said device 10 . The device 10 comprises an upper jaw 20 and lower jaw 25 , thereby providing a means thereto grip electrical wires 70 therein a stationary position (also see FIGS. 3 and 4 ). The jaws 20 , 25 are attached to an arcuate upper mouth 21 and an opposing arcuate lower mouth 26 , respectively via fastening means such as integral forging, welding, or the like. The upper mouth 21 is attached to an upper member 40 via a first upper jaw anchor 22 and a second upper jaw anchor 23 . The anchors 22 , 23 are preferably standard pivoting rivets, yet other fastening means may be utilized without limiting the scope of the device 10 . The upper member 40 provides an upper gripping means and the lower member 45 provides a lower gripping means, thereby enabling the user to grasp said device 10 for common operations. The lower mouth 26 is attached to a lower member 45 and the upper member 40 via a lower member pivot point 46 and a lower jaw pivot point 27 , respectively, which enable the lower mouth 26 to be pivotally adjusted in a conventional manner. The lower member 45 provides a lower gripping means and houses an unlocking lever 50 . The device 10 locks into position when the upper member 40 and lower member 45 are pressed toward each other simultaneously locking the jaws 20 , 25 and mouths 21 , 26 in a closed state as illustrated herein. The jaws 20 , 25 and mouths 21 , 26 are unlocked via pushing downwardly on the unlocking lever 50 , thereby enabling said jaws 20 , 25 and mouths 21 , 26 to disengage. The unlocking lever 50 pivots about an unlocking lever pivot point 55 fastened to the lower member 55 .
A spring 29 is attached between the upper member 40 and lower member 45 to enable the device 10 to open. The spring 29 is attached to a spring aperture 28 on a rear portion of the lower jaw 25 . An adjustable link 47 is also attached between the upper member 40 and lower member 45 , thereby providing a fulcrum point for said lower member 45 . The adjustable link 47 protrudes from the upper member 45 and is attached to the lower member at the adjustable link pivot point 48 , thereby enabling said lower member to operate. The gap between the mouths 21 , 26 and concurrently the jaws 20 , 25 is adjusted via an adjusting screw 49 which is threadably engaged to a rear proximal surface of the upper member 40 . The adjusting screw 49 is rotated to cause each mouth 21 , 26 to be opened at a desired distance, thereby enabling the gripping of the jaws 20 , 25 to appropriately grip a desired electrical wire 70 .
Referring now to FIG. 3 , a perspective view of the device 10 depicting an open state and FIG. 4 a side cut-away view depicting a wire placement, according to the preferred embodiment of the present invention, are disclosed. The jaws 20 , 25 comprise six (6) parallel channels 30 that are perpendicular to the pivoting axis of the device 10 . Each channel 30 is sized to hold one (1) individual wire 70 thereby facilitating control thereto the unwieldy electrical wires 70 . Each wire 70 slides freely as it is guided through the associated channel 30 and over a one-way fixture 35 . The one-way fixture 35 resists opposite motion of the wires 70 , thereby holding the wires 70 into place there by grazing and puncturing the underside of the wires 70 . Once the electrical wires 70 are placed therein the device 10 , the jaws 20 , 25 can be pressed together which bends the one-way fixture 35 downward and releases the wires 70 , as shown thereon FIG. 4 .
When the jaws 20 , 25 are completely closed they may be locked together by means of depressing the members 40 , 45 toward each other. The locked state provides the device 10 with a closed position to hold the wires without the user holding said device 10 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the device 10 , it would be utilized as indicated in FIGS. 1 through 4 .
The method of installing and utilizing the device 10 may be achieved by performing the following steps: acquiring the device 10 ; adjusting the adjusting screw 49 to separate each mouth 21 , 26 to a desired width; inserting at least one (1) and up to six (6) electrical wires 70 into an individual channel 30 and over-top the one-way fixture 35 ; pressing the upper member 40 and lower member 45 towards each other thereto close the jaws 20 , 25 and secure the electrical wire 70 within the jaws 20 , 25 ; rotating the device 10 in either direction thereto twist the electrical wires 70 ; unlocking the device 10 , thereby pressing downwardly on the unlocking lever 50 ; removing the electrical wires 70 from the device 10 ; and, repeating if necessary.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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A specialty tool to aid in twisting of up to six (6) individual wires for a cable assembly is herein disclosed, comprising a series of six (6) parallel channels perpendicular to the fulcrum line of the pliers. Each channel is sized to hold one (1) individual wire, facilitated by a one-way fixture that slightly penetrates the wires insulation thus holding it securely. Once the wires are in the tool, the jaws can be locked together and can be rotated in either direction to twist the wires. This procedure would be used with cable assembly during manufacturing processes.
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The invention described herein may be manufactred used and licensed by or for the Government for Governmental purposes without the payment to us of any royalty thereon.
BACKGROUND OF THE INVENTION
1. Field of The Invention
The invention relates to ordnance devices and more particularly to the structure and method of manufacture of gun tubes or cannon barrels.
2. Description of the Prior Art
Weight reduction of armaments for facilitating transport and field manipulation is a desirable goal in the ordnance art. The present invention reduces weight in a gun tube by replacing a substantial portion of a conventional steel base with a sleeve of lighter material, for example, a titanium alloy.
As known to the inventor, neither the device nor the method of manufacture disclosed herein exist in the prior art.
SUMMARY OF THE INVENTION
The invention may be summarized as a gun tube or barrel of reduced weight achieved by replacing the outer portion of, for example, a conventional steel base with a sleeve of lighter material, as for further example, one composed of titanium alloy.
In designing a gun barrel it is necessary to provide sufficient mass and thickness to meet ballistic design requirements, to prevent the barrel from initial rupturing, and further to withstand the heat and mechanical stress of repeated use. It is also desirable to utilize a structure which, to a certain degree, will withstand external assault, for instance, small arms fire.
For these reasons, weight reduction cannot be achieved by the simple elimination of material from the barrel, but must be accomplished by the substitution of a material of lesser weight but closely related mechanical characteristics. Additionally, due to the size, fabrication of the finished barrel requires in the instant case the matching of a selected material and series of fabrication steps which is in and of itself unique. Specifically, a particular titanium alloy, Ti-3Al-8V-6Cr-4Mo-4Zr ("Beta C" alloy) has been found to be especially suitable for this purpose due to its mechanical properties and an amenability to air cooling during heat treatment. Such air cooling is required by the inherently large structures which are the subject of this invention.
Accordingly, the invention consists of weight reduction in a gun tube by the substitution o a lighter outer sleeve for a portion of the heavier base, the use of a specific titanium alloy particularly suited for this purpose, and the unique methods by which such sleeve and final assembly are fabricated.
The advantages and features of the invention will be more fully understood from the description of the preferred embodiment and drawings which follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional schematic drawing of the preferred embodiment of the invention;
FIG. 2 is a graphic illustration of the essential phase transformation characteristics of one alloy, Ti-3Al-8V-6Cr- 4Mo-4Zr (Beta C alloy), employed in the preferred embodiment of the invention;
FIG. 3 is a graphic illustration of the mechanical property potential of such alloy; and
FIG. 4 is a graphic illustration of the essential properties achieved in the preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is schematically illustrated a gun tube or cannon barrel comprising the preferred embodiment of the invention. Base 10 is preferably constructed of steel and sleeve 12 of a lighter material for example a titanium alloy.
The material selected for the lighter weight sleeve is required to possess mechanical characteristics which closely match that of the base and must also be capable of being fabricated by methods suited for such large structures.
The utilization of titanium alloy as a sleeve material is based not only on its light weight, but also its potential to meet suitable mechanical characteristics. The processing approach taken wherein to attain the titanium alloy sleeve is comprised of a melt and cast, plastic work, heat treat sequence of operations. More specifically these are: (1) synthesize a primary ingot of the titanium alloy by a double vacuum arc melting method; (2) hot forge the ingot to configuration and dimensions of an extrusion billet, using a series of press forging reductions; (3) hot extrude to tubular form; and (4) precision heat treat to attain final mechanical characteristics.
The principal constraints and unknown factors that arise during the course of this processing relate primarily to the size factors encountered, since titanium alloy components of the present mass and configuration, and conditioned to the present mechanical properties have hereto before not been achieved. Basic to the latter are the microstructural factors, namely crystallographic refinement and compositional homogeneity. It is well known that large crystallites or "grains" of ingot materials, in general, are reduced in size by hot plastic work and further by recrystallization at elevated temperature. In addition, the compositional homogeneity is improved by the accelerated interatomic diffusion that occurs simultaneously with elevated temperature plastic work. Consequently, through a particular series of steps detailed below, general steps, (1), (2) and (3) maximize the preceding and result in a tube formed from a primary ingot in which the cross sectional area is reduced by a substantial percentage, for example in the area of ninety percent.
The methodology of the heat treat process of general step (4) is greatly determined by the size of the finished product. First, the commonly known "solutionize and age harden" approach is employed in general to condition the mechanical characteristics of the titanium alloy. Thus (a) the alloy ingredients are rendered into solid solution at certain elevated temperatures, (b) they are retained in solid solution, in metastable condition, on cooling to room temperature, and (c) they are precipitated at certain elevated temperature to comprise the final age hardened condition. For large metallurgical mass, as that of the present, step (b) requires special attention because of the magnitude of the heat removal requirement. Thus, if fast cooling, or quenching is necessary, as is the case with most titanium alloys, the heat removal rates required cannot be achieved in practice, and therefore the heat treat process is rendered inadequate for the needs of the present sleeve component. From this standpoint therefore it is essential that step (b) be accomplished by relatively slow cooling, and most conveniently b normal air cooling of the metallurgical mass on removal from the furnace in which the solutionizing process of step (a) is accomplished. Therefore it is essential that the alloy employed be characterized with phase transformation kinetic able to accommodate such a cooling. Referring to FIG. 2, a time temperature transformation diagram illustrates the parameters involved in selecting such an alloy particularly suited for use in the invention i.e.,Ti-3Al-8V-6Cr-4Mo-4Zr (Beta C alloy). Here the single phase beta region comprises the solutionized condition. In this light, a time temperature profile for normal air cooling of the tube is seen to be contained in this single phase beta region; thus the solutionized condition is retained as desired. Therefore, the alloy selection, by methods of this invention, is based on the behavior shown in FIG. 2 and further on the age hardening potential illustrated in FIG. 3. This is attained by reheating to the two phase alpha beta region of FIG. 2, where a dispersion of alpha particles is precipitated in a matrix of the beta phase. However, by the methods of this invention, the precise age hardening parameters for the present tube are determined by trial and error since such tube has not heretofore been so processed. The parameters thus determined are indicated in FIG. 4, and described further in the following.
After the fabrication of the sleeve as generally described above, the inside diameter of the sleeve and the outside diameter of the steel base are precision machined for an 0.005 inch interference fit, as is required to shrink fit the two together. This is accomplished as follows. The sleeve and base are held in tandem vertically and co-axially, muzzle end downward, with the base suspended above, and the sleeve anchored below. The sleeve is then induction heated to approximately 800 degrees F. (430 degrees C. ), where the diametric thermal expansion accommodates a slip fit with the steel base that remains at ambient room temperature. The steel base is then promptly lowered into the bore of the titanium sleeve. In order to obtain the ensuing thermal condition as symmetric as possible, water is sprayed radially on the outside diameter of the titanium sleeve, beginning at the top, and then uniformly in axial direction by controlled motion of the water spray in that direction. With the shrink fit thus accomplished, the steel bore is then machined to final diameter.
The following additional operations are now performed, (1) swaging or autofrettaee of the steel bore, and (2) chromium plating of the steel bore, as done conventionally for all steel gun tubes. The swaging operation consists of forcing an oversize mandrel through the steel bore to create residual stresses. In the present case, this swaging causes the steel base to flow plastically, while the titanium sleeve remains elastic, due to the differences in the elastic moduli of the two materials, and the degree of interference between the mandrel and the tube diameters. This not only improves the shrink fit, but also enhances those residual stresses that are favorable to the operational life cycle of the gun tube.
The assembly is then reheated to 700 degrees F. (350 degrees C.) to properly temper the steel, while not affecting the titanium sleeve significantly. The assembly is then machined to whatever the final dimensions are required for integration into a functional armament design.
As a particular example, a gun tube has been manufactured by the above methodology in accordance with the specific steps listed herein.
1. Double vacuum arc melt a 30 inch diameter primary ingot of Ti-3Al-8V-6Cr-4Mo-4Zr alloy (Beta C Alloy).
2. Forge to 18 inch diagonal square at 1975 degrees F. and air cool.
3. Remove surface flaws.
4. Forge to 141/2 inch diagonal square at 1975 degrees F. and air cool.
5. Forge to 141/2 inch diagonal octagon at 1975 degrees F. and air cool.
6. Forge to 14 inch diameter round at 1975 degrees F. and air cool.
7. Cut into 14 inch diameter by 6 foot long sections to form a billet.
8. Trepan a 5 inch diameter hole in the billet.
9Extrude the billet at 1850 degrees F. to a tube, 71/8 inch OD by 43/4 inch ID by 30 feet long and air cool. Cut into 10 feet long sections.
10. Solution treat, at 1550 degrees F. for 30 minutes and air cool.
11. Age harden, at 975 degrees F., for eleven hours and air cool.
12. Machine to final configuration.
13. Shrink fit to steel base.
14. Autofrettage and temper.
15. Finish machine.
A prototype cannon tube was fabricated in accordance with the detailed method described above and then subjected to a field firing test program. The prototype exhibited the following characteristics during the 95 round test:
Mechanically, the cannon delivered projectiles on target with satisfactory dispersion characteristics.
Structurally, the tube was within acceptable limits. The bore size was increased by 1-2 mils in some areas, but this would not be unusual for any cannon. Chrome losses at the bore were also within acceptable limits.
Thermally, the tube achieved a maximum temperature at the outside diameter of 485 degrees F. during firing with no apparent deleterious effects. It was noted that, at elevated temperatures, the steel base expands axially more than the titanium sleeve due to the difference in thermal expansion coefficients. This caused the steel base to protrude slightly beyond the jacket by varying amounts during the test, but no harmful effects were noted.
During a rapid firing sequence, the tube remained on target remarkably well particularly since it had not been fitted with a thermal shroud. Rapid firing often sets up thermal gradients in steel cannon tubes which force the muzzle downward, thus making successive shots fall lower on the target. Without a thermal shroud to control the extent of motion, the projectiles soon begin to miss the target, impacting the ground in front of it. With this prototype tube, all shots stayed on the target, and successive shots moved slightly upward and to the right during firing.
Dynamically, the tube exceeded all expectations. When projectile velocities are low, all tubes dilate radially by an amount which can then be calculated from statics equations. At higher projectile velocities, dynamic amplifications of this static dilation can be significant, in some cases, on the order of 4 to 5. For this prototype, amplifications were unexpectedly low, only about 2. Dynamic finite element analysis indicated the reason is related to the ability of the steel base and titanium sleeve to move axially and radially with respect to each other. These results imply that use of the invention may provide a further benefit, i.e., a means by which to attenuate dynamic strain amplifications.
In addition to the above firing prototype, four jacketed cylinders were fabricated by the same techniques described in the preceding. The length of the cylinders however was foreshortened by three feet to allow hydraulic pressurization to be accomplished by the laboratory.
In the first test, internal pressure was increased until the cylinder burst. The "Strain vs. Pressure" and "Burst Pressure" measurements compared very favorably with analytical predictions, indicating that the design precepts were well understood.
In the second and third tests, the cylinders were subjected to multiple high-pressure pulses in order to assess fatigue modes of failure. The second cylinder was tested as fabricated and the third cylinder alone was intentionally notched at the inner diameter to initiate an early crack. In both cases the fatigue crack initiated at the inside diameter and grew outward to the steel titanium interface. At that point, it was necessary to stop both tests because of leaking hydraulic fluid. This leak-before-break mode of failure is considered very favorable, in terms of a fail-safe characteristic.
In the fourth test, the cylinder was shot at close range with a 0.30 caliber armor piercing projectile. The projectile completely penetrated the titanium jacket, stopping at the steel base. The cylinder thus damaged was subjected to a hydraulic fatigue test and withstood 388 pressure cycles before failing by axial rupture of the jacket. The conclusion is that the tube of the invention can still be safely fired for a significant number of rounds, even after sustaining severe ballistic damage.
The novel device and method having been fully described by the above, the scope of the invention is hereby defined by the following claims:
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A gun tube having an outer sleeve of reduced weight from that of the base d having improved characteristics in firing accuracy. A method of fabrication pertaining to a selected titanium alloy sleeve in combination with a steel base is also disclosed.
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TECHNICAL FIELD
This invention relates to a third generation network that provides services to end-users, services such as telephone calls, VPN, multiple access, information services, etc.
BACKGROUND
The H.323 standard of the International Telecommunication Union (ITU) specifies signalling and transport for multimedia traffic over a packet switched network. Another protocol that addresses this same issues as the H.323 standard is referred to as SIP (Session Initiation Protocol) standard.
Network solutions according to H.323 and SIP mainly and typically support multimedia communication between end-points that by some means are connected to a packet-based network, such as for instance an IP (Internet Protocol) network. Networks and end-points that support H.323 or SIP (or, are given this support via other means, such as e.g. an H.323 or SIP enabled gateway), can provide services and functions as can be found in a typical PSTN (Public Switched Telephone Network). Accordingly, depending on the capabilities of the end-point, such networks can support and provide to a user more than plain voice communication. Other examples of supported communication types are video, fax, data sharing, information services, etc.
Telecommunication solutions according to H.323 or SIP will typically support the same type of services as those provided by a normal PSTN. Such services are call forwarding, call waiting, call screening, etc. Because H.323 and SIP telecommunication solutions are using new network architectures, such as e.g. based on IP, and have support for smarter end-points than PSTN, a new sets of services will be supported in those networks.
Although H.323 and SIP are new protocols, telecommunication solutions according to those protocols will encounter problems with regard to service interaction similar to those experienced in the PSTN. A reason for the occurrence of a service interaction problem is that some services are invoked when an end-user establishes a call. This means that services are applied after some of the routing of a call is already done, which in turn can lead to adverse interaction of a service or services.
In the following and with reference to the accompanying FIG. 1 , a typical known service solution in a typical telecommunication network, as will be readily appreciated by a person skilled in the art, will be explained by way of a model description.
In FIG. 1 the normal network model is shown. It should be noted that the reference numerals only give an indication on the normal or typical call path flow, as other call path scenarios also are known to exist:
1: The services are configured by a network operator and potentially also by an end user
2: The call is triggered at the user side and signalling handler on the user side communicates with the signalling handler on the network side
3: The service executor is invoked
4: The service executor communicates with the service configuration part in order to download information on e.g. available services
5: The service executor returns service information to the signalling handler, that might be ordinary PSTN services like CLIP (Calling Line Identity Presentation)/CLIR (Calling Line Identity Restriction), PNP (Private Numbering Plan), OCB (Outgoing Call Barring) etc.
6: The signalling flow can be “flooded” to the terminating side (the “reflected side”)
7: When the signalling part is executed, information on which media channels to set up are passed over to the media generator.
Accordingly, the media is set up through the network. Note that media and signalling usually do not follow the same paths. Note also that the “reflection plane” indicated in FIG. 1 illustrates that the originating side may or may not see a “mirrored” or “reflected” terminating side that is similar to the originating side.
The service configuration and service executor shown in FIG. 1 can also exist on the user side. The advantage of having the service configuration and service executor on the network side is that the operator is given fill control over the service environment and all possible interactions between services.
U.S. Pat. No. 5,822,419 to Enstone, et al., discloses a method of detecting interactions between services in a set of services in a telecommunications system. A service abstract is produced based on a Basic Call State Model (BCSM) which gives a high level description of a Call Processing Subsystem and a data processing sequence performed by basic call processing and by the services in respect of a global data item. For detecting service interactions, a service abstract is produced based on a Basic Call State Model and a data processing sequence performed by basic call state processing and by the services in respect of a global data item.
European Patent publication no. EP0825787 to British Telecomm (GB) discloses, in a connection management system for setting up connections in a communications network, run-time negotiation is carried out to avoid feature interaction. Users of the network are provided with user agents (intelligent software) who have access to user profiles. When a calling user wants to set up a particular connection configuration, which may involve service features such as ring back later on busy, their user agent sends a connection configuration proposal to the user agent or a called user. The two user agents then negotiate to establish a mutually acceptable connection configuration, if one is available. The negotiation is based on alternative connection configurations stored in order of preference in the respective user profiles. These are proposed and counter-proposed by the user agents in descending preference order until the mutually acceptable configuration is reached or the connection fails.
Patent publication no. WO9750232 to Bell Communications Res (US) discloses a method for managing communications between a service origination node and a plurality of serving nodes where the serving nodes are simultaneously active for a particular trigger to thereby generate a reply to the service origination node. The method includes the step of determining control options for each trigger indicative of service categories by capturing service interaction principles supplied by a serving node services expert acting as a mentor. The service interaction principles are based upon a requirement of executing service categories in each of the serving nodes for each trigger. The method also includes the step of controlling execution of each of the service nodes and the service categories for the particular trigger with reference to the control options to generate the reply.
Patent publication no WO9429993 to TELEFON AB L M ERICSSON (SE), discloses a method of avoiding undesirable interferences between services in a telecommunications system that includes basic software for a basic service and supplemental software for services supplemental to the basic service. The supplemental software is divided into action software, which acts solely on the basic service, and supplemental software, which acts on the remaining supplemental software. A supplemental service is represented by action elements. Combinations of action elements form nodes in a mathematical binomial tree. Only those combinations, which correspond to interference, i.e., an undesirable behaviour, between supplemental services will form a number of structures, called interference event trees. Before a supplemental service can be executed, its action elements are compared with nodes in the interference event trees, with the intention of ascertaining whether or not the former coincide with action elements belonging to the nodes in the latter. Only those interference event nodes whose sets of action elements are equivalent with the set of action elements of the supplemental service or a set thereof are selected. An interference event node whose set of action elements is a subset of the action elements of a node that has already been chosen cannot be selected. Interaction software belonging to selected nodes in the interference event trees is added to the basic software.
It is an object of the invention to provide an improved solution in a modem telecommunication network for mitigation of service interaction or service conflict problems that may occur when conflicting services pertinent to a subscriber are invoked.
It is a further object of the invention to provide an improved solution in a modem telecommunication network for mitigation of network load problems resulting from service interaction or service conflict problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a schematic drawing illustrating a typical known call path scenario, with sequence illustrated by numbers.
FIG. 2 . is a schematic drawing illustrating an exemplary call path scenario according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
In the following the invention will be explained in more detail, by way of example and with reference to the accompanying drawings.
Referring to FIG. 2 , instead of starting call from the signalling layer and through the media layer as is common according to current solutions as illustrated in FIG. 1 , in a solution according to the invention the call is started at the service layer. This means that the service layer on the user side and the service layer on the network side will communicate directly. It will then be the service layer on the network side that informs the signalling handler on the signalling layer on the network side to establish the call. After the service executor on the originating side has been informed about the destination of the call and has performed applicable local services, it routes the call to the service executor on the destination side. When the destination side service executor has finished executing it's services, dependent upon network architecture, either the originating side service executor or the destination side executor will inform the media executor to start the call.
In reference numeral order, in the following is given a detailed explanation of the various items shown in FIG. 2 . As different call path scenarios can exist in a solution according to the present invention, it should be noted that the order in which of the references numerals appear only give an indication of one of a number of possible call path flows, that is likely to occur:
1: The services are configured by a network operator, and possibly also by an end user
2: The call is triggered at the user side and the associated service executor on the network side is informed
3: The service executor communicates with the service configuration part in order to download available information, such as e.g. information on available services.
4: The service information can be flooded to the terminating (destination) side (i.e. the “reflected” side.)
It should be noted, that, in a solution according to the invention, the signalling handlers and generators are eliminated on the network side as well as on the user side. They are not needed because call routing and transport of service information is done on the service layer.
Although the Signalling handler, the media generator and the media handler shown in FIG. 2 are depicted by dotted lines, they are still present. They are, however, involved in the service execution. When one or more services are executed at the Service Executors, the service executors inform the signalling handler at the network side to initiate the call (point 4 in FIG. 2 ), but the rest of the call set-up follows the normal procedure as described in the applicable standard call control protocol (e.g. H.323 or SIP). Accordingly, in the actual call handling between, the difference between the solutions indicated by FIGS. 1 and 2 , respectively, is that in FIG. 2 it is only the signalling handler at the network side that is allowed to initiate calls, such as e.g. sending Q.931 “Set-up” according to H.323 or “SIP-Invite” according to SIP.
Further, with reference to FIG. 2 , after the Service executor has informed the signalling handlers to initiate the call in step 4, the signalling handlers at the network side initiate the call towards the signalling handler at the user side (step 5 in FIG. 2 ). The signalling protocol can be of any standard type (e.g. H.323 or SIP), adapted such that the call initiation is only allowed from the network side. When the signalling is complete, the signalling handler informs the media handler that it is able to receive or send information, as indicated in step 6. Both the network and the user side are now ready to receive media, as indicated in step 7.
Referring to the solution illustrated in FIG. 2 , and comparing it with the known solution illustrated in FIG. 1 , it can be seen that the novel solution further represents an extension represented by a service handler. As depicted, the service handler represents the users access to the network, and represents the point at which the user will initiate a call. Because a call, in the novel solution, is considered equal to any other service, and hence is separated from the actual signalling that is used to establish calls, a requirement for this is that the service handler is able to communicate with the network side service handler over a simple standard protocol, such as for example HTTP (hypertext transport protocol). Accordingly, the service handler at the user side does not communicate with the signalling handler at the user side.
The service executor at the network side in a solution according to the invention, of which an exemplary model representation is illustrated by FIG. 2 , can be seen to differ in two ways from the service executor shown in FIG. 1 :
a) The service executor (shown in FIG. 2 ) receives service-triggering information directly from a service handler located at the user side instead of a triggering service from the signalling handler at the network side. That means that the service executor at the network side must have support for a protocol that is understood by the service handler at the user side. A simple protocol like http should be used.
b) The service executor at one network talks directly with a service executor in another network (in this context and at this point, the meaning of network is the service executor handling services for a different user or domain), instead of communicating indirectly through the standard call control signalling (as shown in FIG. 1 ). The protocol used between the different service executors should be optimised according to the services that are supported. Because most of the information sent on this communication link is data related, a data protocol will be used, where XML (extended Mark-up Language) over http could be one example of such a protocol.
In FIG. 2 , the new scenario in a solution according to the invention is drawn by solid lines. However, the novel way of invoking services may still invoke “old” services of existing solutions, which can be included, as shown, by the features illustrated in FIG. 2 by dotted lines. If “old” services are invoked, the service executor preferably is designed with a backend and different frontends, depending on which protocol to interface to.
If several networks provided by different network providers or ISPs are involved, there must exist some standard protocols on the service layer; see reference numeral 3 in FIG. 2 .
The protocols used for configuring the services as well as on the service execution layer typically can advantageously be HTTP.
ADVANTAGES
Provides a solution to the service interaction problem.
Eliminates the need for standardising the way originating and terminating services are “talking” to each other, as they communicate directly and not via the media layer.
Eliminates the need for a special and often quite complex call handling protocol.
ABBREVATIONS
IP
Internet Protocol
ISP
Internet Service Provider
LAN
Local Area Network
PSTN
Public Switched Telephone Network
VPN
Virtual Private Network
WAN
Wide Area Network
WAP
Wireless Application Protocol
WML
Wireless Mark-up Language
REFERENCES
[ 1 ] ITU-T Recommendation H.323, February 1998 “Packet-based multimedia communications system”.
[ 2 ] WAP white paper, June 99,
[ 3 ] Session Initiation Protocol—SIP IETF RFC 2543,
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In a telecommunication system, adapted to provide subscriber related services, a layered architecture including on a service layer a network side service executor and a user terminal service handler is employed. A call is triggered through a user interface provided by the service handler, which conveys a call set-up request and information to the service executor. The service executor communicates directly with a corresponding service executor at a service layer of a destination system and exchanges service information to detect a service interaction problem. A requested call can be established by other signalling and media handler functions when no essential service interaction problem is detected.
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Pyrroline N-oxides are effective spin traps for the trapping of free radicals to facilitate their detection and study by electron spin resonance (ESR) spectroscopy techniques. A spin trap is a diamagnetic compound that reacts with a transient free radical to produce a more stable adduct. This adduct gives rise to an ESR signal which allows identification of the original free radical through parameters including hyperfine coupling constants and g-values.
This invention is directed to substituted pyrroline N-oxide derivatives and their preparation. With alkyl groups at the 3- and 5-positions of pyrroline N-oxide, it has been found possible to introduce different substituents in the 4-position. One of the 3,5-alkyl groups may be phenyl. These derivatives with different substituents at the 4-position are advantageous over spin traps with alkyl substituents present only in the 3- and 5-positions of pyrroline N-oxide, due to the flexibility to introduce a wide variety of functional groups at the 4-position; for example:
(a) attachment of a group to enhance the specificity for specific free radicals
(b) attachment of a polar group to enhance the solubility of a spin trap in water;
(c) attachment of a specific group that provides a strong binding affinity to biological substrates in order to facilitate in vivo trapping studies.
BACKGROUND AND PRIOR ART
In recent years, interest in the behaviour of free radicals in biological systems has increased. Radicals such as hydroxyl, peroxyl and superoxide radical anion have been implicated in a variety of cellular responses including aging, cancer, ischemic tissue injury and phagocytosis. Despite major efforts to study the role of free radicals in cell injury, identification of these reactive species remains a problem. The technique of spin trapping the free radicals has been used to address this difficulty. In this method, transient radicals are scavenged by appropriate nitrone or nitroso compounds to form persistent nitroxide adducts that can be identified spectroscopically. Currently used spin traps include 5,5-dimethylpyrroline-N-oxide (M 2 PO,), 3,3,5,5-tetramethylpyrroline-N-oxide (M 4 PO) and N-tert-butyl-α-phenylnitrone (PBN).
For example see J. Org. Chem. 1988 Vol. 53, 1566-1567 A. Dehnel et al and J. Med. Chem. 1988, Vol. 31, 428-432 G. M. Rosen et al. These references disclose the preparation and spin trapping properties of 3,3-dimethyl-5,5-disubstituted-4-carbethoxypyrroline N-oxide; 3,3,5,5-tetramethyl pyrroline N-oxide and 3,3-diethyl-5,5-dimethylpyrroline-N-oxide. These compounds are effective spin traps or scavengers for free radicals such as t-BuO*, *CH 2 OH, *OH and Ph* with the half-lives of the adducts being several hours; however poor selectivity as well as poor solubility in water are evident.
It would be desirable to design other derivatives of pyrroline N-oxide having improved, additional and/or more selective spin trapping properties. We have prepared derivatives having other selected substituents in the 4-position, these substituents bestowing properties from among: extended adduct half life, enhanced selectivity toward specific free radicals, ability to bind to a wide variety of proteins, or other biological substrate and enhanced solubility in aqueous media.
SUMMARY OF THE INVENTION
The following derivatives have been prepared as part of the invention:
substituted pyrroline N-oxides having the formula ##STR1## where R 0 is selected from the group consisting of (1) ester --R 5 --CO--O--R 6 where R 5 is an alkylene group of 1-6 C atoms and R 6 is an alkyl group of 1-4 C atoms;
(2) polyether --O--[R 7 --O] x --R 8 where R 7 is an alkylene group of 1-3 C atoms, R 8 is an alkyl group of 1-2 C atoms, and X is 1-4;
(3) substituted alkanoyl --O--CO--R 9 --y where R 9 is an alkyene group of 1-6 C atoms, and Y is a group having an affinity for or binding to, a biological substrate;
and where R 1 , R 2 , R 3 , and R 4 are alkyl, deuterated alkyl or cyclic alkyl groups of up to 6 C atoms, or phenyl groups; with the proviso that only up to one of the R 1 -R 4 groups may be phenyl.
Illustrative compounds include the 4-[2-(ethoxycarboxyl)ethyl]-, the 4-(methoxymethoxymethyl)-, the 4-(methoxyethoxymethoxymethyl)-, the 4-(N-malimidobutyryloxymethyl) and the 4-biotinyl-derivatives.
The invention includes the process of preparing substituted pyrroline N-oxides comprising:
(a) providing a pyrrolidine compound of the formula ##STR2## where R 1 -R 4 are alkyl, cyclic alkyl or phenyl, and protecting the amine N with a protecting group;
(b) conducting one step from
(i) reacting this 3-hydroxymethyl-N-protected compound with one of the group consisting of halogenated ethers including polyethers, and carboxylic acids, to form an ether- or ester-linked substituent; and
(ii) oxidizing the 3-hydroxymethyl group to the corresponding aldehyde and reacting the 3-aldehyde with a phosphorane alkenyl carboxylate via a Witting reacting to attach a carboxylate substituent; and
(c) removing the N-protecting group, and oxidizing to form the corresponding substituted pyrroline N-oxide.
These compounds are useful as spin traps for free radicals i.e. form adducts with short-lived free radicals, the adducts having a longer life allowing detailed characterization and observation. The compounds can be chosen to have the capability to bind to proteins and other biological substrates.
DETAILED DESCRIPTION
The pyrroline N-oxide spin traps function by having a charge distribution and steric configuration between the N-oxide and the 2-position favourable for attracting and retaining various free radicals as adducts. Substituents in the 3- and 5-positions serve the function of bestowing a limited increase in adduct lifetime but have no effect on the selectivity. Recent tests have indicated that substituents in the 4-position have a further effect on adduct formation and stability as well as on the selectivity. In the course of investigating this further effect, we have prepared various 4-substituted derivatives.
The first type of compound investigated was one having a carboxylic acid ester group spaced from the pyrroline C-4 ring carbon by at least two carbon atoms. It was found possible to prepare this type by starting with the 4-carbethoxypyrroline, reducing to form the 3-(hydroxymethyl) pyrrolidine, selectively protecting the amine group e.g. with benzyl formate (CBz group), oxidizing sufficiently to form the 3-aldehyde (3-formal), reacting with a phosphorane alkenoate (Witting reaction) to introduce an alkenoate group on the aldehyde carbon, hydrogenating the alkene double bond and removing the protecting group, and reoxidizing to form the pyrroline-N-oxide. This process is illustrated in Example 1.
Suitable reducing agents to form the 3-hydroxymethylpyrrolidine include lithium aluminum hydride and its equivalents and the protecting groups for the pyrrolidine (secondary amine) include benzyl formyl, and alkyl formyl. Oxidizing to form the 3-aldehyde-pyrrolidine can be carried out by mild oxidizing agents such as pyridinium chlorochromate (PCC) or under Swern oxidation conditions. Hydrogenation to reform the free amine can be conducted using Pd over carbon (5 or 10%) or alternatively the blocking group can be removed under mild acidic conditions. The oxidation to reform the nitrone or pyrroline N-oxide can be carried out using hydrogen peroxide with sodium tungstate as a catalyst or using Davis reagent. Davis reagent (2-(phenylsulfonyl)-3-aryloxaziridine) may be needed to facilitate the oxidation in some cases (see Examples 3 and 4). Still other oxidation systems could be used.
The 4-carbethoxypyrroline starting compound can have various alkyl (1-6 C atoms), cyclic alkyl (3-8 membered ring) or phenyl groups in the 3- and 5-positions, with the proviso that no more than one substituent can be phenyl. The carboxylic ester group can be spaced from the C-4 carbon by from 2 to 7 C atoms (achieved by varying the Wittig reagent). The esterifying group can be an alkyl group of from 1-4 C atoms (again by adjusting the Wittig reagent).
The second type of compound investigated was that having a polyether chain in the 4-position. The preparation proceeds similarly to that for type one as far as the 3-hydroxymethyl-N-protected-pyrrolidine. The 3-hydroxymethyl group then is condensed with a halogenated ether (or polyether) to form a di- or poly-ether chain. The 3-polyether-pyrrolidine then is hydrogenated and oxidized to re-form the pyrroline N-oxide as before. This second type is illustrated in Example 2.
The halogenated ether reactant usually will have the halogen on one of the end C atoms but this is not essential. The halogen may be chlorine, bromine or iodine. The internal alkylene groups in the polyether chain may be the same or different and have up to 3 C atoms and there may be up to 4 such groups. The end alkyl group usually will be methyl or ethyl. The condensation with the halogenated ether may be carried out in dichloromethane or in tetrahydrofuran (THF) in the presence of diisopropylamine at room temperature. Other suitable reagents such as triethylamine or sodium hydride could also be used.
The third type of compound is one having the 4-position substituent (substituted alkanoyl) coupled by an esterification reaction to the 4-hydroxymethyl group. Examples are 4-(N-malimidobutyryloxymethyl)-3,3,5,5-tetramethylpyrroline N-oxide (see Example 3) and 4-(O-biotinoxymethyl)-3,3,5,5-tetramethylpyrroline N-oxide (see Example 4). Compounds having a an esterifyable alkanoic carboxylic group, spaced from the binding group are esterified by the 3-hydroxymethyl group on the N-protected pyrrolidine and the coupled product converted to the corresponding pyrroline-N-oxide as before. In this third type, in the 4-position substituent the space between the carboxylic acid group and the substrate binding group can be that of an alkylene group of from 1-6 C atoms. In general, the alkanoyl-binding group substituent has the formula --O--CO--R 9 --Y where R 9 is an alkylene group of 1-6 C atoms, and Y is a group having an affinity for, or binding to, a biological substrate.
The biotin and N-malimidobutyric acid used in Examples 3 and 4 are available commercially. Other N-malimidoalkanoic acids can be prepared by known techniques, the alkanoic acid having from 2-7 C atoms.
We have found it preferable to activate the carboxylic acid group of this third type to render it in the form of an active ester as shown in scheme 3 and 4. These forms are found to be more reactive with the 3-hydroxymethylpyrrolidine and can lead to increased yields. Suitable activation procedures are described in Examples 3 and 4. Alternative ways of making such active esters are using dicyclohexylcarbodiimide (DCC) or N-hydroxysuccinic anhydride or carbonyldiimidazole to activate the carboxyl group.
In general, the preparation process may be summarized as follows:
(a) providing a pyrrolidine compound of the formula ##STR3## where R 1 -R 4 are alkyl, cyclic alkyl or phenyl, and protecting the amine N with a protecting group;
(b) conducting one step from
(i) reacting this 3-hydroxymethyl N-protected compound with one of the group consisting of halogenated ethers including polyethers, and carboxylic acids, to form an ether- or ester-linked substituent; and
(ii) oxidizing the 3-hydroxymethyl group to the corresponding aldehyde and reacting the 3-aldehyde with a phosphorane alkenyl carboxylate via a Wittig reaction to attach a carboxylate substituent; and
(c) removing the N-protecting group, and oxidizing to form the corresponding substituted pyrroline N-oxide.
Each of these 3 types of compounds are useful as spin traps for free radicals. The first type, having a carboxylate group remote from the ring has a specificity for the hydroxyl free radical, and extended half-life of the adduct (the adduct has stability in a superoxide flux). The second type, having a polyether chain, has general properties of trapping free radicals, and some enhancement of water solubility. The polyether chain has good stability in alkaline media: however these chains are very sensitive to mild acidic conditions to provide the free hydroxyl group again.
In recent years, interest in the knowledge of free radicals in biological systems has increased. Reactive intermediates such as hydroxyl and superoxide radical anion have been proposed to mediate a variety of cellular responses including cancer. Despite efforts to study the role of free radicals in cell injury, the biggest common hurdle is the identification of these reactive species. The technique of spin trapping has been used to address this difficulty. However, the use of the trapping technique in biological systems has not been explored to its full potential due to the limited variety of available spin traps.
The third type i.e. the alkanoyl with remote binding group (e.g. malimido and biotin) has the properties of binding to biological substrates especially a wide variety of proteins as well as to certain specific proteins e.g. avidin and streptavidin. Spin traps with a malimido group can covalently bind to proteins containing cysteine amino acids using a sulphydryl group of the amino acid; whereas biotinylated spin traps have a specificity towards specific proteins such as avidin and streptavidin due to the strong binding affinity of biotin for these two proteins. This binding means that the microsite of free radicals initiation in vivo can be pin-pointed in many cases.
The following Examples are illustrative.
EXAMPLE 1
4-[Ethoxycarbonyl)ethyl]-3,3,5,5-tetramethyl-1-pyrroline N-oxide(7)
The starting compound 3,3,5,5-tetramethyl-4-carbethoxy-1-pyrroline (1) was prepared as outlined in the A. Dehnel et al 1988 reference given above (see IVa in Scheme I therein).
To a mixture of lithium aluminum hydride (LAH, 0.8 g, 20.0 mmol) in ether (10 mL) was added dropwise a solution of this 4-carbethoxy pyrroline compound (1, 4.95 g, 25.12 mmol) in ether (100 mL), over a period of three h. After the addition was completed, the mixture was refluxed for 1 h. It was then quenched by careful dropwise addition of 1/1 solution of 10% NaOH and 95% ethanol. The organic layer was separated, dried and evaporated to dryness. Crystallization in 95% ethanol gave 3-Hydroxymethyl-2,2,4,4-tetramethyl-1-pyrrolidine (2, 3.8 g, 97%) as white crystals.
To a mixture of 2 (4.7 g, 30.0 mmol and K 2 CO 3 (4.8 g, 35.0 mmol) in acetonitrile (100 mL) was added a solution of benzyl chloroformate (4.7 mL, 33 mmol) in acetonitrile (15 mL). After stirring at -20° C. for 2.5 h, the mixture was brought to 25° C., quenched with a phosphate buffer solution (20 mL) and extracted with dichloromethane (200 mL). The combined organic phase was dried and evaporated. The oily residue was purified by flash chromatography over silica gel and eluted with 1:3 ethyl acetatehexane to give 8.2 g of N-benzyloxycarbonyl-3-hydroxymethyl-2,2,4,4-tetramethyl-pyrrolidine (3, 92%) as a white solid.
To a solution of 3 (2.9 g, 10.0 mmol) in dichloromethane was added pyridinium chlorochromate (PCC, 3.2 g) at room temperature and the mixture stirred for 3 h. The corresponding 3-aldehyde compound 4 was obtained in 93% yield.
When aldehyde compound 4(2.9 g, 10.0 mmol) dissolved in benzene (30 mL) was subjected to Wittig reaction conditions by warming to 55°-60° C. in the presence of (carbethoxymethylene)triphenylphosphorane (5.2 g, 15.0 mmol), the unsaturated ester derivative 5 was obtained in 76% yield.
A solution of the unsaturated ester 5 (3.6 g, 10 mmol) in 95% ethanol (35 mL) and 10% palladium on charcoal (200 mg) was hydrogenated with H 2 at atmospheric pressure for 10 h. The mixture was filtered through Celite® 545 (5 g) and the solvent evaporated to give 2.1 g of the N-deprotected pyrrolidine 6 (free amine). This latter compound then was oxidized to the nitrone as follows.
To a stirred solution of 6 (1.13 g, 5.0 mmol) and Na 2 WO 4 .2H 2 O (0.82 g, 20 mmol in methanol (25 mL) was added dropwise hydrogen peroxide 33% (2 mL) at 0° C. After stirring at 0° C. for 4 h the solvent was evaporated and the residue taken up with dichloromethane (50 mL), washed with brine (10 mL), dried and evaporated to dryness. The residue was purified by flash chromatography over silica gel and eluted with 20:1 dichloromethane:methanol to give 7 (85%) as a yellow oil.
Similarly the same steps were repeated with 5,5-bis(deuteriomethyl)-3,3-dimethyl-4-carbethoxypyrroline to give the same compound 7 except having two --CD 3 groups at the C-5 position.
By using other phosphorane esters in the Wittig reaction, the number of carbon atoms between the carboxyl ester and the C-4 ring carbon can be varied from 2 carbons e.g. to 6 C atoms. The synthesis is summarized in scheme 1. ##STR4##
EXAMPLE 2
4-(Methoxymethoxymethyl)-3,3,5,5-tetramethyl-1-pyrroline N-oxide(10)
The N-protected 3-hydroxymethylpyrrolidine (3) was prepared as in Example 1. To a solution of 3 (1.45 g, 5.0 mmol) in dichloromethane (50 mL) was added diisopropylamine (1.29 g, 10 mmol) dropwise at 25° C. It was followed by a dropwise addition of a solution of methoxymethylchloride (9.55 g, 6.0 mmol) in dichloromethane (10 mL). After stirring at 25° C. for 2 h, it was diluted with dichloromethane (200 mL) and buffer solution (pH 7, 25 mL). The organic layer was collected, dried over MgSO 4 and evaporated. The resulting solid residue was purified by flash chromatography over silica gel and eluted with 1:5 ethylacetatehexane to give 8 (1.35 g, 81%) as a white solid.
A solution of 8 (10.0 mmol) in 95% ethanol (50 mL) and palladium on charcoal (10%, 200 mg) was hydrogenated under atmospheric pressure for 10 h. The mixture was filtered over Celite® 545 (5 g) and the solvent was evaporated to give 9 in 95% yield as a colourless oil.
To a stirred solution of 9 (5.0 mmol) and Na 2 WO 4 ×2H 2 O (5.0 mmol %) in methanol (25 mL) was added dropwise hydrogen peroxide 33% (15.0 mmol) at 0° C. After stirring at 0° C. for 4 h, the solvent was evaporated to dryness. The solid residue was taken up with dichloromethane (50 mL), washed with brine (10 mL), dried and evaporated to dryness. The residue was purified by flash chromathography over silica gel and eluted with 20:1 dichloromethane:methanol to give 10 4-(methoxymethoxymethyl)-3,3,5,5-tetramethyl-1-pyrroline N-oxide. The procedure is summarized in scheme 2A. ##STR5##
4-(Methoxyethoxymethoxymethyl)-3,3,5,5-tetramethyl-1-pyrroline N-Oxide (13)
To a solution of 3 (1.45 g, 5.0 mmol) in dichloromethane (50 mL) was added diisopropylamine (1.29 g, 10 mmol) dropwise at 25° C. It was followed by a dropwise solution of methoxyethoxymethylchloride (0.74 g, 6.0 mmol) in dichloromethane (10 mL). After stirring at 25° C. for 32 h, the solution was diluted with dichloromethane (200 mL) and pH7 buffer solution (25 mL). The organic layer was collected, dried over MgSO 4 and evaporated. The resulting solid residue was purified by flash chromatography over silica gel and eluted with 1:5 ethylacetate:hexane to give 11 (75%) as a white solid.
A solution of 11 (10.0 mmol) in 95% ethanol (50 mL) and palladium on charcoal (10%, 200 mg) was hydrogenated under atmospheric pressure for 10 h. The mixture was filtered over Celite® 545 (5 g) and the solvent was evaporated to give 12 in 93% yield as a white oil.
To a stirred solution of 12 (5.0 mmol) and Na 2 WO 4 ×2H 2 O (5.0 mmol%) in methanol (25 mL) was added dropwise hydrogen peroxide 33% (15.0 mmol) at 0° C. After stirring at 0° C. for 4 h, the solvent was evaporated to dryness. The solid residue was taken up with dichloromethane (50 mL), washed with brine (10 mL), dried and evaporated to dryness. The residue was purified by flash chromathography over silica gel and eluted with 20:1 dichloromethane:methanol to give 13 in 80% yield as a yellow oil. This preparation is summarized in scheme 2B. ##STR6##
By varying the chloroether reagent, it is possible to introduce other polyether groups in the 4-position.
EXAMPLE 3
4-(N-Malimidobutyryloxymethyl)-3,3,5,5-tetramethylpyrroline-N-oxide (17)
Compound 3 from example 1 was used as starting material to couple with N-malimidobutyric acid after activation. Two alternative activation /coupling procedures are illustrated.
Procedure (a) Activation of carboxyl group of N-malimidobutyric acid: A solution of N-malimidobutyric acid (14, 0.001 mol, 0.183 g) and SOCl 2 (0.002 mol, 0.238 g) in benzene (15 mL) was warmed at 70° C. for 2 h. The solvent was evaporated in vacuo and the residue collected was used directly for the next step.
Coupling:
The residue dissolved in 3 ml of THF and added dropwise to a solution of 3 (0.001 mol, 0.291 g), Et 3 N (0.0015 mol, 0.2 mL) and 4-dimethylaminopyridine (DMAP, 2 mol %) in THF (15 mL) under argon. The solution was further stirred at 55° C. for 3 h. The reaction mixture was diluted with CH 2 Cl 2 (50 mL) and quenched with NH 4 Cl solution. The organic layer was separated, dried and evaporated in vacuo. The residue was flash chromatographed (elution with ethyl acetate:Hexane, 1:3) to give N(benzyloxycarbonyl)-3-(N-malimidobutyryloxymethyl)-2,2,4,4-tetramethyl-pyrrolidine (15, 0.237 g, 52%).
Procedure (b) Activation of carboxyl group of N-malimidobutyric acid: To a solution of N-malimidobutyric acid (14, 0.0024 mol, 0.439 g) and Et 3 N (0.003 mol, 0.4 mL) in THF (25 mL), under argon, added dropwise freshly prepared 2,4,6-trichlorobenzoyl chloride (0.0024 mol, 0.583 g) in THF (15 mL) at room temperature. The mixture was stirred for 1.5 h. Et 3 N.HCl was filtered and the mother liquor was directly used for the coupling reaction.
Coupling:
The liquor was added to a solution of 3 (0.002 mol, 0.582 g), DMAP (0.0022 mol, 0.268 g) in THF (20 mL) under argon. The solution was stirred at room temperature for 30 minutes. The reaction mixture diluted with CH 2 Cl 2 (100 mL) and quenched with an addition of pH 7 buffer solution (10 mL). The organic layer was collected, dried over MgSO 4 and evaporated in vacuo. The residue was flash chromatographed (elution with EtOAc:Hexane, 1:3) to give 15 (0.848 g, 93%).
30% HBr in Acetic acid (1.0 ml) was added dropwise to a solution of 15 (0.001 mol) in CH 2 Cl 2 (5 mL) at room temperature. After 15 minutes, the reaction was quenched with 10% Na 2 CO 3 solution. The organic layer was collected, dried over MgSO 4 and evaporated in vacuo. The residue was flash chromatographed (elution with CH 2 Cl 2 :MeOH, 40:3) to give 16 (0.276 g, 85%).
Freshly prepared Davis' reagent (0.0022 mol, 0.574 g) was added to a solution of 16 (0.01 mol, 0.322 g) in THF (15 mL). The solution was stirred at room temperature for 20 minutes. The residue obtained was filtered and the solvent was collected and evaporated in vacuo. The residue was flash chromatographed (elution with CH 2 Cl 2 :MeOH, 40:1.5) to give 17 (0.292 g, 87%). This preparation is summarized in scheme 3. ##STR7##
EXAMPLE 4
4-biotinyl-3,3,5,5-tetramethyl-1-pyrroline N-oxide (21)
3-hydroxymethyl-N-(benzyloxycarbonyl)-2,2,4,4-tetramethyl-1-pyrrolidine (compound 3 from Example 1) was used as starting material to couple with biotin after biotin activation.
Activation of carboxyl group of biotin: To a solution of biotin (18, 0.002 mol, 0.488 g) and Et 3 N (0.003 mol, 0.4 mL) in dimethylformamide (DMF) (15 mL), under argon, was added dropwise freshly prepared 2,4,6-trichlorobenzoyl chloride (0.002 mol, 0.486 g) in DMF(5 mL) at 37°-40° C. The mixture was stirred for 1.5 h. It was directly used for the coupling step.
Coupling:
To the above solution was added compound 3 (0.002 mol), and DMAP (0.003 mol) under argon. The mixture was stirred at 40°-45° C. for 1.5 h. The reaction mixture was diluted with CH 2 Cl 2 (100 mL) and quenched with pH7 buffer solution (20 mL). The organic layer was collected, dried over MgSO 4 and evaporated in vacuo. The residue was flash chromatographed (elution with CH 2 Cl 2 :MeOH, 30:1) to give 19 (0.672 g, 65% and 93%) based on recovered starting material.
Trimethylsilyliodide (0.002 mol, 0.4 g) was added dropwise to a solution of 19 (0.001 mol, 0.517 g) in CH 3 CN at room temperature. After 20 minutes, the reaction was quenched with 10% Na 2 CO 3 solution. The organic layer was collected, dried over MgSO 4 and evaporated in vacuo. The residue was flash chromatographed (elution with CH 2 Cl 2 :MeOH, 10:1) to give 20 (0.31 g, 81%).
Freshly prepared Davis reagent (0.0035 mol, 0.9135 g) was added to a solution of 20 (0.001 mol, 0.383 g) in THF (15 mL). The solution was stirred at room temperature for 20 minutes. The residue obtained was filtered and the solvent was collected and evaporated in vacuo. The residue was flash chromatographed (elution with CH 2 Cl 2 :MeOH, 10:1) to give 21 (0.351 g, 85%). This preparation is summarized in scheme 4.
During this formation of the nitrone 21 from free amine 20 the sulfide group of biotin was oxidized to sulphoxide. A milder oxidation would avoid forming the sulphoxide: however the sulphoxide is not detrimental. Both the biotin and oxidized biotin bind to avidin and streptavidin. ##STR8##
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Derivatives of 3,5-substituted pyrroline N-oxides having substituents in the 4-position have been prepared, with the 4-position substituents being selected from certain ester, polyether, and alkanoyl groups, the latter having components which bind to biological substrates. These specific derivatives are effective as spin traps for different types of free radicals to form persistent nitroxide adducts of extended half life. These adducts can be characterized by ESR spectrometry technique and provide information e.g. concerning the identification of free radicals.
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FIELD OF THE INVENTION
This application relates to data communications networks and more particularly to systems and methods for providing communications security in data networks.
BACKGROUND
Communications over data networks has become an essential aspect of today's commercial activities and personal correspondence. One of the major hindrances to a greater acceptance of this medium is the concern over the security of personal and corporation-sensitive information carried between the inside world and the outside world. An important part of any network connected to the outside world today is a security mechanism frequently known as a firewall. A firewall has one simple function, to examine data and pass or reject it based on some established policy information. This policy could range from a very simple set of rules to one that is highly complex with thousands of rules. A firewall that is fast, tolerant to internal faults, and whose policies can be easily changed is desirable, particularly for carrier-grade services.
PRIOR ART
Most current solutions involve large, complex systems to evaluate data, and are mostly static in terms of architecture i.e. their policies can not be changed easily.
There are, of course, several firewall products on the market today. The architecture of some of these products, such as the Netscreen architecture, is composed of several hardware modules in parallel, while others are based entirely in software.
In the hardware based architecture, hot fail-over may be taken into account, but real time policy changing and reconfiguration is limited. i.e. once a session policy examination is launched, policy rule changes are limited in scope.
The prior art in relation to firewall technology is well described in the publication: “A reference Model for Firewall technology” Christopher L. Schuba and Eugene H. Spafford COAST Laboratory, Department of Computer Sciences, Purdue University, 1398 Computer Science Building West Lafayette, Ind. 47907-1398. The publication introduces a reference model that captures existing firewall technologies and allows for an extension to networking technologies to which it was not applied previously. It can serve as a framework in which firewall systems can be designed and validated.
The relevant firewall prior art also includes U.S. Pat. No. 6,141,755 which issued Oct. 31, 2000 to Dowd, et al entitled “Firewall security apparatus for high-speed circuit switched networks”. In this patent, security management is achieved through active connection management with authentication and is suited to the cell-based environment of high-speed circuit switched networks and to the mix of circuit switched traffic, where Internet Protocol (IP) datagrams comprise a fraction of the total traffic. In the patent, information in the signalling cells is used to determine which flows, rather than which individual cells, are allowed to pass through the firewall. A hierarchical method has been devised, in which the physical location of the inter-related components may be de-coupled. Once a flow has been validated, the cells associated with that flow are allowed to proceed through the firewall at line-speed with limited intervention and no performance degradation. The patented invention addresses the need for high-speed throughput but may lack desired fault tolerance because of the single point of failure in flow validation.
Current parallel solutions, i.e. the closest to the present architecture, employ modules, which are complete, or close to complete, firewalls. Consequently, in order to address performance of the firewall relating to a particular policy, entire modules that contain additional, unneeded, functionality must be added.
Hardware-only solutions can make it very difficult to make fast policy changes in the firewall, while software solutions allow fast changes but have slower throughput.
SUMMARY OF THE INVENTION
The firewall architecture of the present solution allows a structure of hardware and software modules to dynamically take advantage of the benefits of both implementations. The architecture allows for the failure or temporary removal/disabling of some of the modules, without the collapse of the entire system.
The present solution allows aspects of the firewall performance relating to particular policies to be upgraded independently of other policies, thereby avoiding the addition of unnecessary functionality. This capability is provided by an architecture based on modules that each address a particular policy.
In the prior art, firewalls are constructed with a small number of complex elements and may or may not have redundant elements. The present solution provides a dynamic, complex structure of simple elements. The structure allows for both hardware and software implementations of the small elements and for redundancy of the modules.
Notes: the term “packet” is used generically herein to refer to a piece of data, not to be confused with the IP term “packet”. A packet hereinafter could refer to data in any layer of the OSI reference model.
Therefore in accordance with a first aspect of the invention there is provided a firewall for a data communications network comprising: sets of modules, each set of the sets including at least one module communicatively coupled to at least one module of another set, and each module being operable to send a received data packet to a communicatively coupled module in dependence upon information contained in the received data packet being in compliance with a particular policy, which compliance is determined by the module.
In accordance with a second aspect of the invention there is provided a method of filtering data packets in a data communications system comprising: providing sets of modules, each set of the sets including at least one module communicatively coupled to at least one module of another set, and operating each module to send a received data packet to a communicatively coupled module in dependence upon information contained in the received data packet being in compliance with a particular policy, which compliance is determined by the module.
In accordance with another aspect of the invention there is provided a method of processing data packets at a firewall in a data communications system, the firewall having sets of modules, each communicatively coupled to at least one module of another set, the method comprising: receiving the data packet at a first set of modules; examining the data packet in relation to a particular policy; and passing the data packet to a communicatively coupled module if the data packet is in compliance with the particular policy.
Accordingly, this invention provides a new way of providing very high-speed firewalls having carrier class availability.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to the attached drawings wherein:
FIG. 1 shows a prior art firewall architecture; and
FIG. 2 is a pictorial view of the firewall architecture of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a high level drawing of the aforementioned Netscreen architecture.
As shown in FIG. 1 the prior art architecture is composed of multiple hardware processing modules 12 connected in parallel. As discussed earlier policy rules for a firewall architecture comprising hardware modules can not be changed dynamically. Thus, once a session has been launched policy rules regarding acceptance or rejection of data cannot be changed.
FIG. 2 illustrates the module concept according to the present invention.
A module can be modelled as a switch 20 as can be seen at the upper section of FIG. 2 . The module evaluates it's data against some defined policy, allowing the data to pass through if the rules are met, or to block it if they are not. A module could examine a single part of a packet at one layer or could analyse the packet across many layers. Each module 22 is implemented in either hardware or software. A module 22 could be implemented in both hardware and software, with both modules having exactly the same functionality. An example module could be a device that examines the source IP address of a packet (in this case we refer to the layer 3 meaning of the term “packet”) and checks it for validity. Each module provides a signal indicating if it is currently busy processing a packet or whether it is free for use.
The basic modules are created into a structure as can be seen in the lower section of FIG. 2 . Each column of the structure contains modules with identical functionality, but not necessarily the same implementation. Some could be built using hardware others written in software.
Each module is connected to some or all of the modules in the next column. Each connection 24 has an assigned weight, with the sum of all weights for connections from a module adding to a constant value. Data is then processed in the following manner:
1. Incoming packets of data are passed to the ingress column (left column in FIG. 2 ) of the structure. 2. The first modules examine their packets and determine whether the data matches their rules and should be passed on or not. If a module determines that the data fails it's criteria, it is discarded and the module indicates that it is free for another packet. 3. Modules that have elected to pass data pick one of its connections for use based on a weighted random calculation. 4. If the connected module indicates that it is busy, the corresponding weight for that connection is adjusted downwards and the weights for the remaining connections are adjusted upwards. Then step 3 is repeated until a free module is found. 5. Once a free module is obtained, the data is passed to it for processing and the current module indicates that it is ready to receive another packet of information. 6. Packets that exit from the right-most column of the structure have met all policy rules.
Preferably, the modules are arranged such that the most important rules concerning the system to be protected are checked first, i.e. the modules associated with these rules are on the ingress side of the structure. In this way, packets that do not conform to these rules are immediately stopped so that module resources are not wasted by first checking other, less important, rules.
There are several advantages with this method of connecting modules in this fashion. The modules can be implemented in either hardware or software at each level of the structure. This allows for some of the modules to take advantage of fast turnaround time for policy changes in software, while still having the faster processing speeds of hardware modules. Although there will be a difference in the processing time for different hardware and software modules, the weighting system for connections will automatically balance the packet loads to compensate.
Another advantage comes from the redundancy of the structure if one or more modules are removed due to a fault or for updating. The adaptive weighting will adjust to compensate for the missing elements and redirect packets to the remaining modules.
In addition, modules may be added to address specific performance problems rather then duplicating the entire system. In particular, policies for a given application may strain one column or the other more heavily than typical; by the addition of modules only to that column the performance bottleneck can be addressed without adding unnecessary functionality.
The solution efficiently filters packets by having modules on the ingress side examining the most important rules concerning the system to be protected in order to immediately stop packets that do not conform to this rule in order not to waste time examining other rules.
As shown in FIG. 2 an underlying traffic management bus allows modules in each or certain columns to communicate with modules in other columns without using inter-module connections 24 . This allows for policy shortcut options 26 which might occur, for example, if a packet need not be examined in accordance with some rules. In this case the packet is sent directly to a downstream module for examination there. The management bus also facilitates a feedback option 28 . This option might be invoked, for example, if a downstream module determines that a packet is encapsulated and should be reexamined by a previous module or element.
A potential disadvantage of this system is the complexity in the actual implementation of the structure. The number of connections between two columns of N and M modules is N×M, and a firewall with thousands of rules would have a like number of columns. Therefore, the number of connections that could be present in even a small dimensional system could be very large. This causes problems in arbitrating the traffic between modules. Another disadvantage could include difficulty in mapping actual policy to the structure.
Although particular embodiments of the invention have been described and illustrated it will be apparent to one skilled in the art that changes can be made without departing from the basic concept. It is to be understood, however, that such changes will fall within the full scope of the invention as defined in the appended claims.
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A communications security system has been described. The security system in the form of a firewall is made up of a plurality of communicatively coupled sets of modules in a matrix configuration. The modules may be implemented in hardware and software in order to rely on the advantages of each technology. Data packets are typically coupled to an ingress side of the firewall where policy rules having the highest importance are checked first. The result is a high speed system having carrier class availability.
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TECHNICAL FIELD
[0001] The present invention relates to an electric actuator for driving a home-automation screen, of any of the following types: roller blind, shade, curtain, gate, projection screen, or garage door. The actuator of the invention is provided with a spring brake. This type of brake is more particularly adapted to tubular motors.
STATE OF THE ART
[0002] Use of a helical-spring brake in actuators for home-automation screens is known, in particular from Patent Document FR B 2 610 668. In that document, a helical spring is mounted in a friction part. At least one turn of the spring is stressed radially by a bore in the friction part. Each end of the spring forms a tab extending radially towards the inside of the spring. Each tab can be moved in order to drive the spring in rotation about its axis. The inlet part, the outlet part, and the spring are arranged specifically to obtain the following dynamic behavior: action from the inlet part situated on one side of the first tab causes the spring to move in rotation in a first direction. This movement releases the outlet part, i.e. it tends to reduce the diameter of the outside envelope of the spring. Thus, the friction between the bore in the friction part and the turns of the spring decreases, thereby reducing the radial stress between the spring and the friction part. Conversely, action from the outlet part on the opposite side of the first tab causes the spring to move in rotation in the second direction, i.e. in the opposite direction. This movement blocks the outlet part, i.e. it tends to increase the diameter of the outside envelope of the spring. The friction between the bore in the friction part and the turns of the spring therefore increases. The same applies for the radial stress between the spring and the friction part. In addition, the inlet part can also act on the second tab of the spring in order to drive the spring in rotation in the second direction, while also releasing the outlet part. Furthermore, the outlet part can also act on the second tab of the spring in order to drive the spring in rotation in the first direction. In which case, the outlet part is blocked, or at least is braked by means of the spring rubbing against the friction part. Therefore, the inlet part moving in rotation makes it possible for the spring and for the outlet part to be moved in rotation, while the outlet part moving in rotation blocks the movement begun by the outlet part.
[0003] The main braking of the outlet part is thus obtained by the spring rubbing against the friction part. A second phenomenon contributes to the braking of the outlet part, namely the outlet part rubbing at its guide means. This rubbing is directly related to the torque applied to the brake. When drive torque is exerted on the inlet part, the inlet part applies a force on the outlet part via a tab of the spring. Since that force is asymmetrical about the axis of the outlet part, it induces a radial force that causes the outlet part to be moved until it bears against its guide means. That contact brakes the outlet part. When torque is exerted on the outlet part, said outlet part applies a force on a tab of the spring that tends to hold the spring stationary in rotation. In reaction to that asymmetrical force, a radial force causes the outlet part to be moved until it bears against its guide means. Thus, in conventional spring brake designs, secondary braking torque exists that is added to the main braking torque of the spring against the friction part. That secondary braking torque is then applied both while the screen is being raised and also while it is being lowered.
[0004] In Patent EP-B-0 976 909, a spring brake comprises an inlet part having two teeth, an outlet part also having two teeth, a spring, and a friction part. The drive torque exerted on the inlet part is transmitted to the outlet part via a tooth bearing against one of the tabs of the spring, which tab bears against a tooth of the outlet part. Since the force exerted on the outlet part is asymmetrical, it results in a radial force being applied to said outlet part and thus in secondary braking torque being applied. When torque is applied to the outlet part, a phenomenon occurs that is similar to the phenomenon that occurs in the brake of FR-B-2 610 668. A tooth of the outlet part bears against a tab of the spring that blocks the spring. In reaction to that asymmetrical force, a radial force causes the outlet part to be moved until it bears against its guide means.
[0005] The way in which conventional spring brake designs as described in the preceding examples operate suffers from drawbacks in certain configurations. When the actuator drives a screen in the lowering direction, i.e. when the load torque exerted by the weight of the screen at the outlet part is in the same direction as drive torque from the actuator that is exerted at the inlet part, it is advantageous for secondary braking torque to be added to the main braking torque because that reduces the response time of the brake, thereby making the installation safer. Unfortunately, the existence of secondary braking torque while the screen is being raised, i.e. when the load torque exerted by the weight of the screen at the outlet part is opposed to drive torque from the actuator that is exerted at the inlet part, is particularly disadvantageous because the brake brakes continuously, thereby requiring the motor to be over-dimensioned. The motor must not only raise the load, i.e. exert torque that is greater than the load torque, but must also compensate for the secondary braking torque, since said secondary braking torque is added to the load torque.
SUMMARY OF THE INVENTION
[0006] The invention proposes an electric actuator provided with a spring brake that improves the operation of the above-described brakes, while also preserving the advantages of those brakes. In order to optimize dimensioning of the motor, the invention aims to eliminate the secondary braking torque while the load is being raised. To this end, the invention provides an electric actuator for driving a home-automation screen mounted to move between an open position and a closed position, said actuator being provided with a spring brake, said brake comprising:
a helical spring, each end of which forms a respective tab extending radially or axially relative to a central axis of the spring; a friction part having a substantially cylindrical friction surface against which at least one turn of the helical spring bears radially; an inlet part driven by an electric motor of the actuator, and suitable for coming into contact with at least one tab of the spring, in such a manner as to drive the spring in rotation about a central axis of the brake, in a direction making it possible to reduce the contact force between the helical spring and the friction surface; and an outlet part connected to the screen and suitable for coming into contact with at least one tab of the spring in such a manner as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the helical spring and the friction surface.
[0011] In this actuator, while the screen is being lowered, the inlet part drives the spring in rotation with the contact force being decreased to the extent that the outlet part is released in rotation, without direct contact between the inlet part and the outlet part. According to the invention, the inlet part has at least two contact surfaces suitable for transmitting drive torque for raising the screen, by direct contact, to at least two corresponding contact surfaces of the outlet part.
[0012] The screen generates load torque at the outlet part, which torque makes it possible to generate secondary braking torque. As a result, this actuator is particularly suitable for screens that move vertically and whose weight makes it possible to generate the preceding load torque. This may be for winding an apron around a tube or for swinging a garage door between a horizontal position and a vertical position.
[0013] The inlet part and the outlet part are in direct contact only while the screen is being raised. Thus, during lowering, these two parts are not in direct contact for transmitting the drive torque. During lowering, the inlet part releases the brake by acting only on one of the tabs of the spring. The drive torque is exerted on that tab. No force is transmitted between the inlet part and the outlet part. The outlet part is retained by the other tab of the spring. As a result, it exerts a force, generated by the load torque, on that tab only, so as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the helical spring and the friction surface.
[0014] In the present description “direct contact” between two parts means that one part acts on the other either by direct co-operation of complementary surfaces, or by co-operation between complementary surfaces through another part that is rigid disposed between these surfaces, or else by a combination of the preceding types of co-operation. Direct contact can be obtained by one or more contact surfaces disposed on the outlet part, such a contact surface being a surface against which there comes to bear a complementary contact surface of the inlet part or a complementary surface of an intermediate part urged by the inlet part. In order to implement the invention, it is necessary for the torque to be transmitted via at least two contact surfaces of the outlet part.
[0015] The balancing of the drive torque that makes it possible to reduce the secondary braking torque during raising can be achieved astutely by transmitting the drive torque via a plurality of sets of contact surfaces disposed, about the axis of rotation of the spring, in a manner such that the drive torque is transmitted in substantially balanced manner, making the outlet part relatively unstressed radially. These sets of surfaces can be disposed about the axis of the outlet part in a manner such as to reduce or eliminate the induced radial force. For example, the torque can be transmitted via two contact surfaces of the outlet part that are substantially identical and that are diametrically opposite each other about the axis of the outlet part. This solution is simple to implement.
[0016] Advantageously, operation of the brake is identical, regardless of the direction of the drive torque for raising the screen. This characteristic makes it possible to obtain a versatile actuator that can be installed independently of the configuration of the screen. For example, for a tubular actuator that fits into a winding tube, operation of the actuator is identical regardless of whether the screen is wound in one direction or in the opposite direction. This symmetrical operation of the brake makes it possible to rationalize a product range and to facilitate installation of the actuator because there is no need to distinguish whether the motor should be mounted in a particular manner relative to the screen.
[0017] According to other advantageous but non-essential aspects of the invention:
in the absence of drive torque, the outlet part exerts a force on the tab of the spring in such a manner as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the spring and the friction surface; at at least one contact surface, the direct contact between the inlet part and the outlet part is achieved by means of a rigid part such as one of the tabs of the spring; the configuration of the contact surfaces makes it possible to balance the transmission of the raising drive torque, in such a manner as to eliminate or significantly reduce the radial component, relative to the axis of rotation of the spring, of the forces transmitted to the outlet part; and the two contact surfaces of the outlet part are diametrically opposite each other about the axis of the outlet part.
[0022] Provision may be made for the outlet part to be suitable for coming into contact with a part having dynamic behavior different from that of the outlet part, in particular a part secured to or integral with the friction part or the inlet part, when a radial force is exerted on the outlet part, said radial force being generated only while the screen is being lowered.
[0023] The outlet part is advantageously suitable for coming to bear against a centering member for centering the outlet part relative to the inlet part under the effect of the radial component of the resultant of the load torque exerted by the screen, while the screen is being lowered.
[0024] Provision may be made for the outlet part to be guided in rotation relative to the inlet part. The inlet part and the outlet part must be centered relative to each other. The inlet part and the outlet part may be centered by a shaft passing through said parts. The shaft is mounted in tight-fitting manner in the inlet part or in the outlet part and is mounted to slide in the other part, i.e. respectively in the outlet part or in the inlet part. This centering is simple to achieve and is compact. The sub-assembly formed by the inlet part and by the outlet part is then advantageously centered relative to the friction part. This centering may be achieved either by the outlet part, or by the inlet part. Preferably, the sub-assembly is centered by the inlet part, because that makes it possible to reduce the vibration of the brake considerably.
DESCRIPTION OF THE DRAWINGS
[0025] The invention can be better understood on reading the following description given merely by way of example and with reference to the accompanying drawings, in which:
[0026] FIG. 1 is a diagrammatic view of the architecture of a tubular actuator of the invention that incorporates a spring brake of the invention;
[0027] FIG. 2 is an exploded perspective view of a spring brake belonging to the actuator of FIG. 1 ;
[0028] FIG. 3 is a diagrammatic cross-section view of operation of the spring brake 2 of FIG. 2 during raising of a load;
[0029] FIG. 4 is a diagrammatic cross-section view of operation of the spring brake 2 during lowering of a load;
[0030] FIG. 5 is a diagrammatic cross-section view of operation of a prior art spring brake during raising of a load;
[0031] FIG. 6 is an exploded perspective view of a second embodiment of a spring brake that can be part of the actuator of FIG. 1 ;
[0032] FIG. 7 is an exploded perspective view from a different angle of certain component elements of the spring brake of FIG. 6 ;
[0033] FIG. 8 is a diagrammatic end view seen looking along arrow F in FIG. 6 , and partially in cross-section, showing operation of the spring brake of FIG. 6 during raising of a load that generates torque in the clockwise direction on the outlet part of the brake;
[0034] FIG. 9 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during lowering of a load that generates torque in the clockwise direction on the outlet part of the brake;
[0035] FIG. 10 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during raising of a load that generates torque in the counterclockwise direction on the outlet part of the brake; and
[0036] FIG. 11 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during lowering of a load that generates torque in the counterclockwise direction on the outlet part of the brake.
DESCRIPTION OF EMBODIMENTS
[0037] FIG. 1 diagrammatically shows a rotary tubular actuator 100 designed to drive in rotation a winding tube 1 on which an apron 2 for closing an opening 0 can be wound to various extents. The tube 1 is driven by the actuator 100 in rotation about an axis of revolution X-X that is disposed horizontally at the top of the opening. For example, the opening O is an opening provided in the walls of a building. The actuator 100 , the tube 1 , and the apron 2 then form a motor-driven roller blind.
[0038] The actuator 100 comprises a stationary cylindrical tube 101 in which a motor-and-gearbox unit 102 is mounted that is made up of an electric motor 103 , a first gearbox stage 104 , a spring brake 105 , a second gearbox stage 106 , and an outlet shaft 107 that projects at one end 101 A of the tube 101 , and that drives a wheel-ring 3 that is constrained to rotate with the tube 1 .
[0039] The winding tube 1 turns about the axis X-X and about the stationary tube 101 by means of two pivot couplings. A bearing-ring 4 mounted on the outside periphery of the tube 101 in the vicinity of its end 101 B opposite from the end 101 A forms the first pivot coupling. The second pivot coupling is installed at the other end of the tube 1 and is not shown.
[0040] The actuator 100 further comprises a fastening part 109 that projects from the end 101 E and that makes it possible to fasten the actuator 100 to a frame 5 . Said fastening part 109 is, in addition, designed to close off the tube 101 and to support a control module 108 for controlling the power supply to the motor 103 . Said control module is powered via a mains power supply cable 6 .
[0041] While the tubular actuator 100 is operating, the motor-and-gearbox unit 102 drives in rotation the shaft 107 which, in turn, drives in rotation the tube 1 via the wheel-ring 3 . For example, when the actuator 100 is installed in a roller blind case, the shaft 103 rotating causes the opening O to be opened and to be closed in alternation. The apron 2 thus moves vertically in the opening O, between an opening high position and a closure low position.
[0042] FIGS. 2 to 4 more particularly show the structure of the spring brake 105 in a first embodiment of the invention. As shown in FIG. 1 , a rotor of the motor 103 drives an epicyclic gear train of the first gearbox stage 104 . The cylinder 110 of the epicyclic train that carries three planet gears also forms an inlet part of the brake 105 . The brake 105 includes a helical spring 130 having its turns centered on an axis X 130 that coincides with the axis X-X when the brake 105 is in place, as shown in FIG. 1 . Said spring is mounted in tight-fitting manner inside a bore 141 in a friction part 140 . In other words, the outside envelope 131 of the spring 130 , which envelope is defined by the outside generator lines of its turns, bears against the radial surface of the bore 141 , thereby tending to secure together the spring 130 and the part 140 by friction.
[0043] Each end of the spring 130 forms a tab 132 a, 132 b extending radially towards the axis X 130 and towards the inside of the spring, from its turns.
[0044] The inlet part 110 is provided with two protuberances or “teeth” 111 a and 111 b that fit into the helical spring 130 . Each protuberance 111 a or 111 b has a face 113 a or 113 b suitable for being in contact respectively with a surface 133 a of a first tab 132 a forming the first end of the spring or with a surface 133 b of the second tab 132 b forming the second end of the spring. The surface 133 a is disposed in a manner such that action on said surface causes the spring to be moved in rotation about the axis X 130 in a direction that is opposite from the direction of rotation of the spring if the action is exerted on the surface 133 b.
[0045] Action by one of the teeth 111 a or 111 b on a surface 133 a or 133 b tends to release the brake, i.e. to move one of the tabs 132 a or 132 b in a manner such that the radial stress between the outside envelope 131 of the helical spring 130 and the friction surface of the bore 141 decreases. This action from one of the teeth 111 a or 111 b tends to contract the spring 130 radially about the axis X-X, so that its outside envelope moves away from the surface of the bore 141 . The part 110 thus makes it possible to act on the spring 130 to reduce the contact force between the spring and the friction surface of the bore 141 . The spring can then turn about the axis X 130 that coincides with the central axis X 105 of the brake 105 , itself coinciding with the axis X-X when the actuator 100 is in the assembled configuration shown in FIG. 1 . A direction or a dimension is said to be “axial” when it extends or is measured parallel to the axis X 105 . A direction is said to be radial when it is perpendicular to and intersects the axis X 105 .
[0046] An outlet part 120 of the brake 105 is situated in register with the inlet part 110 . The outlet part is provided with two lugs 121 a, 121 c also fitting into the helical spring 130 . The lug 121 a is provided with two recesses or setbacks 122 a, 122 b disposed on either side of said lug. Each recess 122 a or 122 b is designed to receive a respective one of the tabs 132 a, 132 b of the spring and is defined partially by a surface 124 a, 124 b suitable for being in contact with a surface 134 a, 134 b of a tab 132 a, 132 b. The surfaces 134 a and 134 b are opposite from respective ones of the surfaces 133 a and 133 b.
[0047] Action on one of the surfaces 134 a, 134 b tends to move the tabs 132 a and 132 b apart, thereby causing the turns of the spring 130 to expand radially relative to the axis X 130 and increasing the contact force between the spring 130 and the friction surface of the bore 141 . This results in actuating the brake, i.e. in blocking or in strongly braking the rotation of the spring 130 relative to the part 140 . Thus, the radial stress between the outside envelope 131 of the helical spring and the friction surface 141 increases, thereby holding the part 120 stationary or braking it strongly about the axes X 105 and X 130 .
[0048] In order to enable the brake to operate, it is necessary to have angular clearance between the teeth 111 a and 111 b of the inlet part 110 and the tabs 132 a and 132 b of the spring. Similarly, angular clearance is also necessary between the lug 121 a and the tabs 132 a and 132 b of the spring. The width of the lug 121 a is designed for this purpose. In addition, the axial length L 111 or L 121 of the portions 111 a, 111 b, and 121 a is slightly greater than the axial length L 130 of the spring.
[0049] The outlet part 120 is also provided with a set of teeth 129 forming the interface with the second gearbox stage 106 .
[0050] The necessary centering of the outlet part 120 relative to the inlet part 110 is achieved by a shaft 118 projecting axially relative to the inlet part, on the same side as the outlet part 120 . Said shaft 118 serves as guide means for guiding the outlet part, by means of a bore 128 provided through the center of said outlet part.
[0051] As appears more particularly from FIGS. 3 to 4 , the load L constituted by the apron 2 can be considered as being secured to the outlet part 120 , via the elements 1 , 3 , 106 , and 107 , as indicated by the vertical dashed line in FIGS. 3 and 4 .
[0052] The weight of the load L exerts torque C L on the outlet part 120 that tends to cause it to turn about the axis X 105 , in the clockwise direction in FIGS. 3 and 4 .
[0053] Reference X 120 designates the central axis of the outlet part 120 , which axis coincides with the axis X 105 when the brake is in the assembled configuration.
[0054] While the load L is being raised, and as shown diagrammatically in FIG. 3 , rotation of the outlet part 120 in the clockwise direction in FIG. 3 , which rotation is normally induced by the torque C L , is blocked by the inlet part 110 . The inlet part 110 is driven in rotation in the counterclockwise direction in FIG. 3 by torque C M generated by the motor and weighted by the efficiency of the first gearbox stage 104 . The two protuberances 111 a and 111 b of the inlet part 110 pivot about the coinciding axes X 105 and X-X until one of the protuberances 111 a or 111 b is in contact with a face 123 a or 123 b of the lug 121 a of the outlet part. Whereupon, the other protuberance 111 b or 111 a also enters into contact with one of the faces 123 c or 123 d of the second lug 121 c of the outlet part. Therefore, the drive torque C M is transmitted to the outlet part via two sets of contact surfaces, formed between the faces 113 a and 113 d and the faces 123 a and 123 d that are diametrically opposite each other about the axis X 105 and about the axis X 120 of the outlet part, thereby causing the radial component of the resultant of the torque C M exerted on the outlet part 120 to be reduced or eliminated. The drive torque C M is of opposite direction to the load torque C L . The faces 123 a and 123 d constitute the contact surfaces of the outlet part 120 .
[0055] The balance of the forces to which the outlet part 120 is subjected is shown in FIG. 3 . The load torque C L is balanced by forces F 1a and F 1b resulting respectively from the surface 113 a of the tooth 111 a and the surface 123 a of the lug 121 a bearing against each other, and from the surface 113 d of the tooth 111 b and the surface 123 d of the lug 121 c bearing against each other. These two forces F 1a and F 1b express in terms of forces the drive torque C M necessary for overcoming the load torque C L . Since the two forces F 1a and F 1b are of substantially the same magnitude and are substantially symmetrical about the central axis X 120 of the outlet part, the radial component of the resultant of the torque C M of the outlet part 120 is negligible, or even zero. It should be noted that the shaft 118 of the inlet part making it possible to center the outlet part is not in contact with the bore 128 of the outlet part in this configuration, due to the fact that the radial component of the above-mentioned resultant is negligible.
[0056] In order to raise the load, the torque C M must be greater than the sum of the load torque C L and of the drag torque of the brake spring due to the residual friction between the outside envelope 131 of the spring and the friction surface of the bore 141 . At start-up, the torque C M to be exerted must be larger because, in order to release the brake 105 , it is necessary to overcome a static friction force. Thus, the protuberance 111 a acts on one of the tabs of the spring, which tab is, in this example, the tab 132 a, received in the recess 122 a, as soon as the lug 121 a is driven in rotation.
[0057] While the load L is being lowered, and as shown diagrammatically in FIG. 4 , the outlet part rotating in the clockwise direction in FIG. 4 is not stopped by the inlet part but by the spring 130 . Thus, the load torque C L presses the lug 121 a against one of the tabs 132 a or 132 b, namely the tab 132 a in this example. The effect of this is to expand the turns of the spring 130 radially and to activate the brake 105 , as explained above. The torque C L exerted by the lug 121 a on the surface 134 a of the tab 132 a is weighted by the efficiency of the second gearbox stage 106 . The tab 132 a is engaged in the recess 122 a. The drive torque C M is in the same direction as the load torque C L .
[0058] The balance of the forces of the outlet part is shown in FIG. 4 . The load torque C L is balanced by two forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the face 134 a of the tab 132 a of the spring 130 against the bearing face 124 a of the recess 122 a. Since said first force F 2a does not make it possible to compensate for the load torque C L fully, the outlet part 120 tends to move perpendicularly to the axis X 105 , relative to the preceding bearing configuration, until the outlet part comes into contact with its guide means formed by the shaft 118 that is secured to or integral with the inlet part 110 . The bore 128 for guiding the outlet part thus comes into contact with the shaft 118 , then generating the second radial force F 2b making it possible to balance the load torque C L . Said second force F 2b generates friction during the downward movement of the load. This friction brakes the load and is added to the braking torque of the spring. It thus contributes to the reactivity of the brake. The response time of the brake is faster than the response time of a brake for which said friction does not exist.
[0059] It should be noted that, for this embodiment, the inlet part 110 is itself centered relative to the friction part 140 by means of a cylindrical web whose envelope surface (not shown) co-operates with the bore 141 in the friction part. Therefore, the preceding force F 2b induces an equivalent force (not shown) between the inlet part 110 and the friction part 140 . Said equivalent force participates in the secondary braking torque and contributes to the reactivity of the brake.
[0060] In order to make it possible to lower the load, it is necessary to release the brake. For this purpose, the drive torque C M drives the protuberances 111 a and 111 b of the inlet part 110 in rotation, the protuberance 111 b being driven by said drive torque until it comes into abutment against the face 133 b of the tab 132 b of the spring 130 . By this action, the spring 130 is relaxed and the outlet part 120 can turn, by means of the load torque C L . The parts 110 and 120 are then not in direct contact.
[0061] If the direction of winding of the load is reversed, operation is identical. Operation of the brake is thus symmetrical, which makes it easier for it to be installed because the performance of the brake is the same, regardless of the raising direction of the actuator, i.e. regardless of the direction of the drive torque C M that serves to raise the screen 2 .
[0062] FIG. 5 shows a conventional prior art spring brake, and more particularly how it behaves during raising. The portions of the brake that are shown in FIG. 5 and that are analogous to the portions of the brake 105 bear like references minus 100 . For that type of brake, the outlet part is not designed to balance the load torque during raising. The outlet part 20 is provided with one lug 21 a only. During raising, operation is similar to operation of the brake 105 in the configuration shown in FIG. 3 . The drive torque C M drives a protuberance 11 a in rotation until said protuberance comes into contact with one face 33 a of a tab 32 a of the spring 30 . The opposite face 34 a of the tab is in abutment against a face 23 a of the lug 21 a of the outlet part 20 by means of the load torque C L .
[0063] Therefore, the drive torque C M is transmitted to the outlet part 20 via the tab 32 a of the spring 30 .
[0064] In the embodiment of the invention that is described above with reference to FIGS. 1 to 4 , the drive torque is transmitted directly to the outlet part 120 by contact between one face 113 a of the inlet part 110 and one face 123 a of the outlet part 120 , the spring tab then being retracted into the recess 122 a provided for this purpose. This makes it possible to achieve better torque transmission and to stress the parts less.
[0065] In the brake shown in FIG. 5 , the load torque CL is not sufficiently taken up by a tab 32 a of the spring to balance said torque, and therefore induces a radial force on the outlet part 20 . That radial force causes the outlet part to move until it is in contact with its guide means that are formed by the bore 41 in the friction part 40 . The outlet part 20 has a cylindrical web whose envelope surface 25 makes it possible to perform the guiding in the bore 41 . Thus, the load torque is balanced firstly by a force F′ 1a corresponding to the lug 21 a bearing against the tab 32 a of the spring 30 and secondly by a force F′ 1b , resulting from the outlet part 20 bearing against the bore 41 in the friction part 40 . Given that, during raising, the outlet part 20 has a relative speed relative to the friction part 40 , said force F′ 1b generates friction during the load-raising movement. In order to lift the load L, the drive torque C M must therefore be greater than the sum of the load torque C L , of said friction, and, on start-up, of the torque necessary to release the brake. Therefore, said friction adversely affects the dimensioning of the motor because said motor must be more powerful in order to compensate for the additional friction resulting from the force F′ 1b .
[0066] For lowering the load, operation is analogous to the operation shown in FIG. 3 for the brake of the invention. Balancing of the forces is, however, more similar to the balancing shown in FIG. 5 . The load is braked by the braking torque of the spring 30 and by the friction with the guide means formed by the bore 41 in the outlet part.
[0067] FIGS. 4 and 5 show two different guide means for guiding the outlet part 20 or 120 . In FIG. 4 , the outlet part 120 is guided relative to the inlet part 110 . The inlet part 110 is also centered relative to the friction part 140 . In FIG. 5 , the outlet part 20 is guided relative to the friction part 40 that is stationary. Tests have shown that the brake 105 behaves better in the FIG. 4 situation. The centering of the outlet part relative to the inlet part makes it possible to reduce the vibration of the brake.
[0068] FIGS. 6 to 11 show a second embodiment of the brake. The operating principle is close to the first embodiment. The references of these parts are analogous to the references of the first embodiment, plus 100 .
[0069] The outlet of the epicyclic gear train of the first gearbox stage 104 drives in rotation a part 210 forming the inlet of the brake 105 . The inlet part 210 is provided with a polygonal shaft 219 designed to receive and to transmit torque coming from the gearbox stage 104 . The brake 105 includes a helical spring 230 whose turns are centered on an axis X 230 that coincides with the axis
[0070] X-X when the brake 105 is in place as shown in FIG. 1 . The axes X 230 and X-X coincide with the central axis X 105 of the brake 105 when an actuator 100 incorporating the brake 105 of this second embodiment is in the assembled configuration.
[0071] The spring 230 is mounted in tight-fitting manner inside a bore 241 in a friction part 240 . In other words, the outside envelope 231 of the spring 230 , which envelope is defined by the outside generator lines of its turns, bears against the radial surface of the bore 241 , thereby tending to secure together the spring 230 and the part 240 by friction.
[0072] Each end of the spring 230 forms a tab 232 a, 232 b extending radially towards the axis X 230 and towards the inside the spring, from its turns.
[0073] The inlet part 210 is provided with a protuberance or “tooth” 211 a that fits into the helical spring 230 , between the tabs 232 a and 232 b. Said tooth 211 a has two faces 213 a, 213 b suitable for being in contact respectively with a surface 233 a of a first tab 232 a forming the first end of the spring and with a surface 233 b of the second tab 232 b forming the second end of the spring. The surface 233 a is disposed in a manner such that action on said surface causes the spring to be moved in rotation about the axis X 230 in a direction that is opposite from the direction of rotation of the spring if the action is exerted on the surface 233 b.
[0074] Action by the tooth 211 a on a surface 233 a or 233 b tends to release the brake, i.e. to drive the tab 232 a or 232 b in rotation about the axes X 230 and X 105 , in a direction such that the radial stress between the outside envelope 231 of the spring 230 and the friction surface of the bore 241 decreases. Action from the tooth 211 a on one of the faces 233 a or 233 b tends to contract the spring 230 radially about the axis X-X, so that its outside envelope moves away from the surface of the bore 241 . The part 210 thus makes it possible to act on the spring 230 to reduce the contact force between the spring and the friction surface of the bore 241 .
[0075] An outlet part 220 of the brake 105 is situated in register with the inlet part 210 . The outlet part is provided with two lugs 221 a, 221 b also fitting into the helical spring 230 . Each lug is provided with a recess or a setback 222 a, 222 b designed to receive a respective one of the tabs 232 a, 232 b of the spring 230 . Each recess 222 a, 222 b is defined partially by a surface 224 a, 224 b suitable for being in contact with a surface 234 a, 234 b of a tab 232 a, 232 b. The surfaces 234 a and 234 b are opposite from respective ones of the surfaces 233 a and 233 b.
[0076] Action on one of the surfaces 234 a, 234 b tends to move the tabs 232 a and 232 b towards each other, thereby causing the turns of the spring 230 to expand radially relative to the axis X 230 and increasing the contact force between the outside envelope 231 of the spring 230 and the friction surface of the bore 241 . This results in actuating the brake, i.e. in blocking or in strongly braking the rotation of the spring 230 relative to the part 240 . Thus, the radial stress between the outside envelope 231 of the helical spring and the friction surface 241 increases.
[0077] In addition, each lug 221 a, 221 b of the outlet part 220 is provided with a projecting portion 226 a, 226 b extending axially towards the inlet part and suitable for being received in respective ones of banana-shaped slots 216 c, 216 d in the inlet part 210 , once the brake 105 is assembled. Said projecting portions 226 a and 226 b are dimensioned and disposed in a manner such that their faces 227 a, 227 b are in contact with respective ones of inside faces 217 c, 217 d defining the corresponding slots 216 c, 216 d when the face 213 b, 213 a of the tooth 211 a of the inlet part 210 is in contact with the face 223 b, 223 a of a lug 221 b, 221 a of the outlet part 220 .
[0078] FIGS. 8 and 10 show the two possible configurations for the brake 105 . The dimensioning of the slots 216 c, 216 d is such that, outside the two preceding configurations, the projecting portions 226 a, 226 b do not come into abutment against any inside surface of the slot.
[0079] In order to enable the brake to operate, it is necessary to have angular clearance between the tooth 211 a of the inlet part 210 and the tabs 232 a and 232 b of the spring. Similarly, angular clearance is also necessary between the lugs 221 a and 221 b and the tabs 232 a and 232 b of the spring. The width of the tooth 211 a is designed for this purpose. In addition, the axial length L 211 or L 221 of the portions 211 a, 221 a, and 221 b is slightly greater than the axial length L 230 of the spring.
[0080] The necessary centering of the outlet part 220 relative to the inlet part 210 is achieved by a shaft 270 . Said shaft is engaged in a centered bore 218 of the inlet part 210 . A portion of the shaft 270 projects from the same side as the outlet part 220 .
[0081] FIGS. 8 to 11 show how the brake 105 operates. FIGS. 8 and 9 correspond to the screen being wound on the shaft 1 in the clockwise direction in said figures. FIG. 8 shows the load being raised, while FIG. 9 shows the load being lowered. FIGS. 10 and 11 correspond to the screen being wound on the shaft 1 in the counterclockwise direction in these figures. FIG. 10 shows the load being raised while FIG. 11 shows it being lowered.
[0082] Firstly, operation of the brake is explained relative to the first screen-winding configuration, i.e. to winding in the clockwise direction in FIGS. 8 and 9 .
[0083] By default, the weight of the load L exerts torque C L on the part 220 that presses one of the lugs 221 a or 221 b, namely the lug 221 b in this example, against one of the tabs 232 a or 232 b, namely the tab 232 b in this example, as shown in FIG. 9 . The effect of this is to expand the turns of the spring 230 radially and to activate the brake 105 , as explained above. The torque C L exerted by the lug 221 b on the surface 234 b of the tab 232 b is weighted by the efficiency of the second gearbox stage 106 . This torque is shown by a vector associated with the lug 221 b. The tab 232 b is then engaged in the recess 224 b.
[0084] While the load L is being raised, and as shown in FIG. 8 , the inlet part 210 is driven in rotation by torque C M generated by the motor and weighted by the efficiency of the first gearbox stage 104 . The protuberance 211 a of the inlet part then turns until it is in contact with the lug 221 b of the outlet part, at the interface between the surfaces 213 b and 223 b. In order to raise the load, the torque C M must then be greater than the sum of the torque C L and of drag torque of the brake spring due to the residual friction between the outside envelope of the spring and the friction surface of the bore 241 . The torque C M is represented by a vector in dashed lines associated with the inlet part.
[0085] At start-up, the torque C M to be exerted must be larger because, in order to release the brake 105 , it is necessary to overcome a static friction force. In order to release the brake 105 , the protuberance 211 a acts on the tab 232 b received in the recess 222 b whenever the lug 221 b is driven in rotation. The drive torque C M is transmitted from the inlet part 210 to the outlet part 220 by double contact. On one side, the face 213 b of the protuberance 211 a bears against the face 223 b of the lug 221 b. And, diametrically opposite, the inside face 217 c of the slot 216 c bears against the face 227 a of the projecting portion 226 a. Thus, the load torque C L is balanced by efforts F 1a and F 1b resulting from the bearing between the portions 211 a and 221 b, on one side, and 216 c and 226 a, on the other side. Since these two forces are of substantially the same magnitude and are substantially symmetrical about the central axis X 105 of the brake 105 and about the axis X 220 of the outlet part, the radial component of the resultant of the torque C M on the outlet part is negligible, or indeed zero. The faces 223 b and 227 a constitute contact surfaces of the outlet part.
[0086] While the load L is being lowered, as shown diagrammatically in FIG. 9 , the outlet part 220 is not stopped by the inlet part 210 but rather it is stopped by the spring 230 . Thus, the load torque C L presses the lug 221 b against one of the tabs 232 a or 232 b, namely the tab 232 b in this example. The effect of this is to cause the turns of the spring 230 to expand radially and to activate the brake 105 , as explained above.
[0087] The torque C L exerted by the lug 221 b on the surface 234 b of the tab 232 b is weighted by the efficiency of the second gearbox stage 106 . The tab 232 b is engaged in the recess 222 b. The drive torque C M is in the same direction as the load torque C L . The balance of the forces is then different from the balance during raising. The load torque C L is balanced by forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the spring that blocks the load at the interface between the face 234 b of the tab 232 b of the spring 230 and the bearing face 224 b of the recess 222 b of the lug 221 b of the outlet part. Since the first force F 2a does not make it possible to compensate for the load torque C L , the outlet part 220 tends to pivot relative to the preceding bearing configuration until the outlet part is in contact with its guide means formed by the shaft 270 that is secured to or integral with the inlet part 210 . The bore 228 for guiding the outlet part 220 relative to the shaft 270 thus comes into contact with the shaft 270 , thereby generating the second force F 2b making it possible to balance the load torque C L . This force is radial relative to the axis X 220 . This force F 2b generates friction while the load L is moving downwards. This friction brakes the load and is added to the braking torque of the spring. It therefore contributes to the reactivity of the brake. Its response time is faster than the response time of a brake for which such friction does not exist.
[0088] It should be noted that, for this embodiment, the inlet part 210 is itself centered relative to the friction part 240 by means of a cylindrical web whose envelope surface (not shown) co-operates with the bore 241 of the friction part. Therefore, the preceding force F 2b then induces an equivalent force (not shown) between the inlet part 210 and the friction part 240 . This equivalent force participates in the secondary braking torque contributing to the reactivity of the brake.
[0089] In order to enable the load to be lowered, it is necessary to release the brake. For this purpose, the drive torque C M drives a protuberance 211 a on the inlet part in rotation until it comes to bear against the face 233 a of the tab 232 a of the spring 230 . By this action, the spring 230 is relaxed and the outlet part 220 can turn, by means of the load torque C L , since the parts 210 and 220 are then not in direct contact.
[0090] Operation of the brake in the second winding configuration is shown in FIGS. 10 and 11 .
[0091] During raising, and as shown in FIG. 10 , the load torque C L is balanced by the forces F 1a and F 1b resulting firstly from the contact between the face 213 a of the tooth 211 a and the face 223 a of the lug 221 a, and secondly from the contact between the inside face 217 d of the slot 216 d, and the face 227 b of the projecting portion 226 b. Since these forces F 1a and F 2a are balanced, the radial component of the resultant of the torque C M on the outlet part 220 is negligible. The motor must thus deliver drive torque that is greater than the load torque C L to which only the drag torque of the brake is added, which drag torque results from the friction between the spring 230 and the friction part 240 . There is little or no secondary braking torque generated by the friction between the outlet part 220 and its guide shaft 270 . The faces 223 a and 227 b constitute the contact surfaces of the outlet part.
[0092] During lowering, the load torque C L is balanced by the forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the spring 230 blocking the load L at the interface between the face 234 a of the tab 232 a of the spring 230 and the bearing face 224 a of the recess 222 a in the lug 221 a. The second force F 2b corresponds to a localized force at the guide shaft 270 of the outlet part 220 , while the parts 210 and 220 are not in direct contact. This friction generates a radial force braking the load. Thus, the brake reacts rapidly because the secondary braking torque no longer becomes negligible.
[0093] The two embodiments describe a brake spring whose ends are folded over towards the inside of the spring. Naturally, said ends can be folded over towards the outside of said spring. Another variant consists in folding over the ends parallel to the central axis of the spring. The tabs then extend axially on either side of the spring, while extending away from the center of the spring.
[0094] In addition, the spring brake does not specifically have to be received between two gearbox stages. It can be disposed at the outlet of the motor or at the outlet of the gearbox.
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This electric actuator for driving a home-automation screen is provided with a spring brake ( 105 ) comprising a helical spring ( 130 ), a friction part ( 140 ) having a friction surface ( 141 ) against which the helical spring ( 130 ) bears radially. Said brake further comprises an inlet part ( 110 ) suitable for driving the spring in rotation in a direction reducing the contact force between the spring ( 130 ) and the friction part ( 140 ), and an outlet part ( 120 ) connected to the screen.
While the screen is being lowered, the inlet part ( 110; 210 ) drives the spring ( 130; 230 ) in rotation with the contact force being decreased to the extent that the outlet part ( 120; 220 ) is released in rotation, without direct contact between the inlet part and the outlet part. The inlet part ( 110; 210 ) has at least two contact surfaces ( 113 a, 113 d; 213 b, 217 c ) suitable for transmitting drive torque (C M ) for raising the screen ( 2 ), by direct contact, to at least two corresponding contact surfaces ( 123 a, 123 d; 223 b, 227 a ) of the outlet part ( 120; 220 ).
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TECHNICAL FIELD
[0001] The subject matter described herein relates to the projection of future credit scores for individuals.
BACKGROUND
[0002] A credit score is a numerical expression based on a statistical analysis of credit files (e.g., credit bureau data, etc.) of an individual to represent credit risk associated with such individual. Credit scores can be used by banks, credit card companies, insurance companies, and other entities to evaluate and monitor the potential risks for credit-related transactions with individuals. In particular, credit scores are often used as part of an underwriting process to determine what particular products or services to extend to a particular individual. In some cases, an individual may not immediately qualify for a particular product or service based on their current credit scores or their credit related activity is insufficient to generate a credit score. However, such individuals might, at a future point in time, be eligible for such products or services.
SUMMARY
[0003] In a first aspect, data is received that characterizes a request for a credit score at a future date. Thereafter, data is received that comprises values for each of a plurality of variables used by a predictive scoring model to generate a credit score. With such an arrangement, at least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window can comprise a fixed number of days prior to and including the scoring date. The predictive model can be trained using historical credit data derived from a population of individuals. Subsequently, the values for at least one of the variables are modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including the future date and comprising the fixed number of days. It is then determined, using the modified values and the predictive model, a projected credit score at the future date. Data can then be provided (e.g., transmitted, loaded, persisted, displayed, etc.) that characterizes the projected future credit score.
[0004] In a first interrelated aspect, data is received that characterizes a request for a date at which a consumer will first have a specified credit score. Thereafter, data is received that includes values for each of a plurality of variables used by a predictive scoring model to generate a current credit score for the consumer. At least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window includes a fixed number of days prior to and including the scoring date and the predictive model is trained using historical credit data derived from a population of individuals. Subsequently, values for a least one of the variables are recursively modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including a future date and comprising the fixed number of days and the credit score is determined using the predictive model until such time that the current credit score for the consumer will first equal the specified credit score. Data is then provided that characterizes the date at which the current credit score will first equal the specified credit score.
[0005] In a further interrelated aspect, data is received that characterizes a request for a date at which a consumer will first have a specified increase in a credit score. Thereafter, data is received that includes values for each of a plurality of variables used by a predictive scoring model to generate a current credit score for the consumer. At least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window includes a fixed number of days prior to and including the scoring date and the predictive model is trained using historical credit data derived from a population of individuals. Subsequently, values for a least one of the variables are recursively modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including a future date and comprising the fixed number of days and the credit score is determined using the predictive model until such time that the current credit score will increase to the specified amount. Data is then provided that characterizes the date at which the current credit score will first increase by the specified amount.
[0006] Computer program products are also described that comprise non-transitory computer readable media storing instructions, which when executed by one or more data processors of one or more computing systems, causes at least one data processor to perform operations herein. Similarly, computer systems are also described that may include one or more data processors and a memory coupled to the one or more data processors. The memory may temporarily or permanently store instructions that cause at least one processor to perform one or more of the operations described herein. In addition, methods can be implemented by one or more data processors either within a single computing system or distributed among two or more computing systems. Such computing systems can be connected and can exchange data and/or commands or other instructions or the like via one or more connections, including but not limited to a connection over a network (e.g. the Internet, a wireless wide area network, a local area network, a wide area network, a wired network, or the like), via a direct connection between one or more of the multiple computing systems, etc.
[0007] The subject matter described herein provides many advantages. For example, the current subject matter can be used to identify segments of a population whose credit score is likely to change materially in the near future, so that offerings/underwriting strategies can be tailored to that population based not only on their current credit score but also where such score is likely to be headed. Furthermore, the current subject matter can be used to estimate dates at which credit scores can be generated for individuals with incomplete credit histories.
[0008] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a chart illustrating how various categories of credit related data are weighted by one type of credit score;
[0010] FIG. 2 is a table illustrating the score algorithm for one type of credit score, including various time-based attributes;
[0011] FIG. 3 is a table illustrating credit related data for a first consumer;
[0012] FIG. 4 is a diagram illustrating a sequence of events for the first consumer;
[0013] FIG. 5 is a table illustrating credit related data for a second consumer;
[0014] FIG. 6 is a process flow diagram illustrating a method for projecting future credit scores;
[0015] FIG. 7 is a process flow diagram illustrating a method for projecting a date at which a consumer will have a specified credit score; and
[0016] FIG. 8 is a process flow diagram illustrating a method for projecting a date at which a consumer will have a specified increase in credit score.
DETAILED DESCRIPTION
[0017] Credit scores are typically calculated from several different pieces of credit data from an individual's credit report. With some credit scores, such data can be grouped into five categories: payment history, outstanding debt, credit history length, pursuit of new credit, and credit mix. FIG. 1 is a chart 100 that illustrates percentages that reflect the relative contribution of each category in calculating one type of credit score. With some credit scoring models, points from each such category can be aggregated to result in an overall credit score.
[0018] With reference to the table 200 of FIG. 2 , each category can have one or more time-based attributes which are used to generate points which can, for example, be aggregated (and weighted) across all categories to result in the credit score. For example, for the payment history, the number of points can be based on a number of months since the most recent delinquency exceeding thirty days. The outstanding debt category can be based on an average balance of an individual. The credit history length category can be based on a number of months an individual has a credit bureau file. The pursuit of new credit category can be based on a number of credit inquiries occurring within a pre-defined time period (e.g., 6 months, etc.). The credit mix category can be based on the mix of credit cards, retail accounts, installment loans, finance company accounts and mortgage loans for an individual.
[0019] FIG. 3 is a table 300 that shows details with regard to a particular consumer named Brian. The credit score for Brian is indicated as being incomplete due to insufficient credit history because Brian has only five months of credit history (and six months of credit history are required for the corresponding credit scoring model). As will be described in further detail below, using the future credit score projection models, it can be predicted that Brian's credit score will be 655 as of April 2013. Based on this projection, future actions can be taken prior to the time at which Brian becomes scoreable (i.e., the data at which a credit score can first be generated for Brian).
[0020] FIG. 4 is a diagram 400 illustrating some of the advantages provided by the current subject matter. Brian first applies for and receives a credit card in October 2012. In early March 2013, a first credit card issuer initiates a pre-screen process in which it identifies (by utilizing the current subject matter) potential customers who are not yet scoreable but whom have a future credit score projection above a pre-defined threshold. Thereafter, in early April 2013, Brian first becomes scoreable with a credit score of 651 (very close to the originally projected score of 655). Soon afterwards in April 2013, the first credit card issuer mails Brian a credit card solicitation. At the same time, other credit card issuers also become aware of Brian and begin to mail solicitations to him. Given typical delays in direct mailing campaigns, Brian begins receiving solicitations from other credit card issuers starting in May 2013. In this scenario, the first credit card issuer is in a much better position to convert Brian into a customer given their early direct mailing (which was enabled by the future credit score projection).
[0021] The current subject matter can also be used to project future credit scores for individuals that have sufficient credit history. For example, referencing diagram 500 of FIG. 5 , a customer Stacy currently has a credit score of 637. She has 6 accounts, she has a credit history (i.e., she has had a credit file) for 95 months, her credit card utilization is 54%, there are two delinquency events, one recent card inquiry, and she has a mix of credit sources. A one month projection of Stacy's credit score results in an increase by 15 points to 652. This 15 point increase is due to Stacy's number of months in file value shifting from 95 to 96 in the projection, and the resulting point differential associated with having number of months in file between 48-95 months (40 points) and that of 96-120 months (55 points).
[0022] FIG. 6 is a process flow diagram illustrating a method 600 in which, at 610 , data is received that characterizes a request for a credit score at a future date. Thereafter, at 620 , data is received that comprises values for each of a plurality of variables used by a predictive scoring model to generate a credit score. With such an arrangement, at least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window can comprise a fixed number of days prior to and including the scoring date. The predictive model can be trained using historical credit data derived from a population of individuals. Subsequently, at 630 , the values for at least one of the variables are modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including the future date and comprising the fixed number of days. It is then determined, at 640 , using the modified values and the predictive model, a projected credit score at the future date. Data can then be provided, at 650 , that characterizes the projected future credit score.
[0023] FIG. 7 is a process flow diagram illustrating a method 700 in which, at 710 , data is received that characterizes a request for a date at which a consumer will first have a specified credit score. Thereafter, at 720 , data is received that includes values for each of a plurality of variables used by a predictive scoring model to generate a current credit score for the consumer. At least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window includes a fixed number of days prior to and including the scoring date and the predictive model is trained using historical credit data derived from a population of individuals. Subsequently, at 730 , values for a least one of the variables are recursively modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including a future date and comprising the fixed number of days and the credit score is determined using the predictive model until such time that the current credit score for the consumer will first equal the specified credit score. Data is then provided, at 740 , that characterizes the date at which the current credit score will first equal the specified credit score.
[0024] FIG. 8 is a process flow diagram illustrating a method 800 in which, at 810 , data is received that characterizes a request for a date at which a consumer will first have a specified increase in a credit score. Thereafter, at 820 , data is received that includes values for each of a plurality of variables used by a predictive scoring model to generate a current credit score for the consumer. At least a portion of the variables characterize an occurrence or non-occurrence of credit-related events associated with an individual within at least one historical first time window preceding a scoring date. The at least one first historical time window includes a fixed number of days prior to and including the scoring date and the predictive model is trained using historical credit data derived from a population of individuals. Subsequently, at 830 , values for a least one of the variables are recursively modified to only characterize the occurrence or non-occurrence of events within at least one second time window prior to and including a future date and comprising the fixed number of days and the credit score is determined using the predictive model until such time that the current credit score will increase to the specified amount. Data is then provided, at 840 , that characterizes the date at which the current credit score will first increase by the specified amount.
[0025] Various types of predictive models can be utilized including, without limitation, scorecard models, logistic regression models, neural network-based models, and the like. Regardless of the type of model, the values that are based on events occurring or not occurring within a time window can be modified based on a shifting of the applicable window to some point in the future. During the shifted time window, in some variations, it is assumed that no material changes to the credit file and/or no adverse events (i.e., events negatively affecting creditworthiness) occur during such time period. In other variations, an average of historical events for the particular category can be utilized/projected going forward rather than assuming that no adverse events occur within the shifted time window.
[0026] One or more aspects or features of the subject matter described herein may be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations may include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device (e.g., mouse, touch screen, etc.), and at least one output device.
[0027] These computer programs, which can also be referred to as programs, software, software applications, applications, components, or code, include machine instructions for a programmable processor, and can be implemented in a high-level procedural language, an object-oriented programming language, a functional programming language, a logical programming language, and/or in assembly/machine language. As used herein, the term “machine-readable medium” refers to any computer program product, apparatus and/or device, such as for example magnetic discs, optical disks, memory, and Programmable Logic Devices (PLDs), used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor. The machine-readable medium can store such machine instructions non-transitorily, such as for example as would a non-transient solid state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium can alternatively or additionally store such machine instructions in a transient manner, such as for example as would a processor cache or other random access memory associated with one or more physical processor cores.
[0028] To provide for interaction with a user, the subject matter described herein can be implemented on a computer having a display device, such as for example a cathode ray tube (CRT) or a liquid crystal display (LCD) monitor for displaying information to the user and a keyboard and a pointing device, such as for example a mouse or a trackball, by which the user may provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well. For example, feedback provided to the user can be any form of sensory feedback, such as for example visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including, but not limited to, acoustic, speech, or tactile input. Other possible input devices include, but are not limited to, touch screens or other touch-sensitive devices such as single or multi-point resistive or capacitive trackpads, voice recognition hardware and software, optical scanners, optical pointers, digital image capture devices and associated interpretation software, and the like.
[0029] The subject matter described herein may be implemented in a computing system that includes a back-end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front-end component (e.g., a client computer having a graphical user interface or a Web browser through which a user may interact with an implementation of the subject matter described herein), or any combination of such back-end, middleware, or front-end components. The components of the system may be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (“LAN”), a wide area network (“WAN”), and the Internet.
[0030] The computing system may include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0031] The subject matter described herein can be embodied in systems, apparatus, methods, and/or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flow(s) depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
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The current subject matter provides models that enable a projection of credit scores at a specified future date as well as an estimation of a date when a credit score will reach a certain level. Related apparatus, systems, techniques and articles are also described.
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BACKGROUND OF THE INVENTION
This invention pertains to surface cleaning vacuum nozzles of the type having a dispenser attached thereto for dispensing hot water, cleaning fluids, powders, or the like and are adapted to operate in conjunction with hot water extraction carpet cleaning systems. It is desirable that such nozzles can be quickly, easily and conveniently removed from and reassembled to a hand held wand which is in vacuum communication with a suction source. In such an arrangement the same wand may then be used with a variety of nozzles and other tools for upholstery and other fabric cleaning tasks.
When assembling such a nozzle to the wand, two fluid connections must be made; the first being the body of the nozzle to the vacuum port of the wand, and the second being the dispenser to the cleaning fluid supply conduit. Generally, the fluid supply conduit is rigidly attached to the wand, and the dispenser rigidly attached to the nozzle body, wherein the fluid connection is made by use of two matting threaded portions having a resilient seal disposed therebetween. The suction connection is merely a slip fit coupling between the inside diameter of the suction part of the nozzle body and the outside diameter of the suction part of the wand. A spring loaded detent holds the two parts in operational engagement.
Inherent in the arrangement described above is the difficulty encountered when attempting to assemble the nozzle to the wand. Of the suction and fluid connections, one cannot be completely connected until the other is at least partially connected. This is the case because the mating elements for the two connections are rigidly attached to the two parts being connected and each connection requires a substantial amount of lead-in from the point where the connection is first begun to where the connection is complete. Thus, the traverse of the lead-in for each connection must necessarily be done, more or less, simultaneously in order to assemble the two parts without binding one of the two connections. A similar problem exists when attempting to disconnect the nozzle from the wand.
Typical surface cleaning vacuum devices are constructed as special purpose devices in that the nozzle portion is not intended to be easily disconnected from the wand for replacement by other attachments. See, for example, U.S. Pat. No.: 3,883,301, May 13, 1975, Emrick et al; U.S. Pat. No. 3,909,197, Sept. 30, 1975, Cremers; U.S. Pat. No. 3,942,217, Mar. 9, 1976, Bates; U.S. Pat. No. 4,158,575, June 19, 1979, Townsend; and U.S. Pat. No. 4,127,913, Dec. 5, 1978, Monson, all of which disclose relatively long hand held wands having nozzles and cleaning fluid dispensers that are not easily detached from the wand. Other surface cleaning vacuum devices such as U.S. Pat. No. 4,074,387, Feb. 21, 1978, Arato et al. and U.S. Pat. No. 4,159,554, July 3, 1979, Knight et al. utilize a relatively short handle portion integrally molded to a nozzle. The free end of the handle portion is fitted to a flexible conduit for supplying suction. Heretofore, there has been no entirely satisfactory provision for the quick and convenient removal and reattachment of an upholstery cleaning vacuum nozzle or other similar tools to the wand.
SUMMARY OF THE INVENTION
The present invention overcomes these difficulties of the prior art by providing a novel upholstery cleaning nozzle having a capability for permitting the quick and convenient coupling and decoupling of a cleaning vacuum nozzle or the like from a hand held wand having a suction connection and a cleaning fluid connection.
It is therefor an object of this invention to provide a means for easily and quickly coupling the suction connection independent of the cleaning fluid connection.
It is another object of this invention to provide a coupling means for the cleaning fluid dispenser so that the dispenser may be coupled to the cleaning fluid connection of the wand after the suction connection is made.
It is another object of this invention to provide a mounting means for the cleaning fluid dispenser so that the dispenser is held captive to the cleaning vacuum nozzle.
Other objects and advantages of the invention will become apparent through reference to the accompanying drawings and descriptive matter which illustrate a preferred embodiment of this invention.
According to the present invention, there is provided a surface cleaning vacuum nozzle, or the like, having a body of hollow interior adapted for connection to a vacuum source. The body contains an orifice which is in vacuum communication with the interior for engaging the surface and removing loose dirt or the like therefrom. A cleaning materials dispenser is slidingly attached to the body and has a cleaning fluid connector which is adapted to be connected to a cleaning materials supply for applying the cleaning material to the surface in close proximity to the orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention be more fully understood, it will be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a surface cleaning vacuum nozzle having the present invention incorporated therein;
FIG. 2 is a perspective view showing the cleaning fluid dispenser disconnected from the nozzle body;
FIG. 3 is a side view taken in section;
FIG. 4 is a view taken along lines 4--4, FIG. 3;
FIG. 4a is a detailed view of a portion of FIG. 4;
and,
FIG. 5 is a view taken along lines 5--5, FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 5 there is shown a surface cleaning vacuum nozzle having a body 2, a vacuum inlet port 4 having an inside diameter adapted to slidingly engage the outside diameter 6 of the hand held wand 8 which is connected to a suction source. The body 2 is held in engagement with the wand 8 by a spring biased latch 5 that is well known by those skilled in the art. The nozzle body 2 has a curved portion 10 terminating in an elongated intake orifice 12. The orifice 12 is in vacuum communication with the wand 8. A cleaning fluid dispenser 20, as shown in FIG. 3, comprising a manifold 22, a fluid seat 23, a captive nut 24, and a spray head 26, is slidingly supported on the body 2. The fluid seat 23 and nut 24 are positioned on one end of the manifold 22 and are adapted to engage a threaded outlet 25 which is formed integral to a cleaning fluid valve 27 for providing a fluid seal between the manifold 22 and the outlet 25. The cleaning fluid valve 27 is rigidly attached to the hand held wand 8 and includes a housing 28 having a hollow interior, an outwardly spring biased valve seat 30, and a finger operated trigger 31 for moving the valve seat 30 inwardly in opposition to the spring bias. A cleaning fluid supply tube 29 is connected to the housing 28 so that cleaning fluid may be introduced into the interior. In operation, the valve seat 30 is urged into sealing engagement with the fluid seat 23 of the dispenser 20. As the trigger 31 is actuated, the valve seat 30 is moved away from the fluid seat 23 permitting cleaning fluid to flow from the supply tube 29 into the dispenser 20. This type of valve is well known in the art and is offered as an example only. Other similar valves will function equally as well.
As shown in FIGS. 4 and 5 the manifold 22 has two parallel support legs 32 each terminating in an outturned projection 34 form flaired surfaces 35. These outturned projections 34, are adapted to slidingly engage the slot, or dovetail 40 of the body 2. The slot, or dovetail 40 is formed with two converging rail members 36 having side surfaces 37 which closely embrace the outer surfaces 35 of the projections 34 thereby forming a dovetail-like joint. The side surface 37 of the rails 36 together with the flat surfaces 38 form the dovetail 40. Upon reviewing this disclosure it will become apparent to one skilled in the art that variations in the shape of the projections 34 and slot 40 which result in dovetail, dovetail-like, or partial dovetail interlocking, but sliding, surfaces will function as well as the structure described above. Such variations are contemplated to be within the spirit and scope of this invention. An end piece 42 formed transversely to the rails 36 is arranged to limit sliding motion of the manifold 22 in the direction of the orifice 12 by providing an abutting surface for the support legs 32. At its opposite end each of the legs 32 has an outturned deformable tab 44 which projects over its respective rail 36. As shown in FIG. 5, the tabs 44 are completely clear of the dovetail 40. There are two lugs 46 formed adjacent and orthogonal to the end of the rails 36 opposite the end piece 42. The lugs 46 are completely clear of the dovetail 40 and are arranged to provide abutting surfaces 45 for the deformable tabs 44 and thereby limiting the sliding motion of the manifold 22 in the direction of the wand 8.
The deformable tabs 44 and lugs 46 have formed thereon angled surfaces for aiding initial assembly of the dispenser 20 to the body 2 during the manufacturing of the upholstery cleaning nozzle. It is intended that this initial assembly be performed only once, at the factory, after which the dispenser 20 will remain assembled and captive to the body 2. The deformable tabs 44 have first angled surfaces 48 formed thereon for camming engagement with second angled surfaces 47 formed on the lugs 46. Each pair of angled surfaces 47, 48 are arranged so that when the projections 34 are fully inserted into the dovetail 40 the angled surfaces 47, 48 engage, resulting in a camming action that urges the deformable tabs 44 inward so that they pass the lugs 46. The tabs 44 are sufficiently elastic so that as they pass the lugs 46, the tabs snap outward to their original position and thereby hold the dispenser 20 captive to the body 2 as shown in FIGS. 4 and 4a. The dispenser 20, however, is free to slide longitudinally with respect to the body 2 within the limitations set by the end piece 42 and the lugs 46. The dispenser 20 with its integrally formed tabs 44 and lugs 46 may be constructed of most materials, such as plastic for example, having reasonable rigidity and being sufficiently elastic to permit deformation and restoration of the tabs 44 as described above.
With this arrangement the surface cleaning nozzle may be easily connected to the wand 8 by inserting the outer diameter 6 of the wand 8 into the vacuum inlet port 4 of the body 2 until the latch 5 engages, sliding the dispenser 20 rearward until engagement is made with the valve 27, then assembling the captive nut 24 onto the threaded outlet 25 and tightening to form a fluid seal. When it is desired to disconnect the surface cleaning nozzle from the wand 8 the captive nut 24 is first completely loosened then the latch 5 depressed and the body 2 removed from the wand.
Upon reviewing the present disclosure, a number of alternative constructions embodying the principles of this invention will occur to one skilled in the art. Such constructions may involve a slot 40 of a shape different to that of a dovetail or the lugs 46 may project radially outward or in another suitable direction. Such other constructions embodying these principles are deemed to be within the scope and spirit of this disclosure. It is to be understood that the preferred embodiment described herein is for purposes of illustration only and not to be construed as a limitation of this invention.
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A surface cleaning vacuum nozzle having a cleaning materials dispenser slidingly attached thereto, the entire assembly being connectable to a hand held suction wand having a valve attached thereto which is in fluid communication with a cleaning fluid supply. The sliding action of the dispenser aids in the connecting or disconnecting of the nozzle.
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CROSS-REFERENCE TO RELATED APPLICATION
My allowed application, Ser. No. 677,797, filed Apr. 16, 1976, now U.S. Pat. No. 4,073,035.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an enclosure for wet chambers and more particularly refers to a new and improved enclosure having several slideable partitions suspended in an upper guide rail, an adapter seated on the edge of a wet-chamber tub, and a lower guide integrated with the adapter.
2. Description of the Prior Art
In one known enclosure of this type for wet chambers, the lower guide member is made of two parts for reasons of hygiene, i.e., it consists of a compensation member and a guide rail which can be slipped onto the compensation member (German Published Prosecuted Application No. 25 16 851). The surface of the compensation member and/or the bottom surface of the guide member are slightly inclined, so that spray water that may have found its way into the U-shaped guides, open toward the top, can flow off toward the damp room side via discharge openings in the guide member. For cleaning, the guide rail is removed from the compensation member and is rinsed off. A snap-in fastening arrangement is provided to facilitate this job. Solid dirt particles and bacteria, however, can settle relatively quickly in the U-shaped guides.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an enclosure for wet chambers with a detachable guide rail, having a lower guide which is basically less dirt-prone, and permits ready disassembly, cleaning or repair and installation.
With the foregoing and other objects in view, there is provided in accordance with the invention an enclosure for wet chambers, particularly for bathrooms/or shower rooms with adjacent slideable partitions which are movably suspended side by side from an upper guide rail, and having a lower guide member including an elongated, box-shaped adapter seatable on the edge of a wet-chamber tub, and an elongated guide rail integrated with the elongated box-shaped adapter of the lower guide member, the guide rail having at least one guide which has an inverted approximately U-shaped cross section transversely to the longitudinal axis of the adapter with the opening of the U facing the top surface of the adapter and with an outer leg wall of the inverted U constituting an outer longitudinal wall along the dry side of the room and another leg wall of the inverted U constituting an inner free leg wall with the opening of the inverted U having a width which is larger than the thickness of a lower guide strip extending from the first adjacent slideable partition, the lower guide strip extending from the partition, first downwardly, then under the free U leg wall, then upwardly to form a pocket open at the top into which the free U leg wall extends.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in shielding for damp rooms, it is nevertheless not intended to be limited to the details shown, since various modifications may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, however, together with additional objects and advantages thereof will be best understood from the following description when read in connection with the accompanying drawings, in which:
FIG. 1 is a sectional view of a lower guide member showing a first embodiment of the enclosure with partitions guided by means of their lower guide strips and a detachable guide rail;
FIG. 2 is a subvariant of the first variant shown in FIG. 1;
FIG. 3 is a second embodiment with a stepped lower guide member having a detachable guide rail;
FIG. 4 is a third embodiment of the enclosure with a uniformly stepped lower guide member and a detachable guide rail; and
FIG. 5 is a fourth embodiment of the enclosure with a one-piece adapter and with guidance between a curved surface of the lower guide strip of each partition and a fitting curved surface of the corresponding guide wall of the lower guide.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, a first, approximately U-shaped guide is open at the bottom toward the top surface of the compensation member and is located in the region of the outer longitudinal wall facing the dry side of the room, of the guide rail. The lower guide strip of a first one of the partitions has a cross section which is open toward the top, i.e. U-shaped. The lower guide strip fits or engages the free U-leg wall of the first inverted U-shaped guide by passing behind and below the free U-leg wall. The other guides are likewise open at the bottom. In this manner, the guides in the guide rail are advantageously shielded against spray water. They do not form collectors, in which solid particles can accumulate.
A curtain for bath and/or shower rooms which can be pushed together in accordion-fashion and which carries as stiffening elements, guide rolls which engage in U-shaped guides, open toward the bottom, of a lower guide member integral with the edge of the tub is disclosed in U.S. Pat. No. 3,500,481. The known U-shaped guides are arranged in steps one below the other, with an overall inclination toward the tub side. Contrary thereto, the present invention provides, for one, a compensation member for adapting the enclosure to already installed bath or shower tubs, and in addition, a guide rail that can be detached from this compensation member, and/or releasable lower guide strips which will be described in detail in the following. Finally, the lower roll guidance can be dispensed with and, with an appropriate choice of the material for the guide rails and the lower guide strip and, with the indicated adaptation of the profile of the lower guide strip to the guide wall of the lower guide member, a simple sliding guide can be obtained.
In one embodiment of the invention the lower guide strip of each partition has a guide groove which is open toward the top surface of the compensation member or adapter. The opening width of the guide groove is matched to the thickness of an upward-pointing extension of the lower guide strip of the adjacently installed partition. In this embodiment, only the partition which, in the installed condition of the partition, is closest to the dry space among the parallel partitions, is consequently held with its lower guide strip in a U-guide of the detachable guide rail, while the adjacent partition, which hangs closer to the damp room, is held by the upward-pointing extension of its lower guide strip in the guide groove of the first-named partition. This system can be supplemented, of course, by further partitions which are arranged toward the damp room side and can be moved parallel to the others and are held together at the bottom. As is shown in the German Published Prosecuted Application 25 16 851, the lower guide member is provided on its upper side, in the vicinity of its outer longitudinal wall intended for the dry room side, with a rib for fastening the guide rail. According to the invention, this rib has a thickened outer end and the guide rail has a snap-in recess corresponding to this end. The axis of its outer longitudinal wall is parallel to the longitudinal wall of the adapter. The guide rail is held at this wall, for instance, by means of a tongue-and-groove joint, and is flush with the adapter on the outside, so that the lower guide member has no interfering, projecting parts on its outer longitudinal side.
In a modification or subvariant of the first embodiment, two partitions are held, one behind the other in the guide direction, in the U-guide behind the longitudinal wall facing the dry space, while a third partition has an extension of its lower guide strip with a guide groove open toward the top. An additional guide strip extends from above from the second partition in a direction facing away from the extension engaging the first-mentioned U-guide, and engages the guide groove of the third partition. In the closed position, the third partition shields, in this embodiment, the area between the first two partitions, while normally, in the first embodiment and the other embodiments, the third partition is situated in the closed position on an outer side, and the second partition shields the middle area.
In a second embodiment of the invention, the guide rail has, spatially adjacent to the first U-guide and at the same height as the latter, a second U-guide open at the bottom and, offset in stair-fashion from both, at least one further (third) U-guide. The lower guide strip of a second partition reaches under the guide strip of the first partition and engages with its extension behind the free U-leg wall of the second U-guide. The guide strip has a cross section open at the top, which is fitted to the second U-guide. The lower guide strip of a third partition, which is intended for cooperation with the third U-guide located lower than the first U-guide, is of a form corresponding to that of the first guide strip. This second embodiment has the advantage over the first embodiment in that each partition is held by itself in a U-guide and corresponding tolerances do not cumulate, so that the enclosure overall is more stable against shifts transversely to the panel plane and therefore, also minimizes chatter.
In both of the above-described embodiments of the invention, it is of course advantageous to make the top surface of the adapter or compensation member or the bottom surface of the guide rail, respectively, slightly inclined toward the damp room side.
In a third embodiment of the invention with a detachable guide rail, the starting point is a steep inclination in the abovementioned direction of the compensation member. All U-guides open at the bottom are located one below the other in stair-fashion and the lower guide strips of the partitions are of identical design and correspond to the lower guide strip of the first partition held at the lower guide member in the first-described embodiment. In the third embodiment, a prismatic hollow box profile is preferably used as the compensation member, the cover surface of which, being opposite the right angle and dropping approximately at an angle of 45°, is overlaid by the snapped-on guide rail. This third embodiment is preferred over the ones previously described. It can be designed advantageously so that each lower guide strip is held in its corresponding partition, vertically movable against spring force, and can be detached from the position reaching behind the guide wall.
To replace an individual partition, the side posts of the enclosure need not be detached in such an embodiment. The lower guide strip of the partition is simply snapped out of engagement with the guide wall of the guide rail; it is then pulled by spring force into the lower part of the partition. It is clear that the partition can be tilted somewhat about its upper guide. While the partition is suspended, the lower part of the frame can be detached and the panel can be replaced. Likewise, the partition can also be detached in known manner from its upper guide strip (German Published Non-Prosecuted Application No. 26 04 376) or unhung if the upper guide is designed accordingly.
The lower guide strips can be unsnapped, of course, in all partitions, which makes the lower guide rail accessible. This avoids removing the lower guide member for cleaning. The guide rail and the compensation member can be formed as an integrated cross section which is more advantageous or cheaper for production.
In a preferred fourth embodiment, a prismatic hollow-box profile is therefore used as the adapter as in the third embodiment, but its inclined cover surface is stepped and exhibits the approximately U-shaped guides open at the bottom which are arranged one below the other in stair-fashion and are delineated by guide walls. Each guide consists of a junction between the guide strip and the guide wall by means of engaging curved surfaces. The guide wall may have a cylindrical bead and the guide strip a correspondingly formed recess. This embodiment means a simplified profile for the guide rail and is particularly advantageous if the compensation member and the guide rail are made of one piece. To avoid friction in the normal hanging position of the partitions, the surfaces are shaped to effect loose engagement between the U-guide and the guide strip.
The backward spring movement of the guide strips is advantageously limited in both embodiments having unlatchable guide strips by a stop, so that a narrow gap remains in the vertical direction between the surfaces.
The invention will now be explained in greater detail with reference to the embodiment examples shown in the drawings.
The upper guide rail, which is constructed in known manner, (German Pat. Nos. 2 325 032 or 2 314 444) is not shown. In this upper guide, for instance, three partitions 1 to 3 are in the installed condition suspended side by side. A lower guide member 10 consists of an elongated, box-like adapter or compensation member 11 which can be placed on the edge of the bath or shower tub, and a detachable guide rail 12 with a guide 13 (FIG. 1) which transversely to the longitudinal axis of the compensation body 11 is of U-shaped cross section and is open toward the bottom. An extension 14 of a lower guide strip 15 of the partition 1 engages from below into the opening. The partitions 2 and 3 have similar guide strips 16 and 17, but their corresponding extensions 18 and 19 engage with guide grooves 21, 22 of the second and third guide strip 15 and 16 which are open toward the top surface 20 of the compensation member 11. The first guide strip 15 and its extension 14 cooperate with little clearance with the free U-leg wall 23 of the first U-guide 13. The thickness of the free U-leg wall 23 and its distance from the top surface 20 or its extent downward, and the opening width and depth as well as the thickness of the first lower guide strip 14 in the area of their engagement are matched to each other. This is true, of course, also for the guide grooves 21 and 22 and the corresponding extensions 18 and 19. The third guide strip 17 can have a guide groove 24 for connecting an additional partition. The partitions 1, 2, 3 are thus guided in telescope fashion, with the axes displaced. The compensation member 11, on its upper side, in the area of its longitudinal wall 25 intended for the dry room side, has a rib 26, which has a bead 27 at its free end. The guide rail 12 has a snap-in recess 28 corresponding to bead 27. The guide rail 12 runs with its outer longitudinal wall 29 axis-parallel to the longitudinal wall 25 of the compensation member 11, and is held at the wall 25 by a tongue-and-groove connection 30. Wall 29 is flush with wall 25 on the outside.
The embodiment according to FIG. 2 differs from that of FIG. 1 in that two guide strips 15, 16 or their extensions 14, 18, respectively, disposed serially in guidance direction, engage in the first U-guide 13. The second partition 2 has an additional lower guide strip 16a, which engages from above in a guide groove 24a, open toward the top, and formed, in this case, in an upwardly bent extension 19a of the guide strip 17 of the third partition The other parts correspond to the embodiment as per FIG. 1. In order to extend the possible opening of this variant, which is limited to the width of one partition, provision can be made for the lower guide strips 15 and 16 to engage each other at least partially in telescope-fashion.
Similar parts are designated in the following figures with the same end numerals.
In a second embodiment according to FIG. 3, the compensation member 111 and the guide rail 112 are stepped. The two common steps are designated by numeral 131. The guide rail 112 extends over the compensation member 111, and are secured by a tongue-and-groove connection 130 with an inclined surface 132 facing away from the top surface 120 of the compensation member 111 on the one side and an extension 134, which is in engagement with the inclined side surface 133 enclsoing an acute angle with the top surface 120, of the rail 112. The U-shaped guide 113 and the first lower guide strip 115 correspond in substance to the first embodiment. Next to the first U-shaped guide 113, there is, however, in an upper part 135 of the guide rail 112, at the same height as the first U-guide 113, a second U-guide 136 defined by a shank wall 123a serving as guide wall. An extension 118 of the second partition 102 traversing underneath the lower guide strip 115 of the first partition 101 engages U-guide 136 from below. A third U-shaped guide 137 is situated in the region of the step 131. This third guide 137 engages an extension 119 of the third partition 103, which corresponds to the extension 114 of the first partition 101. In this embodiment, the individual lower guide strips 115 to 117 must all be of different design; as can be seen, they have horizontally and vertically different dimensions, while the interleaved guide strips 15 to 17 of the first embodiment can be of identical design. However, the second embodiment is more stable against blows transversely to the plane of the panel of the partitions 102 and 103.
In a third embodiment (FIG. 4), a prismatic hollow-box profile for the compensation member 211 is taken as the basis. The guide rail 212 overlays the inclined surface of the compensation member 211, which drops toward the damp room side, and has guides 213, 236 and 237, which are open toward the bottom and are defined by downwardly extending free guide or flank walls 223. The guide strips 215, 216 and 217 may have the same dimension from top to bottom. In that case, the partition 201, 202, 203 must be of different design. Preferably, however, also the partitions 201 to 203 can be of the same size and the lower guide strips 215 to 217 have a different dimension from the lower edge of the respective partition 201, 202 or 203 to their engagement part or their extension 214, 218 and 219. For the snap-on fastening of the rail 212, similar elements 230, 233 and 234 as in the second embodiment are provided.
The third embodiment has the advantage that the respective downwardly extending free flank wall 233 as guide wall of each U-shaped guide 213, 236 and 237 cooperates, in a close fit, with the corresponding profile, open at the top, of the lower guide strip 215, 216 or 217, respectively, so that in these areas self-cleaning takes place and dirt particles are flushed away via the inclined or curved portions of the rail bottom 240 underneath. In view of this, it is understood that the lower guide strips 15 to 17; and 115 to 117 of the first two embodiments can be perforated in their horizotal areas.
The guide strips 215 to 217 are preferably held vertically movably in the partitions 201 to 203 associated with them. For this purpose, each guide strip 215 to 217 has a sliding piece 241, to which one end of a spring 242 is fastened. The other end of spring 242 is connected to a clamping piece 244 which is held immovably in the lower part 243 of the partition 201, 202 and 203, respectively. Each guide strip 215 to 217 has an extension 245, which also may extend in the form of a strip over the lengthwise direction of the guide strip 201, 202, 203.
The operation of this arrangement is as follows:
To detach each partition 201 to 203 from its lower guide 215, 236, 237, the guide strip and the guide wall, e.g., 217 and 233, are unlatched from each other. To this end, one can push with a tool or by hand on the extension 245 and push the guide strip 217 by at least the distance s downward. The distance a of the lower side of the guide strip 217 from the surface of the guide rail 212 is, for course, somewhat larger than the distance s. By slightly swinging the partition 203 in FIG. 4 out to the right, the guide strip 217 is pulled up by the spring 242. The partition 203 is freely accessible, and so are the further partitions 202, 201 and the guide rail 212 by unlatching the guide strips 216, 215. It goes without saying that a compression spring can be used instead of the spring 242, which is stressed in tension upon unlatching. An extension of the guide strip, for instance, can be brought through a hole in the lower part of the guide wall and carry a top disc which rests on a compression spring (not shown).
The spring 242 is advantageously designed so that in the engagement position of the respective guide strips 215, 216, 217 and the guide wall 223, no force is exerted on the guide rail 212. Even so, the snap-on connection between the guide rail 212 and the compensation member 211 can be secured additionally for safety by a screw connection 246.
In a fourth embodiment according to FIG. 5, the guide rail and the compensation member are of one piece, and form a guide member 310. The guide walls 323 are shaped substantially cylindrically and are engaged by the extensions 314, 318 and 319 of the guide strips 315 to 317. The latter have corresponding recesses 347. This connection is designed so that there is enough play in the engaged position. This can be adjusted, on the one hand, by the amount by which the upward-pointing extension 314, 318, 319 of each guide strip 315 to 317 is brought up. On the other hand, stops 345 are provided for limiting the backward movement of the spring at the lower guide strips 315 to 317. The mounting of the guide strip 315 to 317 in the lower part 343 of each partition 301 to 303 corresponds to that shown and described in connection with FIG. 4.
If oriented as per FIG. 5, the guide strip 315, for instance, is pushed down and somewhat to the left for unlatching it from its connection with the guide wall 323, whereupon it is pulled automatically upward by spring force, limited by the stop 345.
The compensation member 211 and the guide member 310, respectively, are set in both embodiment examples according to FIGS. 4 and 5 at both of their lengthwise ends in posts 248, 348 which are U-shaped in the horizontal cross section and establish the connection to the wall of the room or to another enclosure. The compensation members 11, 111, 211, 310 and the guide rails 12, 112, 212 can be formed of aluminum, and the guide rails 11, 111, 211, (310) can also be formed of synthetic material or coated with synthetic material so as to improve the coefficients of friction with the lower guide walls of the partitions 1, 2, 3.
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Enclosure for wet chamber, particularly for bathrooms or shower rooms with several adjacent slideable partitions with each partition suspended in an upper guide rail and with a lower guide member consisting of an elongated, box-shaped adapter seated on the edge of a wet-chamber tub, an elongated lower guide detachably fastened to the adapter. The guide rail has at least one guide with an inverted U-shape cross section with the outer leg as the longitudinal wall along the dry side of the room and with an inner free leg wall. A lower guide strip extends from the partition, first downwardly, then under the free leg wall, then upwardly to form a pocket open at the top into which the free U leg wall extends.
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BACKGROUND OF THE INVENTION
The search for strong analgesics which also possess minimal potential for dependency has been among the highest priority efforts in pharmacological research. These research efforts have, to a great extent, involved chemical modifications of the opiate structure and the discovery of chemically novel compounds which possess morphine-like activity.
The discovery of endogenous opioids has led workers in the field to consider that these peptides, possessing less rigid structures, might interact with opioid receptors other than those to which the classical rigid structure opiates, such as morphine, bind.
The concept of multiple opioid receptors has been supported by studies with nalorphine and a series of benzomorphans which display unusual pharmacological properties dissimilar from morphine, yet blocked by the selective opioid antagonists. [See, for example, W. R. Martin, et al., J. Pharmacol. Exp. Ther., 197: 517-532 (1976)].
The existence of multiple types of opioid receptors is of importance because it suggests the possibility of separating the desirable analgesic and psychotherapeutic effects of a drug compound from the undesirable abuse potential or habituating effects.
U.S. Pat. No. 4,145,435 describes certain 2-amino-cycloaliphatic amide compounds as analgesics. In particular, trans-3,4-dichloro-N-methyl-N-[2-(1-pyrrolidinyl)-cyclohexyl]-benzacetamide has been reported to possess selective kappa agonist activity, and therefore to possess analgesic activity without attendant dependence liability. [See P. V. Vanvoigtlander, et al., J. Pharmacol. Exp. Ther., 224: 7-12 (1983)].
Recently, the diuretic effect of various opioid agonists and antagonists has been studied, and it has been shown that kappa agonists tend to increase urination, while mu agonists decreased urination. [See J. D. Leander, J. Pharmacol. Exp. Ther., 227: 35-41 (1983)]. These findings suggest that selective opioid agonists and antagonists also possess potential as diuretics.
SUMMARY OF THE INVENTION
The present invention relates to substituted trans-1,2-diamino-cyclohexylamide compounds useful as analgesics, diuretics, and psychotherapeutic agents. The invention is also concerned with a method of preparing such compounds, pharmaceutical compositions including such compounds, and with a method of alleviating pain in a mammal by administering an effective amount of a pharmaceutical composition in accordance with the present invention.
In its broadest aspect, the present invention encompasses compounds having structural formula I ##STR1## where R 1 is methyl and R 2 is hydrogen, alkyl of from one to six carbon atoms, ##STR2## --CH 2 C═CR 3 R 4 where R 3 and R 4 are independently hydrogen or methyl, or where R 1 and R 2 taken together with the nitrogen atom to which they are attached comprise a 5- or 6-membered ring; and wherein A is ##STR3## where n is an integer of from one to six; R 5 is hydrogen, fluorine, chlorine, nitro, alkyl of from one to six carbon atoms, or alkoxy of from one to six carbon atoms; and B is ##STR4## where m is an integer of from one to six; and the pharmaceutically acceptable acid addition salts thereof.
In accordance with a second aspect of the present invention, a method preparing compounds having structural formula I comprising reacting at least two molar equivalents of a substituted trans-cyclohexyldiamine of structure II ##STR5## with one molar equivalent of a substituted dicarboxylic acid of structural formula III. ##STR6##
In accordance with another aspect of the present invention, pharmaceutical compositions useful for the alleviation of pain in a mammal comprise an effective amount of a compound having structural formula I above, in combination with a pharmaceutically acceptable carrier.
In a further aspect of the present invention, a method of alleviating pain in a mammal comprises administering to a mammal suffering from pain an effective amount of a pharmaceutical composition, preferably in unit dosage form, which composition includes a compound having structural formula I, above, in combination with a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION
Compounds of the present invention comprise a class of derivatives of trans-1,2-diaminocyclohexane in which one nitrogen is a tertiary amine nitrogen substituted with methyl and a substituent selected from the group R 2 as defined above or, preferably is a tertiary amine nitrogen attached to the cyclohexane ring and which is part of a pyrrolidinyl or piperidinyl group. The other nitrogen atom of the 1,2-diaminocyclohexane is an N-methyl amide nitrogen.
In the structural formula for subunit "A" given above, the bonds attaching the polymethylene group and "B" to the aromatic ring may be attached to the ring in positions which are ortho, meta, or para with respect to one another, but preferably ortho.
By the term "alkyl of from one to six carbon atoms" as used throughout this specification and the appended claims is meant branched or unbranched saturated hydrocarbon groupings containing one to six carbon atoms. Examples include methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, n-pentyl, and the like.
By the term "alkoxy" is meant a branched or unbranched hydrocarbon grouping such as "alkyl" as defined above, attached to an oxygen atom.
Compounds of the present invention may contain one or more asymmetric carbon atoms and thus exist as enantiomers or diastereomers. The present invention contemplates all possible optical isomeric forms of structural formula I given above. Individual enantiomorphic or diastereomeric forms of the compounds of this invention may be obtained from mixtures by known methods of resolution.
In a preferred embodiment, compounds of formula I are those wherein m is equal to n.
In another preferred embodiment, compounds of formula I are those wherein R 5 is hydrogen.
One specific embodiment is a compound having the name trans, trans-N,N'-dimethyl-N,N'-bis[2-(1-pyrrolidinyl)cyclohexyl]-1,2-benzenediacetamide; and the pharmaceutically acceptable acid addition salts thereof.
In general, compounds of the present invention are prepared by reacting at least two molar equivalents of the appropriate trans-1,2-diaminocyclohexane of structural formula II with one molar equivalent of a dicarboxylic acid of structural formula III ##STR7## or a reactive derivative formed from such a dicarboxylic acid.
The appropriate dicarboxylic acid (III) may be reacted directly with the amine with the aid of such reagents as dicyclohexylcarbodiimide and the like. Alternatively, the dicarboxylic acids are first converted to a reactive derivative such as an activated ester, anhydride, acid halide such as the bromide or chloride, or acyl imidazoles of the formula IV ##STR8## and the resulting dicarboxylic acid derivative reacted with the substituted trans-1,2-diaminocyclohexane (II).
For example the reaction between the cyclic diamine (II) and the appropriate dicarboxylic acid (III) is carried out in the presence of the coupling reagent, dicyclohexylcarbodiimide, in a cyclic ether solvent such as tetrahydrofuran or dioxane until the desired product is formed. The reaction will generally proceed at ambient temperatures but, depending upon the reactivity of the specific materials involved, the desired reaction time, the solvent being employed, and the molar proportions of reagents, the reaction temperature may be varied between about -25° C. and the reflux temperature of the solvent employed.
The reaction between the diacid halide and the cyclic diamine (II) is carried out, generally at ambient temperature, in a suitable solvent in the presence of an acid acceptor such as a tertiary amine or an alkali metal or alkaline earth metal carbonate or bicarbonate. The mixture of the amine and the diacid halide is allowed to stand until reaction is complete.
When the reaction between the cyclic diamine (II) and the diacid (III) or diacid derivative has proceeded to substantial completion, the desired product is recovered from the reaction mixture by techniques well known to practitioners of the organic chemical arts.
For example, the reaction mixture can be evaporated under vacuum, if desired, to remove the solvent and other volatile components of the reaction mixture to yield the product, generally as an oil. This residual material is then taken up in a solvent such as diethyl ether, washed first with a salt solution such as sodium bicarbonate solution and then with water. Separation of the organic phase, drying over, for example anhydrous magnesium sulfate, and evaporation of the ether solvent, yields the desired product, usually as an oil or crystalline solid.
The starting trans-1,2-diaminocyclohexane compounds of the present invention are prepared by the method detailed in U.S. Pat. No. 4,145,435. The dicarboxylic acids (III) are known, or if novel, are prepared by reaction sequences well known in the art. The acyl imidazole derivatives (IV) of the dicarboxylic acids are prepared by reacting carbonyldiimidazole with the appropriate diacid.
The free base form of the compounds of this invention are readily converted, if desired, by known methods to the acid addition salts by reaction with any of a number of inorganic or organic acids including hydrochloric, hydrobromic, hydriodic, sulfuric, nitric, phosphoric, acetic, benzoic, citric, maleic, tartaric, succinic, gluconic, ascorbic, sulphamic, oxalic, pamoic, methanesulfonic, benzenesulfonic, and related acids and mixtures thereof. The free base form of the compounds of the present invention and the acid addition salt may differ in certain of their physical properties, such as solubility in polar solvents, but are otherwise equivalent for the purposes of this invention.
The compounds of the present invention possess significant analgesic activity with potential for minimum dependence liability due to their selective kappa opioid receptor binding properties. In addition to analgesics, selective kappa agonists also cause opioid receptor-mediated sedation, diuresis, and corticosteroid evaluations. Accordingly, the compounds of the present invention may also be useful diuretics and psychotherapeutic agents as well as analgesics.
A representative example of the compounds of formula I has shown positive activity in standard laboratory analgesic tests such as acetylcholine-induced writhing and hot plate with animals such as mice. Abolition of writhing was observed in mice at subcutaneous doses of 100 mg/kg of animal body weight of the compound of Example 1. When compared with control, mice showed longer tolerance, greater than 10 seconds (maximum determined at 40 seconds from control) on a hot plate at 55° C. when given 100 mg/kg of the compound of Example 1 subcutaneously.
A representative example of the compounds of the present invention, when tested in vitro to determine the extent of opioid receptor binding, was found to be selectively bound to the kappa receptors with evidence of little or no binding to the mu and delta receptors. The benefits of this selective binding has already been mentioned above and is also described by M. B. Tyers, Br. J. Pharmac. (1980) 69: 503-512.
The compounds of the present invention, and/or the nontoxic, pharmaceutically acceptable salts thereof, may be administered to mammals in pharmaceutical compositions or formulations which comprise one or more of the compounds of this invention and/or the nontoxic, pharmaceutically acceptable, nontoxic carrier.
The compounds of this invention may be administered parenterally in combination with conventional injectable liquid carriers such as sterile pyrogen-free water, sterile peroxide-free ethyl oleate, dehydrated alcohols, propylene glycol, and mixtures thereof.
Suitable pharmaceutical adjuvants for the injecting solutions include stabilizing agents, solubilizing agents, buffers, and viscosity regulators. Examples of these adjuvants include ethanol, ethylenediamine tetraacetic acid (EDTA), tartrate buffers, citrate buffers, and high molecular weight polyethylene oxide viscosity regulators. These pharmaceutical formulations may be injected intramuscularly, intraperitoneally, or intravenously, or intravenously.
Compounds of the present invention, and/or the nontoxic, pharmaceutically acceptable salts thereof, may be administered to mammals orally in combination with conventionally compatible carriers in solid or in liquid form. These oral pharmaceutical compositions may contain conventional ingredients such as binding agents selected form the group consisting of syrups, acacia, gelatin, sorbitol, tragacanth, polyvinylpyyrolidone, and mixtures thereof. The compositions may further include fillers such as lactose, mannitols, starch, calcium phosphate, sorbitol, methylcellulose, and mixtures thereof.
These oral compositions may also contain lubricants such as magnesium stearate, high molecular weight polymers such as polyethylene glycol, high molecular weight fatty acids such as stearic acid silica, or agents to facilitate disintegration of the solid formulation, such as starch, and wetting agents such as sodium lauryl sulfate.
The oral pharmaceutical compositions may take any convenient form such as tablets, capsule, lozenges, aqueous or oily suspensions, emulsions, or even dry powders which may be reconstituted with water and/or other liquid media prior to use.
Compounds of the present invention and/or the nontoxic, pharmaceutically acceptable salts thereof may be administered topically in the form of an ointment or cream containing from about 0.1% to 10% by weight of the active component in a pharmaceutical ointment or cream base.
Compounds of the present invention and/or the nontoxic, pharmaceutically acceptable salts thereof, may be administered to mammals rectally in the form of suppositories. For preparing suppositories, a low-melting wax such as a mixture of fatty acid glycerides or cocoa butter is first melted, and the active ingredient is dispersed homogeneously therein by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool and thereby solidify.
The solid or liquid forms may contain flavorants, sweeteners, and/or preservatives such as alkyl p-hydroxybenzoates. The liquid forms may further contain suspending agents such as sorbitol, glucose, or other sugar syrups, methyl-, hydroxymethyl-, or carboxymethylcellulose, and gelatin, emulsifying agents such as lecithin or sorbitol monooleate, and conventional thickening agents. The liquid compositions may optionally be encapsulated in, for example, gelatin capsules, in an effective amount.
Preferably, the pharmaceutical compositions of this invention are in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate amounts of the active component. The unit doses form can be a packaged preparation with the package containing discrete quantities of the preparation. For example, the package may take the form of packeted tablets, capsules, and powders in envelopes, vials or ampoules. The unit dosage form can also be a capsule, cachet, or tablet itself or can be the appropriate number of any of these packaged forms.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from 0.5 mg to about 350 mg according to the particular application and the potency of the active ingredient.
When employed systematically in therapeutic use as analgesic agents in the pharmaceutical method of this invention, the compounds are administered at doses of about 0.05 mg to 2.0 mg of active compound per kilogram of body weight of the recipient.
The following example is provided to enable one skilled in the art to practice the present invention. The examples are not to be read as limiting the scope of the invention as defined by the appended claims, but as merely illustrative thereof.
EXAMPLE 1
Preparation of trans, trans-N,N'-dimethyl-bis[2-(1-pyrrolidinyl)cyclohexyl]-1,2-benzenediacetamide
A. Preparation of 7-methyl-7-azabicyclo[4.1.0]heptane [Modification of method of T. Taguchi and M. Eto, J. Amer. Chem. Soc. 80: 4076 (1958)]
i. Cyclohexene oxide (Aldrich, 196.3 g 2M) was added to a 25/30% solution of aqueous methylamine (745 ml, 6M) (25% solution) dropwise with stirring and cooling in an icebath over one hour, during which time the temperature reached 46° C. The solution was stirred at room temperature overnight, and then refluxed for three hours in fume hood. The solution was cooled in an icebath and saturated with solid NaOH, extracted with 4×200 ml ether, dried (MgSO 4 ) and evaporated to dryness on rotary evaporator.
The crude product was distilled under water vacuum pressure, the first small sample of cyclohexene epoxide discarded. The bulk was distilled from a 1-liter flask with a 60 W isomantle and a short Leibig condenser over a two hour period to yield the product.
bp 118° C. (water vacuum)
yield: 208 g (81%)
ii. Trans-2-(methylamino)cyclohexanol (208 g, 1.61M) was placed in a three liter beaker and dissolved in ether (400 ml). Chlorosulphonic acid (1.89 g, 1.62M) was added dropwise to the ice-salt cooled solution. Added a further 200 ml of ether. The solution was hand stirred. Addition took one hour. The solution/solid was allowed to warm to room temperature and stand for three hours. The ether was decanted and the white salt washed with 300 ml ether which was also decanted.
The solid was cooled in ice-salt bath and NaOH (218 g in one liter water) added slowly. The thick white solid was left at room temperature overnight.
The crude product was distilled in Isomantle with continuous addition of water from separating funnel to retain approximately original volume. After 600 ml of liquid had been collected, the total distillate was saturated with solid NaOH, extracted with 5×200 ml ether, dried (MgSO 4 ) and evaporated on rotary evaporator.
The product was distilled using a water vacuum and air bleed, the collection vessel being cooled in an ice bath.
yield: 67 g (37%), b.p. 38° C. (water vacuum and bleed)
iii. Preparation of trans N-methyl-2-(1-pyrrolidinyl)cyclohexanamine
A mixture of 7-Methyl-7-azabicyclo[4.1.0]heptane (7.0 g, 0.063M), pyrrolidine (17.92 g, 0.25M), water (10 ml) and ammonium chloride (0.16 g) was stirred and refluxed for 21 hours. The solution was cooled and solid sodium hydroxide added and extracted with ether (3×50 ml). The extracts were dried over magnesium sulphate and evaporated under reduced pressure to a brown oil. This was distilled under high vacuum to yield a colorless oil.
b.p.: 95° C. (6.0 g)
B. Trans, trans-N,N'-dimethyl-N,N'-bis-[2-(1-pyrrolidinyl)cyclohexyl]-1,2-benzenediacetamide, dihydrochloride
Trans-N-methyl-2-(1-pyrrolidinyl)-cyclohexanamine (0.365 g) was dissolved in methylene chloride (10 ml) and stirred at room temperature. The di-acid chloride of ortho-phenylenediacetic acid (prepared by the action of thionyl chloride on ortho-phenylenediacetic acid, 0.194 g) dissolved in methylene chloride (10 ml) was added and let stand for 0.5 hour. Ether was added to rapidly stirred solution until no more precipitate appeared. After further rapid stirring for one hour, the precipitate was filtered and dried in a vacuum oven at 90° C. for one hour and stored in a predried bottle. The product was in the form of a white solid (400 mg), mp 261°-263° C.
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Substituted trans-1,2-diaminocyclohexyl amide compounds demonstrating selective opioid receptor binding possess utility as analgesic, diuretic, and psychotherapeutic agents. A method of preparing the compounds, pharmaceutical compositions employing the compounds, and a method of alleviating pain employing the compounds are also disclosed.
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[0001] This application claims Paris Convention priority of DE 100 37 586.3 filed Aug. 2, 2000 the entire disclosure of which is hereby incorporated by reference
BACKGROUND OF THE INVENTION
[0002] The present invention concerns a canceling device for a blinker switch in motor vehicles which effects automatic canceling of the blinker switch from one of the two switched positions into the neutral central position, comprising a casing with at least one catch profile, and having a movable pretensioned trigger finger which is disposed in the switched positions such that it can be actuated by a cam connected to a steering shaft, and comprising a switching piece which is pivotable and equipped with at least one pretensioned catch element engaging in the catch profile.
[0003] A canceling device of this type has been commercially available. When the blinker switch is switched on, the switching piece releases the trigger finger which is caused, due to its pretension, to move radially inward towards the steering shaft and projects into a circular path of the cam connected to the steering shaft. The switching piece is held in the switched position by a pretensioned catch element engaging in a depression of the catch profile.
[0004] When, during a corresponding turning motion of the steering wheel, the cam connected to the steering shaft is moved past the trigger finger, the trigger finger is pivoted sidewardly. Carrier surfaces provided on the trigger finger thereby engage a shoulder of the catch element to pull same, in opposition to its direction of pretension, out of the depression in the catch profile. The switching piece together with the blinker switch can thereby snap back into their neutral central positions.
[0005] The forces required for actuating the trigger finger in the known canceling device are relatively large. This does not provide a problem for the user turning the steering wheel, who cannot feel this force due to the very favorable lever conditions. The large forces which occur during actuation cause, however, different problems: In many modern vehicles, a steering angle sensor is also disposed in the region of the canceling device which is used for electronic determination of the steering angle. The signals provided by the steering angle sensor are used e.g. by an electronic stabilization device for the vehicle. The reliability of the signals provided by the steering angle sensor is therefore very important. To reduce the amount of space needed and the number of required parts, the canceling device for the blinker switch and the steering angle sensor are often mounted to a common support.
[0006] The large forces which occur at the canceling device during its actuation can deform the support to which the canceling device and the steering angle sensor are mounted. These deformations falsify the signals provided by the steering angle sensor.
[0007] It is therefore the underlying purpose of the present invention to further develop a canceling device of the above-mentioned type such that the forces produced during actuation of the trigger finger are reduced.
SUMMARY OF THE INVENTION
[0008] This object is achieved in a canceling device of the above-mentioned type in that the catch profile has at least one movable locking section and the trigger finger is connected to the movable locking section such that the locking section releases the catch element when the trigger finger is actuated.
[0009] In accordance with the invention, for automatic canceling of the blinker switch, the catch element is not returned in opposition to the pretensioning force but rather the path which the catch element must follow between the switched position to the neutral central position “is cleared”. The forces which are required for moving the locking section are much smaller than those of prior art which were required to move the catch element in opposition to the spring force. In theory, only the frictional force between the locking section and the catch element must be overcome. For this reason, the deformations to which the canceling device and the carrier connected therewith are subjected during actuation from one of the two switched positions into the neutral central position are very small which considerably improves the measuring accuracy of a steering angle sensor disposed on the same carrier.
[0010] Advantageous embodiments of the invention are given in the dependent claims.
[0011] A locking section which is easy to realize is formed in a further development of the invention on a part which can be pivoted like a door. Alternatively, the locking section can also be formed on a linearly displaceable part.
[0012] A deflecting element can preferably be provided to transfer the actuating motion of the trigger finger to the locking section. A deflecting element of this type can convert the direction of motion of the trigger finger in a simple fashion such that the locking section can be moved in any direction required e.g. by installation considerations. In addition, such a deflecting element permits realization of various lever arms for changing forces or stroke lengths.
[0013] In a preferred further development of the inventive canceling device, the deflecting element comprises a slot in the region facing the locking section whose longitudinal axis is disposed at an angle with respect to the direction of motion of the locking section, wherein the locking section is connected to a pin which engages the slot. The movement of such a deflecting element can be transformed into a motion of the locking section in a simple fashion.
[0014] A further development is particularly preferred wherein the locking section is kinematically locked in its locked position. This type of kinematic locking can be effected without a spring element, the load of which would have to be overcome during motion of the locking section. With such a restoring device, the movement of the locking section into a position in which the catch element is released requires very little force.
[0015] An example of such kinematic locking of the locking section is effected when the longitudinal axis of the slot is bent and the longitudinal axis of that region of the slot containing the pin of the locking section in the neutral central position is substantially at right angles with respect to a radius line intersecting the axis of rotation of the deflecting element and that region.
[0016] When the blinker switch is in the neutral central position, the locking section is in a position in which the catch element is arrested in its central position. In this neutral central position, the described geometrical arrangement allows the locking section to only transfer forces to the deflecting element whose line of action passes through the axis of rotation of the deflecting element. The corresponding lever arm is equal to zero such that loading of the locking section does not move the deflecting element and the locking section remains locked. Only a motion of the deflecting element moves the pin of the locking section into the other region of the slot in which the mechanism is unlocked.
[0017] An alternative to the angled slot is given in a further development, wherein the deflecting element comprises a stepped slot in its section facing the locking section into which a pin, connected to the locking section, engages. Such an embodiment is particularly preferred when the locking section is formed on a linearly displaceable part. The inventive canceling device can comprise at least one tensioning element which loads the deflecting element into its neutral central position. In connection with a purely kinematic locking of the locking section, the force required for actuating the trigger finger is substantially given by the tensioning force of this tensioning element. Since this can be very small, the required actuating force is also correspondingly small.
[0018] The tensioning element can thereby comprise a helical pressure spring whose one end is received in a sleeve having a closed end which is rounded or semi-spherical, wherein the closed end of the sleeve is preferably received in a corresponding depression in the casing. In this further development, the helical pressure spring can be oriented in correspondence with the position of the deflecting element. The depression is thereby preferably also rounded and dimensioned such that a corresponding pivoting motion of the sleeve and simultaneously of the helical pressure spring is possible.
[0019] To improve engagement of the tensioning element on the deflecting element, the invention also provides the deflecting element with a pin-like shoulder which the tensioning element surrounds at its free end, or a recess into which the tensioning element engages.
[0020] To secure the trigger finger against tilting, the trigger finger can be further provided with at least one supporting wing for support on the deflecting element.
[0021] In a further development of the invention, the casing comprises a wall element which is provided with a guiding slot which extends parallel to the longitudinal axis of the trigger finger, into which a guiding pin of the trigger finger engages and/or at least one guiding slot into which a guiding pin engages which is disposed on a section of the deflecting element. Such guiding slots guide the trigger finger and/or the deflecting element to ensure even more accurate motion of the corresponding elements.
[0022] The guiding slot can thereby constitute a stop for the path of motion of the trigger finger or of the deflecting lever. Such a stop can e.g. delimit the maximum linear motion of the trigger finger out of the casing. The final positions of the deflecting lever can likewise be defined in a simple fashion.
[0023] The forces which are required to move the switching piece from its neutral central position into one of the switched positions, can be reduced if the catch element comprises a rotatable roller on its end facing the catch profile. It is, of course, also possible to provide a ball-shaped or a similar element instead of a roller, which turns along the catch profile, with little friction, during motion of the catch elements. The wear on the catch profile and on the catch element in the region of the contact surfaces is thereby also reduced.
[0024] The catch profile can furthermore comprise a canceling section having a step which must be overcome when actuating the catch element into the switched position. Such a step produces a defined engaged position which the user can feel when engaging the blinker switch.
[0025] One further development of the invention is particularly preferred, wherein the locking section comprises a rounded and/or flattened locking edge. A locking edge of this type produces a defined contact point between the catch element and the locking section in the switched position of the indicating switch, i.e. when the catch element is locked by the locking section.
[0026] In accordance with the invention, the trigger finger can abut a pretensioned intermediate part and have a projection in the contacting area which engages with play behind a recess in the intermediate part. This permits pre-mounting and pre-tensioning of the intermediate part on the trigger finger without having it rotate out of the mounted position in response to pre-tensioning. This considerably simplifies installation of the canceling device.
[0027] A further similar development provides that the locking section is connected to a mushroom-like shoulder which engages with play in a corresponding recess in the casing. This mushroom-like shoulder facilitates assembly in that the locking section can be pre-mounted on the casing such that it cannot drop out during assembly of the other parts.
[0028] Finally, it is particularly advantageous when the trigger finger comprises a control body having a substantially square overall contour. Such an actuation section permits a maximum path of motion for the loaded part, in particular of a deflecting element with which the control body cooperates.
[0029] Two embodiments of the invention are described in detail below with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0030] [0030]FIG. 1 shows a plan view of a first embodiment of a canceling device, in its neutral central position;
[0031] [0031]FIG. 2 shows a plan view of the canceling device of FIG. 1 in one of its switched positions;
[0032] [0032]FIG. 3 shows a plan view of the canceling device of FIG. 1 during automatic canceling from the switched position into the neutral central position;
[0033] [0033]FIG. 4 shows a perspective view of the trigger finger and an intermediate part of the canceling device of FIG. 1;
[0034] [0034]FIG. 5 shows a perspective view of a casing part with a catch profile, and two locking sections of the canceling device of FIG. 1;
[0035] [0035]FIG. 6 shows a perspective view of some components of the canceling device of FIG. 1, in the assembled state;
[0036] [0036]FIG. 7 shows a perspective view of a switching piece of the canceling device of FIG. 1;
[0037] [0037]FIG. 8 shows a perspective view from below of several casing parts of the canceling device of FIG. 1;
[0038] [0038]FIG. 9 shows a schematic sketch of a second embodiment of a canceling device, in its neutral central position;
[0039] [0039]FIG. 10 shows the canceling device of FIG. 9 during automatic canceling from a switched position into the neutral central position; and
[0040] [0040]FIG. 11 shows a detailed plan view of the canceling device of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] The overall canceling device for a blinker switch in an motor vehicle is designated with the reference numeral 10 in FIG. 1. It comprises a casing part 12 with a catch profile insert 14 , a trigger finger 16 , two deflecting elements 18 and 20 , two locking doors 22 and 24 and one switching piece 26 of which only the rollers 28 and 30 , the catch elements, a triangular locking part 32 , and a point of rotation 34 are shown for reasons of clarity. The switching piece 26 is only symbolically indicated by dash-dotted lines interconnecting the rollers 28 and 30 , the triangular locking part 32 , and the point of rotation 34 . A blinker switch, also only indicated with dash-dotted lines, has been designated by reference numeral 36 .
[0042] The casing part 12 comprises a bottom 38 (transparent in FIG. 1) and a wall 40 extending perpendicular thereto. FIG. 8 shows the bottom in detail. A collar-like support 42 is also formed on the wall 40 and disposed coaxially with respect to an axis of a steering shaft (only shown with dash-dotted lines: see, in particular, FIGS. 6 and 8).
[0043] The catch profile insert 14 is inserted into the casing part 12 within the wall 40 . Its exact design is shown in FIG. 5. The locking doors 22 and 24 are disposed in a recess of the catch profile insert 14 and pivot about axes 45 a and 45 b via lower pivot pins (not shown in the drawing) in corresponding recesses of the catch profile insert 14 . The visible upper pivot pins 47 a and 47 b engage in corresponding recesses (without reference numerals) in the bottom 38 . Each locking door 22 or 24 bears, on each lever arm 49 a or 49 b , a control pin 51 a or 51 b which cooperates with the deflecting element 18 or 20 in a fashion which will be explained below. To secure the locking doors 22 , 24 from falling out during mounting, a mushroom-like shoulder 43 a , 43 b is formed on their lower side which engages with some play behind a corresponding longitudinal recess 41 a , 41 b in the catch profile insert 14 (see FIG. 6).
[0044] In the position of the locking doors 22 and 24 shown in FIGS. 1 and 5, two upper catch depressions 46 and 48 or two lower catch depressions 50 and 52 are formed in the catch profile insert 14 . The locking doors 22 and 24 bear a locking section 54 or 56 , parallel to their respective pivot axis, which separates corresponding catch depressions 46 and 48 or 50 and 52 from each other. The catch profile insert furthermore comprises two canceling sections 53 a and 53 b , each with one step 55 a , 55 b.
[0045] As seen on the left-hand side of FIG. 1, the casing part 12 has an opening 58 through which the blinker lever 36 passes. While the switching piece 26 and the corresponding catch elements are indicated only symbolically by a dash-dotted line in FIGS. 1 through 3, the exact design of the switching piece 26 can be extracted from FIG. 7. This figure also shows the catch elements 62 and 64 which are guided in the switching piece 26 . In the neutral central position shown in FIG. 1, the catch elements 62 and 64 extend downwardly from the center into the catch depression 52 or vertically upwards into the catch depression 46 . The radially inner sections of the two catch elements 62 and 64 are hollow and accommodate a helical pressure spring (not shown) by means of which the two rollers 28 and 30 of the catch elements 62 and 64 are loaded against the catch profile insert 14 or the locking doors 22 and 24 .
[0046] The trigger finger 16 , shown in particular detail in FIG. 4, has a carrier 66 oriented towards the axis 44 of the steering shaft when installed, which is disposed in a retracted state in the central position of the canceling device 10 (FIG. 1). The carrier 66 is formed on a control body 68 which has a substantially longitudinal shape when viewed from the top. Supporting wings 70 are formed on the sides of the control body 68 . The side of the control body 68 facing away from the carrier 66 is provided with a guiding pin 72 on its upper side and with a stop pin 74 on its lower side. The guiding pin 72 engages in a guiding slot 73 in the bottom 38 of the casing 12 .
[0047] The end of the control body 68 facing away from the carrier 66 is rounded and abuts an end face of a cylindrical intermediate part 76 . The end of the intermediate part 76 facing away from the trigger finger 16 is open. A helical pressure spring 78 is disposed in the intermediate part 76 and is supported, on one side, on the end of the intermediate part 76 facing the trigger finger 16 and, on the other side, on a supporting element 80 which is fixed to the housing and which is only symbolically shown in the figures. The end face of the intermediate part 76 facing the trigger finger 16 is provided with a recess 82 which engages with play behind a hook-shaped pin 84 formed on the control body 68 which has an insertion slope permitting pre-mounting of the intermediate part 76 on the trigger finger 16 to facilitate installation of the canceling device 10 .
[0048] The two deflecting elements 18 and 20 each have the shape of a flat elbow lever, each with one first lever section 98 and 100 and a second lever section 99 and 101 . A pivot axis 90 and 92 is defined by a pin 86 and 88 . The pivot pins 86 and 88 are accommodated in corresponding recesses 94 and 96 in the bottom 38 of the casing part 12 (see FIG. 8).
[0049] Each end of the second lever section 99 and 101 of the deflecting element 18 and 20 facing the respective locking door 22 and 24 has a slot 102 and 104 , which has two sections, disposed at an angle with respect to each other. The longitudinal axis of that region of the slot 102 and 104 , which accommodates the control pin of the locking door 22 and 24 in the neutral central position of the canceling device, 10 (shown in FIGS. 1 and 2) is perpendicular to a radius line intersecting the axis of rotation 90 and 92 of the deflecting element 102 and 104 and that region. FIG. 1 shows the corresponding reference numerals for the upper deflecting element 18 only. The corresponding region of the slot 102 is designated with reference numeral 106 , its longitudinal axis is referenced with 108 , and the radius line with 110 . The other region of the respective slot 102 and 104 is formed such that its longitudinal axis is disposed at an angle with respect to the direction of motion of the respective locking section 54 and 56 .
[0050] The longitudinal axis of the corresponding region of the upper slot 102 has the reference numeral 112 . The control pins 51 a and 51 b of the locking doors 22 and 24 are slidingly accommodated in the slots 102 and 104 . One guiding pin 114 and 116 is formed on the first lever section 98 and 100 proximate the trigger finger 16 and is disposed on a side thereof facing away from the trigger finger 16 to engage with play in corresponding guiding slots 117 a , 117 b in the bottom 38 of the casing part 12 .
[0051] A helical pressure spring 118 is tensioned between the first lever section 98 or 100 of the deflecting element 18 or 20 and the upper or lower wall 40 of the casing part 12 which is shown in detail only in the upper region of FIG. 1 and is otherwise indicated by a dash-dotted line. One end of the helical pressure spring 118 surrounds a projection 120 formed on the lever 98 . The other end is received in a sleeve 122 whose closed end is rounded. This closed end is received in a depression 124 in the wall 40 of the casing part 12 .
[0052] The helical pressure spring 118 loads the lever section 98 or 100 towards the trigger finger 16 . The guiding slots 117 a and 117 b are dimensioned and disposed to form a stop, thereby leaving a gap between control body 68 of the trigger finger 16 and the deflecting levers 18 or 20 in the position shown in FIGS. 1 and 2.
[0053] The function of the canceling device 10 is now explained, in particular, with reference to FIGS. 1 through 3.
[0054] In the neutral central position shown in FIG. 1, the guiding pins 114 or 116 of the deflecting elements 18 or 20 abut the inner ends of the guiding slots 117 a or 117 b . The second lever sections 99 or 101 of the deflecting elements 18 and 20 are therefore located in a position proximate to the wall 40 of the casing part 12 . The control pins 51 a or 51 b on the projections 49 a or 49 b of the locking doors 22 and 24 are located in the locking regions 106 of the two slots 102 and 104 . In this position, the two locking doors 22 and 24 are kinematically locked and inwardly pivoted such that the two locking sections 54 and 56 of the locking doors 22 and 24 form an elevated section within the profile contour of the catch profile insert 14 .
[0055] The two rollers 28 and 30 of the catch elements 62 and 64 lie in the catch inserts 48 or 52 formed in this fashion, thereby locking the blinker lever 36 in the horizontal position shown in FIG. 1. The triangular locking part 32 , which is a component of the switching piece 26 , is disposed in a central position approximately on the central axis of the opening 58 .
[0056] The stop pin 74 of the trigger finger 16 abuts the tip of the triangular locking part 32 . In this position, the trigger finger 16 is loaded by the helical pressure spring 78 and the intermediate part 76 which abuts the trigger finger 16 . The triangular locking part 32 thereby prevents a rightward motion of the trigger finger 16 (in FIG. 1), i.e. towards the steering shaft 44 in response to the direction of loading of the helical pressure spring 78 .
[0057] When the user presses the blinker lever 36 downwards, the switching piece 26 is also pivoted about the point of rotation 34 . The roller 28 of the catch element 62 is thereby moved, via the rising locking door 22 , in opposition to the force of the helical pressure spring (not shown) disposed between the two catch elements 62 and 64 . When the roller 28 of the catch element 62 has overcome the locking section 54 of the locking door 22 , it is pressed, in response to the force of the helical pressure spring, into the catch depression 46 which is delimited on its right-hand side by the locking section 54 . This position of the switching part 26 is shown in FIG. 2.
[0058] The rotary motion of the switching piece 26 also moves the triangular locking part 32 upwards such that the stop pin 74 of the trigger finger 16 is released from the tip of the triangular locking part 32 , and slides along its side surface thereby releasing the trigger finger 16 for motion, in response to the direction of loading of the helical pressure spring 78 , in the direction of the arrow 126 . This release motion terminates when the guiding pin 72 , provided on the trigger finger 16 , abuts the right end of the guiding slot 73 in the bottom 38 of the casing part 12 (see FIG. 2). In the position of FIG. 2, the carrier 66 of the trigger finger 16 clearly projects towards the steering shaft 44 .
[0059] Turning of a steering wheel (not shown in the drawing) produces corresponding turning of the steering shaft 44 . A cam 128 is connected to the steering shaft. In response to the rotary motion, the cam 128 pushes the carrier 66 of the trigger finger 16 in the direction of the arrow 130 (see FIG. 3) thereby pivoting the trigger finger 16 about an axis which extends parallel to the axis of the steering shaft 44 , as defined by the guiding pin 72 . Due to this pivoting motion of the trigger finger 16 , the control body 68 presses against the first lever section 98 of the deflecting element 18 thereby pivoting same about the axis of rotation 90 given by the pivot pin 86 and in the direction of the arrow 132 , in opposition to the direction of loading of the helical pressure spring 118 .
[0060] This pivoting motion also produces pivoting of the second lever section 99 of the deflecting element 18 in the direction of the arrow 134 . This causes the control pin 51 a on the projection 49 a of the locking door 22 to slide out of the locking region 106 of the slot 102 and move towards the upper end of the slot 102 (in FIG. 3). The maximum pivoting angle of the deflecting element 18 is delimited by the guiding slot 117 a in the bottom 38 of the casing part 12 and by the length of the slot 102 .
[0061] The sliding motion of the control pin 51 a of the locking door 22 in the slot 102 pivots the locking door 22 about the pivot axis 45 a until it comes to rest in a substantially horizontal position shown in FIG. 3. In this position, the locking section 54 of the locking door 22 is completely retracted such that the two catch depressions 46 and 48 are no longer present. The roller 28 of the catch element 62 is no longer locked by the locking section 54 .
[0062] The lower roller 30 of the lower catch element 64 of FIG. 3 is pressed by the helical pressure spring at an inclined angle against the wall of the catch profile insert 14 , thereby pivoting the switching piece 26 in the direction of the arrow 138 and back into its original position shown in FIG. 1. The stop pin 74 of the trigger finger 16 is thereby pressed to the left by the side surface of the triangular locking part 32 in opposition to the direction of loading of the helical pressure spring 78 such that the carrier 66 of the trigger finger 16 once more assumes its retracted position.
[0063] As soon as the cam 128 releases the carrier 66 of the trigger finger 16 , same pivots about the axis given by the guiding pin 72 into its neutral central position (shown in FIG. 1) in response to loading by the helical pressure spring 118 as transferred via the first lever section 98 of the deflecting element 18 . The first lever section 98 of the deflecting element 18 and, at the same time, the second lever section 99 provided with the slot 102 perform a corresponding pivoting motion thereby returning the locking door 22 together with the locking section 54 into the position shown in FIG. 1 in which catch depressions 46 and 48 are to the left and right of the locking section 54 .
[0064] A second embodiment of a canceling device 10 will be explained with reference to FIGS. 9 - 11 . The parts having functions equivalent to the first embodiment have the same reference numerals and may not be described in detail.
[0065] The two purely schematic representations of FIGS. 9 and 10 show a stepped slot 102 (not a bent one) in the deflecting element 18 . A linearly displaceable catch element 22 is provided (instead of a pivotable locking door) and is connected to a control pin which is slidingly accommodated in the stepped slot 102 . As shown in FIG. 10, the deflecting element 18 is displaced towards the left in response to loading by the carrier 66 of the trigger finger 16 thereby causing the guiding pin of the catch element 22 to slide in the slot 102 from a locking stage 106 into an opening stage 140 . Consequently, the catch element 22 moves in the direction of the arrow 136 thereby releasing the roller 28 of the catch element 62 which permits movement of the roller 28 in the direction of the arrow 138 and return of the blinker lever 36 into its neutral central position shown in FIG. 11.
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The invention concerns a canceling device ( 10 ) for a blinker switch in motor vehicles for effecting automatic return of the blinker switch from one of the two switched positions into the neutral central position. Towards this end, a casing ( 12 ) having a catch profile ( 14 ) is provided as is a movable pretensioned trigger finger ( 16 ) which can be loaded by the cam ( 128 ) of a steering shaft ( 44 ) and with a pivotable switching part ( 26 ) having pretensioned catch elements ( 62, 64 ). To reduce the actuating forces, the catch profile ( 14 ) is provided with a movable locking section ( 54, 56 ). The trigger finger ( 16 ) should be connected to the movable locking section ( 54, 56 ) such that the locking section ( 54, 56 ) releases the catch element ( 62, 64 ) when the trigger finger ( 16 ) is actuated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a valve device for controlling liquid flow, in particular for use in filling a carton.
2. Description of the Prior Art
European Patent Publication No. 0013132 discloses an aseptic packaging machine which includes a chain conveyor conveying cartons along a path in an aseptic chamber including an advance leg and a return leg each extending along the machine. Ultra-violet germicidal lamps extend over at least a major portion of the advance leg. Aseptic liquid is fed into the cartons by a filling device. After filling, the cartons are top-heated and sealed by a top-heating device and a top-sealing device. The only non-aseptic matter deliberately introduced into the chamber is the cartons. The chamber is cleaned internally by cleaning fluid from spray nozzles. The carton entry to and exit from the chamber have aseptic air curtains.
The filling device is particularly designed to prevent microbes obtaining access to the aseptic liquid product being supplied to the aseptic chamber. The filling device includes a mounting frame which mounts four stainless steel reciprocatory bellows having bottom walls which are reciprocatorally driven by respective reciprocatory plungers and having top flanges fixed to respective lower limbs of fixed T-unions. Respective upper limbs of the unions contain respective spring-loaded, non-return, inlet valves which open to allow downward flow through the limbs. Intermediate limbs of the respective unions are connected to respective arcuate pipes which curve downwardly towards the path of the cartons and which at their lower ends are connected to respective outlet nozzles which contain respective spring-loaded, non-return, outlet valves. The chains advance the cartons stepwise directly below the line of nozzles and a selected number of the bellows are operated each to deliver a predetermined dosage of long-life milk to the vertically upright cartons, the number of bellows operated being dependent upon the nominal capacity of the cartons. Thus, with each bellows being pre-set to deliver a half pint at each reciprocation, all four bellows are operated for cartons which can each hold one quart. On each bellows performing a pressure stroke, because the inlet valve in its union is held closed by its spring and by the milk pressure, the inlet valve is automatically opened against the action of its spring so that the bellows can draw in milk from an expansion chamber.
In a widely used design applicable to that machine, the nozzle would comprise a tubular housing and a valve member in the housing. The tubular housing is formed internally, at a location spaced an appreciable distance above its lower extremity, with a valve seat in the form of a downwardly-facing, frusto-conical surface. Immediately beyond this surface, the housing widens to form an expansion space and then narrows again to continue downwards as a cylindrical bore. The valve member comprises a disc-form driving part, a stem extending downwards from the driving part, and a closure part fixed to the lower end of the stem and having a frusto-conical surface co-axial with the housing and arranged to come face-to-face with the valve seat. This latter surface is formed with a co-axial annular groove containing an elastomeric O-ring for sealing against the valve seat. The valve member is movable axially between a closed condition in which the closure part is within the tubular housing and acts sealingly on the valve seat by way of the O-ring and an open condition in which the closure part is still within the housing but spaced downwards from the valve seat. The valve member is encircled by a closing spring urging the closure part into its closed position. The driving part is a downwardly diverging, frusto-conical disc co-axial with the housing, which has a downwardly diverging, frusto-conical, internal surface encircling the disc and of a cone angle equal to that of the disc. In the closed condition of the valve member, there is a very small clearance between the disc and this surface. The valve member is opened by the pressure differential between the pressure of the liquid upstream of the driving part and the pressure downstream of the driving part. When this pressure differential is sufficiently high to overcome the pressure of the spring, the valve member opens. As the valve member opens, the clearance width between the driving part and its complementary surface of the housing increases linearly. The driving part is considerably smaller in diameter than is the O-ring. The extent of compression of the spring determines the extent of opening of the valve member. The valve member includes a second stem extending downwardly from the closure part and widening at its lower end region to obturate the cylindrical bore in the closed condition of the valve member. In the open condition, the lower extremity of this stem is spaced downwards from the housing and the liquid can flow down therebetween. The valve member also includes two or more fins which extend upwardly from the lower end of the second stem and slide on the surface of the cylindrical bore. Were it not for the fins, in the open condition of the valve member, the liquid would flow from the valve member as a substantially unbroken tube of liquid. This would mean that air trapped within the tube of liquid and increasingly under pressure as the liquid level in the carton climbs would be forced to break through the tube of liquid to escape and in so doing would disturb the smooth flow of the liquid into the carton and cause splashing of liquid beyond the carton. The presence of the fins ensures that corresponding vents are formed along the tube of liquid through which vents air can flow without disturbing the flow of the liquid.
The nozzle described above has a number of disadvantages.
The extent of opening of the valve member is relatively unpredictable, because the clearance width between the driving part and its complementary surface of the housing increases continuously from the closed condition to the maximum open condition, so that the open position of the driving part can be almost anywhere along such complementary surface, depending upon the pressure differential upon the driving part, which itself depends upon the velocity and viscosity of the liquid. Such unpredictability can lead to difficulties in designing and operating the machine to cope with various liquids and various containers, particularly since there is an optimum range of rate of flow of liquid into the carton. Another disadvantage is that, as the valve member reaches its closed condition under the action of the return spring its speed is relatively high and the closure part strikes the valve seat at speed, causing liquid at the valve seat to be spat out in various directions. In addition, the housing has an appreciable area of its internal surface below the annulus of sealing between the valve seat and the O-ring, and this area is normally wetted by contact with the liquid from the open outlet valve, so that there is a risk that liquid will drip from the nozzle even when the outlet valve has been fully closed and thus drip onto the exteriors of cartons or onto the conveyor forwarding the cartons. Such dripping is obviously undesirable.
U.S. Pat. No. 2,962,227 discloses a fuel injection nozzle comprising a tubular body internally screwthreaded to receive a connector nipple having an internal bore terminating at its lower end in a cylindrical chamber. Located in the chamber is a detachable tubular valve housing through which extends a stem carrying at its lower end a valve closure member of apparently frusto-conical form co-operating with an apparently frusto-conical valve seat within the outlet of the housing. The upper end of the stem is externally screwthreaded to receive an internally screwthreaded metal disc formed with angularly drilled apertures each inclined inwardly and downwardly and having its lower end spaced from the stem. These apertures permit fuel to pass to beneath the disc. The valve stem is maintained in position on the disc by a lock nut. The central bore of the valve housing is counterbored to receive a distance piece and a helical spring bearing at its lower end on the distance piece and at its upper end against the underside of the disc. In the bottom of the chamber and underneath the disc is a ring of elastomeric material which is normally separated from the underside of the disc by a small free space. When the nozzle is operated at low delivery rates, fuel enters the chamber and passes through the apertures in the disc and down to the valve seat. The fuel pressure thereby built up downstream of the disc ultimately forces the valve closure member to open against the force of the spring, so that the fuel is injected, but a small free space still remains between the elastomeric ring and the disc. However, at high delivery rates, the valve opens more, thus pressing the disc against the ring and thereby closing the free space. Thereupon, less of the underside of the disc is exposed to the fuel pressure, so that the valve is maintained more reliably in that position.
The fuel injection nozzle just described is clearly not designed for use with liquids of a relatively wide range of viscosities, since the higher the viscosity of the liquid, the greater would be the tendency for the disc to contact the ring at relatively low delivery rates. Furthermore, if an enlarged such nozzle were to be used in the filling of cartons, as the wetted, apparently frusto-conical surfaces of the valve closure member and the valve seat came together as the valve closure member reached its closed position, they would squeeze out downwardly from between them drops of liquid which would be liable to drop onto the cartons or the machine parts below them. A further disadvantage would be that the issuing of liquid from immediately adjacent to the lower end of the housing, which would occur irrespective of the extent of opening of the valve member, would mean that a container conveyed along sideways to immediately beneath the housing would be likely to have liquid splashed onto any top sealing surfaces thereof and over onto the outside of the container, which would obviously be disadvantageous.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a valve device for controlling liquid flow, comprising a tubular housing having a substantially cylindrical internal surface followed longitudinally of the housing by a second internal surface spaced further from the axis of said housing than is said substantially cylindrical internal surface, a valve member, extending substantially co-axially in said housing and movable relative to said housing and axially thereof between an open condition in which liquid can flow between said valve member and said housing and a closed condition, and biassing means urging said valve member into said closed condition, said valve member including an obturating portion which, in said closed condition, substantially obturates said tubular housing at a location along said substantially cylindrical internal surface, and which, in its opening movement, sweeps along said substantially cylindrical internal surface while closely encircled by the same and later sweeps along said second internal surface and arrives at an equilibrium position at a location along the latter surface in which liquid is flowing through between said obturating portion and said second internal surface and in which the total force tending to open said valve member is balanced by the total force tending to close the same.
This arrangement of a substantially cylindrical internal surface followed by an enlargement provided by the said second internal surface enables the open position of the valve member to be relatively predictable, so that the valve device can be made to cope with liquids of considerably differing viscosities. Another advantage is that the possibility of too little opening of the valve member, which would mean that the liquid outlet would be of too small a throughflow area, so that the liquid could spurt out at a high velocity at the top of the container to be filled, with wetting of top sealing surfaces and even of the outside surface of the container, can be avoided.
According to another aspect of the present invention, there is provided a valve device for controlling liquid flow, comprising a tubular housing, an annular valve seat on said housing and substantially co-axial therewith and bounding an internal surface of said housing and a valve member including a valve closure part and extending substantially co-axially in said housing and movable relative to said housing downwardly axially thereof from a closed condition in which said closure part acts sealingly against said valve seat round an annulus of sealing to an open condition in which said closure part is spaced from said valve seat, said housing having wetted internal surface portions which when liquid passes downwardly through said housing when said closure part is open are normally contacted by said liquid and said member having wetted external surface portions which when said liquid passes downwardly through said housing when said closure part is open are normally contacted by said liquid, some of said wetted internal surface portions of said housing below said annulus of sealing or some of said wetted external surface portions of said valve closure part below said annulus of sealing bounding an annular groove substantially co-axial with said housing for receiving and retaining liquid squeezed out downwardly at said valve seat.
Owing to the retention of the squeezed-out drops of liquid in the annular groove, dripping of liquid from the closed valve device can be virtually eliminated. Although there can be only one groove, and that in either the housing or the closure part, there are preferably two grooves, one in the housing and the other in the closure part.
According to a further aspect of the present invention, there is provided a valve device for controlling liquid flow, comprising a tubular housing having a substantially cylindrical internal surface followed longitudinally of the housing by internal surface means which is of slightly greater diameter compared to said substantially cylindrical internal surface and followed longitudinally of the housing by an annular valve seat substantially co-axial with said housing, a valve member including a valve closure part and extending substantially co-axially in said housing and movable relative to said housing and axially thereof between an open condition in which liquid can flow between said valve member and said housing and a closed condition in which said closure part acts sealingly against said valve seat, and biassing means urging said valve member into said closed condition, said valve member including an obturating portion which, in said closed condition, substantially obturates said tubular housing at a location along said substantially cylindrical internal surface, and which, in its opening movement, firstly sweeps along said substantially cylindrical internal surface while closely encircled by the same and then sweeps along said internal surface means, said internal surface means extending downwardly from near to the closed position of said obturating portion.
During the closing stroke of the valve member, the slight clearance between the obturating portion and the said internal surface means allows liquid trapped between the obturating portion and a non-return valve upstream of the valve device to escape to downstream of the obturating portion, so permitting relatively fast return of the valve member. However, since the clearance between the housing and the obturating portion decreases as the valve member nears its closed condition, the moving valve member is thereupon slowed, so that the closure part closes less forcefully under the action of the biassing means, so mitigating any tendency for the liquid to be spat out.
According to a yet further aspect of the present invention, there is provided a valve device for controlling liquid flow, comprising a tubular housing, an annular valve seat on said housing and substantially co-axial therewith and bounding an internal surface of said housing and a valve member including a valve closure part and extending substantially co-axially in said housing and movable relative to said housing downwardly axially thereof from a closed condition in which said closure part acts sealingly against said valve seat round an annulus of sealing to an open condition in which said closure part is spaced from said valve seat, said valve member also including fin means extending upwards from said closure part and a tubular part co-axial with said housing and a sliding fit in said internal surface, said tubular part being fixed to said fin means and downwardly terminating short of said closure part, whereby said tubular part and said closure part bound between them liquid outlet means which in said open condition is spaced from said housing.
Since the liquid outlet means is spaced downwards from the housing in the open condition, a container arranged with its top adjacent to the bottom of the housing can receive at least most of the liquid from the valve device at a level below the top of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be clearly understood and readily carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 shows a diagrammatic perspective view of a packaging machine,
FIG. 2 shows a sectional end elevation of the machine,
FIG. 3 shows a detail of FIG. 2,
FIG. 4 is a view similar to FIG. 3 of a modified version of a nozzle of the machine,
FIG. 5 shows a detail of FIG. 4,
FIG. 6 shows another detail of FIG. 4, and
FIG. 7 shows a view similar to FIG. 3 of another modified version of the nozzle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The machine which will now be described constitutes a development of the machine described in the co-pending U.S. patent application Ser. No. 279,343 of Liquipak International Inc., now U.S. Pat. No. 4,402,461.
Referring to the drawings, the machine 1 for carrying out packaging includes at one end of the machine a conventional device 2 for pre-forming (including bottom-sealing) gable-topped cartons. The open-topped pre-formed cartons are taken to the other end of the machine by means of a chain system (not shown), which advances the open-topped cartons step-wise and in a vertically upright condition.
Vacuum cups on a carton picker (not shown) pull a single carton blank consisting of paperboard coated on both faces with thermoplastics, from a carton basket 3, open it and place it in position in loading guides. A hydraulically operated loader chain pushes the open carton blank onto a forming mandrel 4 which then indexes to the next position.
A bottom breaker 5 closes up on the carton bottom and folds it on pre-scored lines.
At the next two index positions, the carton is placed under bottom heaters 6 and 7, which heat the plastics in preparation for bottom sealing.
As the mandrel indexes to the next station, the carton passes through top folding rails and stops in position under a bottom press 8. The bottom press advances and cools and seals the carton bottom.
At the next index position, a bottom press 9 advances and cools and seals the carton bottom again, and top breakers 10 break the carton top on pre-scored fold lines.
At the next station, the carton is pulled off the mandrel by an unloader 11 and is placed on an unloader vacuum cup on a transfer tube 12.
The transfer tube then tilts the carton through 45° into a filler section 13, at which time a carton lock swings down and holds the carton in place.
The carton is indexed through the section 13 by the chain system.
A spreader plate 14 engages the carton top and guides the carton into position under a row of five dosaging filling devices 15 connected to a supply tank 16 containng milk, for example. The carton is indexed through five stages of filling at the five devices, and receives approximately one-fifth fill at each station, if all the devices 15 are in use.
At the next station, the filled carton top is heated under an electric top heater 17. The carton then passes through cooled top folding rails 18 and is sealed by sealer jaws 19. The filled and sealed carton is then indexed out onto an accumulating table.
The machine as so far described is of a conventional type.
Referring to FIG. 2, each filling device 15 includes a mounting frame 20 which mounts a row of five vertical ducts 28 each consisting of an uppermost ducting section 29 connected to the supply tank 16, an upper bellows 30 attached at its upper end to the section 29 by a clamp 31, a lower ducting section 32 containing a non-return inlet valve 33 and attached at its upper end by means of a clamp 34 to the bellows 30, a lower bellows 35 connected at its upper end by means of a clamp 36 to the section 32, and a nozzle 37 connected at its upper end by means of a clamp 36' to the bellows 35. The bellows 30 and 35 are of polypropylene and have been formed by blow-moulding. The nozzle 37 includes a vertical tubular housing 38 fixed in the mounting frame 20. The mounting frame 20 includes five vertical pillars (of which one is seen in FIG. 2 and referenced 39). Vertically slidably mounted on each pillar is a bracket 40 integral with the ducting section 32 and connected to a piston rod 41 of an hydraulic or pneumatic ram 42 which acts between the frame 20 and the bracket 40 and of which the cylinder is fixed to the frame 20. There is thus one ram for each vertical duct 28. Arranged co-axially in each housing 38 is a valve member 43 which consists of a frusto-conical closure part 44, a vertical central stem 45 extending upwardly from the part 44, a driving part 46 of inverted cup shape attached to the upper end of the stem 45, and four vertical fins 47 extending upwardly from the part 44 and arranged to slide on the internal surface of the housing 38 in order to guide movement of the valve member 43 in the housing 38. A spiral compression spring 48 acting between an internal, upwardly facing shoulder 49 of the housing 38 and the base of the inverted cup-shaped part 46 urges the valve member 43 into a closed condition shown in FIGS. 2 and 3, in which the outer peripheral edge zone of the frusto-conical part 44 bears face-to-face directly against a corresponding frusto-conical valve seat 50 formed at the lower extremity of the internal surface of the housing 38. The fins 47 terminate as closely as practical to the outer peripheral end zone of the part 44, while leaving an adequate seating. From the valve seat 50, the internal surface of the housing 38 continues upwards as a circular cylindrical bore surface 51 and thence as the upwardly facing surface of the shoulder 49. A short distance above the shoulder 49 is another upwardly-facing shoulder 52. Arranged on the shoulder 52 are upstanding lugs 53 integral with the housing, which serve as abutments which co-operate with the outer peripheral edge zone of the part 46 to provide a positive limit to the maximum extent of opening of the valve member 43 and thus define the fully open position of the member 43. The housing 38 has a co-axial downwardly diverging frusto-conical internal surface 54 at an angle of about 10° to the axis of the housing 38 and, immediately above that surface, a co-axial cylindrical internal surface 55 of a diameter equal to the minimum diameter of the surface 54. The outer peripheral edge zone of the part 46 is a sliding fit in the surface 55.
In the following description of the operation of the filling device, it will be assumed that in the initial condition of the device the valve member 43 is in the closed condition shown, and that both of the bellows 30 and 35 are full of liquid to be fed to the nozzle 37.
The ram 42 displaces the bracket 40 upwards from the position shown. The pressure of the liquid in the bellows 30 on the inlet valve 33 opens the valve against the action of its closing spring 33' and the liquid flows into the bellows 35 as the ducting section 32 moves upwards and compresses the bellows 30. Upon the ram 42 reaching its upper end position and beginning to return downwards, the valve 33 closes automatically and the liquid in the bellows 35 is pressed by the ram 42 against the driving part 46, so that the member 43 moves downwards against the action of the spring 48. The outer peripheral edge zone of the part 46 therefore sweeps along the surface 55 and the part 44 opens; then that zone sweeps along the surface 54 so that a continuously widening gap is formed between that zone and the surface 54 through which gap liquid flows downwards at a correspondingly increasing rate until the member 43 arrives at a position at which the upward force on the member 43 is in equilibrium with the downward force thereon. The maximum possible downward movement of the member 43 is determined by the part 46 abutting against the lugs 53, whereat the closure part 44 is opened to its maximum extent. Under the pressure of the ram 42, the liquid in the bellows 35 continues to flow through the gap between the part 46 and the surface 54. The liquid flow through the gap is deflected inwardly by the shoulder 52. Thus the shoulder 52 changes the velocity of the liquid flow from the gap to one the predominant component of which is axial of the housing 38 to one the predominant component of which is inwardly radial of the housing 38. The liquid flow deflected from the shoulder 52 thus interferes with itself. The flow proceeds down the housing 38 and flows in substantially separate streams among the fins 47. Each of the fins 47 is made of such width, at least at its lower end, that the streams of liquid do not re-combine immediately on leaving the fins 47, but instead leave between them vents downstream of the outer peripheral edge zone of the part 44, through which vents air can flow from the inside to the outside of the virtual tube of liquid formed.
It will be appreciated that the equilibrium position of the member 43 is dependent upon the downward pressure, on the part 46, which is itself dependent upon the viscosity of the liquid, and thus that the nozzle 37 constitutes a self-adjusting throttle. Moreover, owing to the provision of the cylindrical surface 55, the member 43 has to perform a considerable minimum downward movement before the equilibrium position can be reached. Therefore one and the same nozzle 37 can be used with a wide range of individual liquids without either the rate of flow of the liquid from the nozzle or the extent of opening movement of the member 43 varying greatly.
Referring to FIGS. 4 to 6, the nozzle 37 shown therein differs in a number of ways from that described with reference to FIGS. 2 and 3. Firstly, the driving part 46 is received with clearance on the stem 45, is supported thereon by a ring of lugs 60 protruding from the stem and is releasably retained thereon by a spring clip 61 mounted in a diametral bore in the stem 45. Secondly, the cylindrical surface 55 terminates short of the uppermost position of the part 46 and is preceded downwardly by a co-axial downwardly diverging frusto-conical internal surface 62 which is of a maximum diameter equal to the diameter of the surface 55 and which is inclined at about 2° to the axis of the housing 38, the surface 62 being itself preceded downwardly by a co-axial circular cylindrical internal surface 63 of a diameter equal to the minimum diameter of the surface 62. The outer peripheral edge zone of the part 46 is a sliding fit in the surface 63. The slight clearance between the surface 55 and the part 46 ensures that, during the major part of the closing stroke of the member 43, the liquid trapped between the closed non-return valve 33 and the part 46 can escape to below the part 46, so that the member 43 can move rapidly upwards. Since the surface 62 provides a narrowing of the slight clearance between the part 46 and the housing 38 as the part 46 approaches its uppermost position shown in FIGS. 4 and 6, the throttling effect thereby obtained slows the moving valve member 43, so that the closure part 44 closes relatively slowly and does not cause the liquid to be spat out at the valve seat 50. Thirdly, the valve seat 50 is formed a very short distance above the lower extremity of the internal surface of the housing 38 and there is provided immediately below the valve seat 50 an annular groove 64 of semi-circular cross-section and formed in that internal surface. Moreover, an annular groove 65 is formed in the external surface of the part 44 immediately above the lower extremity of that external surface. The groove 65 has an upper side of circular cross-section and a lower side of straight cross-section merging tangentially into the upper side. The grooves 64 and 65 thereby bound between them an annular enclosed space 66 in the closed position of the part 44 shown in FIGS. 4 and 5. In use of the nozzle, the coming together of the wetted valve seat 50 and the wetted, co-operating, frusto-conical, external surface 67 of the part 44 as the part 44 closes squeezes out drops of liquid downwardly. The advantage of the provision of the enclosed space 66 is that these drops collect and remain trapped in the space 66, partly through surface tension effects.
The nozzle 37 shown in FIG. 7 differs from those shown in FIGS. 3 and 4 chiefly in that the fins 47 are fixed at their outer peripheries to a circular sleeve 70 which is co-axial with the housing 38. The upper part of the outer periphery of the sleeve 70 is a sliding fit in a bottom part 71 of the housing 38, whilst the lower part of the outer periphery tapers slightly downwards. The lower end of the sleeve 70 is spaced upwardly from the closure part 44 and so leaves a ring of arcuate liquid outlets 72 through which the liquid can flow into the container in this case a bottle B to be filled. This arrangement has the advantage of ensuring that, when the valve member 43 is in its open container, the liquid exits into the condition B at a location significantly below the top of the container, so reducing any risk of the liquid splashing onto the top sealing surfaces of the container or over onto the outside of the container. Since, compared to the versions of FIGS. 3 and 4, the valve member 43 has to penetrate farther into the container before a considerable liquid flow is desired, the surface 55 is of a much greater dimension axially of the housing 38.
The machine equipped with the nozzle of FIG. 7 has the following advantageous features of its filling cycle, some of which are also present with the nozzles of FIGS. 3 and 4.
(i) relatively fast opening of the valve member 43 to an open condition in which the position of the closure part 44 is predictable within very narrow limits,
(ii) filling without considerable turbulence and without significant wetting of the top sealing surfaces or of the outside surfaces of the container,
(iii) relatively fast closing of the member 43 to near to its closed condition,
(iv) relatively slow further closing of the member 43 into its closed condition, and
(v) remaining closed in a drip-free manner.
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A valve device for use in filling cartons includes a tubular housing containing a valve member comprising a closure part co-operating with a valve seat at the lower extremity of the housing, and a driving part movably received with clearance in the housing. During the latter part of the opening movement of the valve member against a spring, the clearance increases smoothly and considerably, and the driving part reaches a force equilibrium position at which the clearance is considerable. Two grooves formed in the housing and the valve member immediately below the annulus of sealing bound an annular enclosed space for receiving liquid squeezed out downwardly at the valve seat.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an imaging optical system having variable focusing function for an imaging lens, more particularly to an imaging optical system for use in an endoscope which is functioning as a variable focusing element and is useful in case of constructing an imaging element required for a compact imaging optical system, such as an endoscope or the like.
2. Related Art Statement
As a conventional imaging optical system for use in an endoscope for an imaging lens or the like having automatic infocusing switching function, there is an imaging optical system described in, for example, Japanese Patent Application Publication No. 35,090/87. This publication discloses that a holding frame of an objective lens mounted within a range of a distal hard portion of the endoscope is so formed as to extend the frame in the longitudinal direction, thereby moving the frame back and forth mechanically in the longitudinal direction by the operation for focusing adjusting at proximal operating section, resulting in a change of a pint position.
In the conventional imaging optical system disclosed in Japanese Patent Application Opened No. 46,423/90, the imaging optical system comprises a mechanism for selecting poplarizing directions and a variable focusing lens utilizing an electro-optical effect of a liquid crystal, thereby changing the focal length of the objective lens by an electrical drive.
The above conventional imaging optical system disclosed in Japanese Patent Application Publication No. 35,090/87, disclosed that the mechanism for moving the holding frame mechanically is accommodated in a minimum space, such as a distal hard section for the endoscope, but it is substantially impossible to obtain such a construction due to the spatial restriction.
The above conventional imaging optical system disclosed in Japanese Patent Application Publication No. 46,423/90, has a requirement of a function for selecting the polarizing directions in order to prevent double images from being generated due to the birefringent of the liquid crystal, so that transmittance of the vari-focus lens becomes decreased to 50% or less. Such a decrease of light quantity becomes fatal to the lens for an endoscope, so that usually, as a countermeasure, the diameter of an aperture diaphragm is increased or the diameter of light guide is increased. The former, however, has a defect that the focal depth becomes shallow, and the later has a defect in that as the diameter of the endoscope itself increases. Therefore, both countermeasures are not practical to accommodate such variable focusing function in the endoscope.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the above described disadvantages of the conventional imaging optical system.
It is another object of the present invention to provide a minimized and space saved imaging optical system for use in such as an endoscope, which has a variable focusing function with about a 100% transmitting factor in the far point infocusing condition and in the near point infocusing condition without an accompanying decrease of light quantity, thereby improving the depth of focus and brightness, and thus, obtaining the possibility of magnified observation.
According to a first aspect of the present invention, there is provided an imaging optical system comprising an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, and the first body and the second body having substantially symmetrical shape against a plane perpendicular to an optical axis.
According to the present invention, the imaging optical system comprises an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto whole the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, so that if such an imaging optical system is loaded as an imaging optical system for an endoscope, a variable focusing function can be added to the endoscope without any requiring a polarizing plate.
That is, according to the present invention, in the condition that a voltage is not applied to the member, an incident light having a polarizing direction perpendicular to a major axis direction of the liquid crystal at an incident end of the first liquid crystal body is subjected to an effect due to ordinary ray refractive index of the liquid crystal in the first body, and is subjected to an effect due to extra-ordinary ray refractive index in the second liquid crystal body, in which the major axis direction of the liquid crystal at the incident end is orthogonal to the major axis direction of the liquid crystal at the emerging end of the first body. Moreover, an incident light having a polarizing direction parallel to a major axis direction of the liquid crystal of the first liquid crystal body is subjected to an effect due to extraordinary ray refractive index of the liquid crystal in the first body, and is subjected to an effect due to ordinary ray refractive index in the second liquid crystal body, in which the major axis direction of the liquid crystal is orthogonal to the major axis direction of the first body. In this case, if the first body and the second body are substantially of the same construction, the difference of focus positions due to the polarizing direction becomes negligible amount. While in the voltage applying condition, the liquid crystal molecular structure is aligned parallel to the optical axis, so that whole incident light flux are subjected to an effect due to ordinary ray refractive index of the liquid crystal and transmitted through the first body and the second body.
The above constructed imaging optical system according to the present invention does not require the function of selecting the polarizing directions for preventing generation of a double image, so that it is possible to obtain an endoscope having a variable focusing function with substantially 100% transmittance both in the far point infocusing condition and in near point infocusing condition.
Particularly, in the micro-optical system, such as an endoscope, the focal length of optical system itself is short, and the diameter of light flux is short, so that in order to load the variable focus liquid crystal lens, the thickness of the liquid crystal may be made thin. Therefore, according to the present invention, it is possible to obtain a variable focus lens with high response speed, high contrast and high transmittance. Moreover, the current endoscope requires high operationally, low invasiveness, and high compaction. If the driving system is an electrical system, therefore, it is preferably compacted that the variable focus liquid crystal lens improves responsibility and contrast property, as the objective system is compacted, thereby imposing the variable focusing function to the endoscope or the like.
Then, if the variable focusing lens is loaded on the endoscope, the following constituent factors to obtain the same lens power for whole polarized light without a plarizer and to obtain sufficient lens power variation and the sufficient response speed as an endoscope, are explained hereinafter.
In order to obtain the same lens power for whole polarized light without arising the double image, as described above, the polarized components incident on the first liquid crystal body as extraordinary ray and the polarized components incident on the first liquid crystal body as ordinary ray must have the same lens power received from the above member. On working and assembling the endoscope, when the first body and the second body have the same liquid crystal material, assuming that the radius curvatures of the front face of the first body, the rear face of the first body, the front face of the second body and the rear face of the second body have the radius curvatures R 1 , R 1 ', R 2 , R 2 ', respectively, and have birefringence n, n o and n e , respectively, and the distance between the first body and the second body is very short, respective radius curvature have to satisfy following equation.
(n.sub.e -n)/R.sub.1 +(n-n.sub.e)/R.sub.1 '+(n.sub.o -n)/R.sub.2 +(n-n.sub.o)/R.sub.2 '=(n.sub.o -n)/R.sub.1 +(n-n.sub.o)/R.sub.1 '+(n.sub.e -n)/R.sub.2 +(n-n.sub.e)/R.sub.2 ' (1)
From the above equation, respective radius curvature have to satisfy following relation.
1/R.sub.1 -1/R.sub.1 '-1/R.sub.2 +1/R.sub.2 '=0 (2)
When the conditions that equation (2) is satisfied and easiness on working and assembling is obtained, are considered, it is desired that the first and the second bodies have a shape substantially symmetrical to a plane perpendicular to the optical axis.
The substantially symmetrical shape of the first body and the second body is a curved surface, and these curved surfaces are displaced opposite to each other.
A substrate in which the first body and the second body are filled in, is formed by a plate, a biconcave lens and a plane lens.
A distance L 12 between the first body and the second body satisfies following equation:
0.1 (mm)≦L.sub.12 ≦0.4 (mm). (3)
It is ideal to make the distance L 12 being 0 in order to prevent a double image from being caused, and desirable to make the distance being at least 0.4 (mm). In this case, the amount of the distance L 12 has a limitation on working, so that if the distance has not more than lower limit 0.1 (mm), the working becomes hard, and if the distance has not less than upper limit 0.4 (mm), the double image is caused, and thus resolution of the image becomes deteriorated.
The thickness d of the first body and the second body, an absolute value |R| of radius curvature of the first body and the second body, and the diameter D of an aperture diaphragm of the first body and the second body satisfy the following relation:
D.sup.2 8·|R|≦d≦0.04 (mm). (4)
If the thickness d of the first and second bodies exceeds the upper limit 0.04 (mm), the response speed becomes slow, and it is not desirable. Particularly, the current main flow of the endoscope is an electronic scope, considering that the feature of driving the lens during one frame scanning is performed by using a liquid crystal having the birefringence difference Δn=0.2, it is necessary to set the thickness d of the liquid crystal to d≦0.01 (mm). The more increase of thickness of liquid crystal, the less contrast and transmittance of the image, so that it is not preferable to increase the thickness of the liquid crystal. In this case, the lower limit of the thickness d is limited by the diameter D of the light flux, so that if the condition D 2 /8·|R|≦d is not satisfied, necessary light flux is subjected to a shading or eclipse. Therefore, the thickness d has to satisfy the above equation (4).
The absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
1 (mm)≦|R|≦80 (mm). (5)
On considering that the smaller the birefringence difference Δn, the smaller the viscosity of the liquid crystal, and thus the faster the response speed, it is desirable to satisfy the relation |R|≦80 (mm). In this case, as shown in the equation (4), the feature of decreasing the radius curvature of the substrate in which the first and the second liquid crystal bodies are enclosed, is that the thickness d of the first and the second bodies is made thick. That is, The smaller the radius curvature, the thicker the liquid crystal layer. It becomes a cause of deteriorating the response speed, the contrast and the transmittance of the liquid crystal. Therefore, it is preferable to satisfy the relation |R|≧1 (mm).
The birefringence difference Δn of the liquid crystal of the first body and the second body satisfies following relation:
0.15≦Δn≦0.35. (6)
The larger the birefringence difference Δn, the larger the radius curvature R in order to obtain necessary lens power, so that as shown in the equation (4), the thickness of the first and the second bodies can preferably be made small. Therefore, it is preferable to satisfy the relation 0.15≦Δn. In this case, the material of large birefringence difference Δn has high viscosity, thereby deteriorating the response speed. Therefore, it is preferable to satisfy the equation (6). If the birefringence difference Δn exceeds the upper limit of the equation (6), the response becomes slow because of viscosity of the material. If the birefringence difference Δn is less than the lower limit, the liquid crystal becomes thick in order to obtain necessary lens power, thereby deteriorating the response speed, the contrast and the transmittance of the liquid crystal.
The birefringence difference Δn of the liquid crystal and the absolute value |R| of radius curvature of the first body and the second body satisfy following relation:
0.005≦Δn/|R|≦0.1. (7)
On considering the condition that necessary lens power is made variable, the amount ΔΦ of lens power variation caused by the variable focusing is shown in following equation, in which n o is an ordinary ray refractive index of liquid crystal, n e is an extraordinary refractive index, and Δn is birefringence difference.
ΔΦ=Δn/R-Δn(n.sub.o -n)R.sup.2 (8)
The effective amount ΔΦ of lens power variation as an endoscope have to satisfy a following relation to the lens power Φ of the imaging lens.
0.005≦ΔΦ/Φ (9)
Particularly, it is most desirable that ΔΦ/Φ is made 0.01 or so. However, if ΔΦ is too large, when liquid crystal lens is used as a two focus switching lens, the focusing depth of near point side and the focusing depth of far point are not superimposed, thereby arising an unobserved region. Therefore, it is desirable for the equation (9) to satisfy following equation.
0.005≦ΔΦ/Φ≦0.1 (10)
A distance L between the optical member and the aperture diaphragm and a focal length f of whole imaging optical system satisfy following relation:
L≦f/2. (11)
The imaging optical system is a retrofocus type.
An outer diameter of the optical member is less than Φ5 mm.
It is effective as an endoscope lens and in order to make the liquid crystal layer thin, it is preferable to make the diameter Φ of lens 5 mm or less.
The substrate filling the first body and the second body therein is constructed by an infrared ray cutting filter.
In the case of the endoscope, the spectral photosensitivity for infrared ray of a solid state imaging element is high, so that it is necessary to arrange a filter having an infrared ray cutting function. Then, the substrate of the liquid crystal lens is formed by the infrared ray cutting filter, resulting in a possibility of a space saving. Moreover, the first liquid crystal body and the second liquid crystal body are made homogeneous alignment, respectively, and the voltage applied to the liquid crystal is continuously changed, so that the focal length can also be changed.
In second aspect of the imaging optical system according to the present invention, there is provided an imaging optical system comprising an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, and a distance L between the optical member and an aperture diaphragm and a focal length f of whole imaging optical system satisfy following relation:
L≦f/2. (11)
As an objective lens of endoscope or the like, generally, there is a lens of a retrofocus type, in which a slant incident on the liquid crystal lens is decreased as the lens is near the aperture diaphragm. Therefore, the displacement of the liquid crystal lens near the aperture diaphragm means that the total image run-out and the coloring caused by birefringence in the liquid crystal are decreased. Moreover, the diameter of the light flux becomes small as accessed to the aperture diaphragm, so that effective aperture can be made small, and thus the thickness of the liquid crystal layer can also be suppressed. Therefore, the focal length f of whole imaging lens system and the distance L between the aperture diaphragm and the liquid crystal lens have to satisfy the above relation of equation (11).
If the distance L exceeds the upper limit of the equation (11), the total image run-out, the coloring caused and the deterioration of the response speed are caused. Therefore, it is necessary to arrange the liquid crystal lens before and after the aperture diaphragm.
The member is placed before or after an aperture diaphragm.
The first body and the second body have substantially symmetrical shape against a plane perpendicular to an optical axis, the substantially symmetrical shape of the first body and the second body is a curved surface, and these curved surfaces are displaced opposite to each other.
The absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
1 (mm)≦|R|≦80 (mm). (5)
A distance L 12 between the first body and the second body satisfies following relation:
0.1 (mm)≦L.sub.12 ≦0.4 (mm). (3)
Assuming that the thickness of the first body and second body is d, an absolute value of radius curvature of the first body and the second body is |R|, and an aperture diaphragm radius of the first body and the second body is D, the following relation is satisfied:
D.sup.2 /8|R|≦d≦0.04 (mm). (4)
The difference of birefringence Δn of the liquid crystal of the first body and the second body satisfies following relation:
0.15≦Δn≦0.35. (6)
In third aspect of the imaging optical system according to the present invention, there is provided an imaging optical system comprising an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a front face of the first body being aligned perpendicular to a rear face of the second body, rear face of the first body and the front face of the second body are made a curved surface, and these curved surfaces are displaced opposite to each other.
According to the present invention, the imaging optical system comprises an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or magnetic field onto the first body and the second body, a front face of the first body being aligned perpendicular to a rear face of the second body, so that if such an imaging optical system is loaded as an imaging optical system for an endoscope, a variable focusing function can be added to the endoscope without any requiring a polarizing plate.
The position setting the first body and the position setting the second body are, in fact, shifted more or less in the imaging system, the total image run-out due to the polarizing direction is slightly caused in accordance with the height difference of ray incident on the first and the second bodies. In order to make this total image run-out minimum, it is necessary to make the positional shift of the plane contributing the lens power variation small as soon as possible by arranging the curved surfaces of the first and the second bodies opposite to each other. Concretely, the substrate for enclosing and sealing the liquid crystal is formed by laminating a plate, biconcave lens and plane lens, in turn, and then, the first body and second liquid crystal bodies are sealed in the void portions formed thereamong. This method has a high effect of preventing double focus by accessing refraction surfaces to each other, and the role in which the aligning directions of the first and second bodies are arranged perpendicular to each other, can be performed by only one biconcave lens, so that an assembling step can be improved.
Assuming that the thickness of the first body and the second body is d, an absolute value of radius curvature of the first body and the second body is |R|, and an aperture diaphragm radius of the first body and the second body is D, the following relation is satisfied:
D.sup.2 /8|R|≦d≦0.04 (mm). (4)
The absolute value |R| of radius curvature of the first body and the second body satisfies following relation
1 (mm)≦|R|≦80 (mm). (5)
An imaging optical system comprises a member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, and a distance L12 between the first body and the second body satisfies following relation:
0.1 (mm)≦L.sub.12 ≦0.4 (mm). (3)
The first body and the second body have an asymmetric shape to a surface perpendicular to an optical axis.
The absolute values |R 1 |, |R 2 | of radius curvature of the first body and the second body satisfy following relation:
0.5≦|R.sub.1 /R.sub.2 |≦2. (12)
In order to prevent a generation of double image, as described above, two liquid crystal layers having its curvature being varied more or less are arranged in the asymmetric form to a plane perpendicular to the optical axis, instead of in the symmetric form, thereby obtaining an effect of correcting the shift of positions of the first and the second bodies, resulting in a possibility of decreasing the arise of double image. In this case, the absolute values |R 1 |, |R 2 | of radius curvature of the first body and the second body have to satisfy the above equation (12).
The absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
1 (mm)≦|R|≦80 (mm). (5)
An imaging optical system comprises an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, the absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
|R|≦150 (mm). (13)
On considering the limit of general birefringent index difference Δn being about 0.3, the absolute value |R| of radius curvature have to satisfy the above equation (13).
The absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
1 (mm)≦|R|≦80 (mm). (5)
The first body and the second body have a plane and curved surfaces, and the absolute value |R| of radius curvature of the first body and the second body satisfies following relation:
1 (mm)≦|R|≦40 (mm). (14)
If the first and the second liquid crystal bodies have the plane and curved surfaces, the above absolute value |R| have to satisfy the equation (14) in order to make the working easy.
An imaging optical system comprises an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, and assuming that the thickness of the first body and the second body is d, an absolute value of radius curvature of the first body and the second body is |R|, and an aperture diaphragm radius of the first body and the second body is D, the following relation is satisfied:
D.sup.2 /8|R|≦d≦0.4 (mm). (4)
An imaging optical system comprises an optical member including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and at least a pair of electrodes for adding an electric field or a magnetic field onto the first body and the second body, a rear face of the first body being aligned perpendicular to a front face of the second body, and the difference of birefringence Δn of the first body and the second body satisfies following relation:
0.15≦Δn≦0.35. (6)
In case of using the endoscope, also, the lens is made accessed to the subject in far point infocusing condition, and the pint of the lens is switched in the near point infocusing condition at a point that the lens is accessed to the subject to some extent, after which the subject is observed in the near infocusing condition. When the object position for performing the pint switching from the near point infocusing condition to far point infocusing condition and the object position for performing the pint change from the far point infocusing condition to near point infocusing condition, are positioned near to each other, if the object is present near the object switching position, even the object is moved slightly back and forth, the pint switching is performed frequently. Therefore, in case of loading a lens utilizing a liquid crystal on an imaging optical system to consider the adding of a variable focusing function, the liquid crystal having large birefringence must be utilized in order to obtain a change of lens power. However, the liquid crystal having large birefringence has high viscosity and slow response speed, so that it is difficult to obtain sharp image in case of performing pint switching frequently.
As a countermeasure of this problem, an imaging optical system capable of always obtaining sharp image by preventing the pint switching from being performed frequently more than requirable, when the object position is near the pint switching position, may be obtained. In this case, an imaging optical system comprises a pint switching means and a means having an auto-focusing function for setting an object position performing a pint switching from the far point infocusing condition to near point infocusing condition, and an object position performing a pint switching from the near point infocusing condition to far point infocusing condition, to different position.
An imaging optical system further comprises a means having a function for detecting the above object position.
Concretely, the object position xb performing a pint switching from the far point infocusing condition to near point infocusing condition and the object position Xb performing a pint switching from the near point infocusing condition to far point infocusing condition, are set to different position to each other, and even the object is moved back and forward more or less near the switching position after once performing the pint switching, the pint switching does not perform more than requirable, and then in case of moving the object back and forward largely, the pint switching is performed, so that the sharp image can always obtained irrespective of the response speed of the liquid crystal.
In order to observe the object up to near point side of the near point infocusing condition, the relation between the object position Xb and the object position xb have to satisfy following relation:
xb≦Xb. (15)
On considering the focal depth required to the endoscope, the object positions xb and Xb have to satisfy following relation:
1 (mm)≦Xb-xb≦25 (mm). (16)
The pint switching position from the far point infocusing condition to near point infocusing condition is set to an object point distance under the near point infocusing condition, and the pint switching position from the near point infocusing condition to far point infocusing condition to different position is set to an object point distance under the far point infocusing condition.
The object position xb is set to the best object position under the near point infocusing condition and the object position Xb is set to the best object position under the far point infocusing condition, so that sharp image can be obtained even at the time of pint switching.
The pint switching means is constructed from a material having an electro-optical effect such as a liquid crystal or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory view showing a construction of first embodiment of an imaging optical system according to the present invention;
FIG. 2 is an explanatory view showing condition of applying voltage on liquid crystal in the first embodiment;
FIG. 3 is an explanatory view showing a construction of second embodiment of an imaging optical system according to the present invention;
FIG. 4 is an explanatory view showing condition of applying voltage on liquid crystal in the second embodiment;
FIG. 5 is an explanatory view showing a construction of third embodiment of an imaging optical system according to the present invention;
FIG. 6 is an explanatory view showing a construction of fourth embodiment of an imaging optical system according to the present invention;
FIG. 7 is an explanatory view defining radius of curvature of respective optical elements and its surface intervals in the first embodiment of the present invention;
FIG. 8 is an explanatory view defining radius of curvature of respective optical elements and its surface intervals in the second and third embodiments of the present invention;
FIG. 9 is an explanatory view defining radius of curvature of respective optical elements and its surface intervals in the fourth embodiment of the present invention; and
FIG. 10 is a perspective view showing a construction of a distal section A of the endoscope shown in respective embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now to the drawings, there are shown various embodiments of an imaging optical system according to the present invention. Like parts are shown by corresponding reference characters throughout several views of the drawings.
FIG. 1 shows a construction of first embodiment of an imaging optical system according to the present invention, which is constructed as an imaging optical system for electron endoscope.
An end face of a distant section A of the endoscope shown in FIG. 1 is provided with a concave lens 1 which also serves as a cover glass, after which, along its optical axis, there are arranged a lens 2, an aperture diaphragm 3, a liquid crystal lens 4, a lens 5 of two lens elements, a lens 6, a lens 7 of two lens elements, a cover glass 8 for a solid state imaging element, and a CCD 24 (charge coupled device) as the solid state imaging element, in the order given. The liquid crystal lens 4 is so formed that liquid crystal members are bisymmetric with respect to a plane-parallel plate lens 9.
That is, the shown left portion of the liquid crystal lens 4 comprises the plane-parallel plate lens 9, a plano-concave lens 10, a transparent electrode 12 and an aligned film 14 which are covered in turn on a left end face of the plane-parallel plate lens 9, a transparent electrode 16 and an aligned film 17 which are covered in turn on a concave surface of the plano-concave lens 10, and a nematic liquid crystal 20 filled in a concave lens shaped void (sell) formed between the left end face of the plane-parallel plate lens 9 and the concave surface of the plano-concave lens 10. Similarly, the shown right portion of the liquid crystal lens 4 comprises the plane-parallel plate lens 9, a plano-concave lens 11, a transparent electrode 13 and an aligned film 15 which are covered in turn on a right end face of the plane-parallel plate lens 9, a transparent electrode 18 and an aligned film 19 which are covered in turn on the concave surface of the plano-concave lens 11, and a nematic liquid crystal 21 filled in a concave lens shaped void (cell) formed between the right end face of the plane-parallel plate lens 9 and the concave surface of the plano-concave lens 11. The above aligned films 14 and 15 are displaced in the orthogonal directions to each other, the transparent electrodes 12, 16; 13, 18 are connected to alternating supply sources P1, P2, (for example 50 Hz) through switches SW1, SW2, respectively. In this case, the aligned films 14 and 15 may be arranged in the directions orthogonal to each other, but it is preferable to set the aligned directions in parallel to each other, in order to change focal length successively.
An illuminating optical system consisting of a light guide 22 and an illuminating lens 23 is disposed on the above distant section A of the endoscope in parallel to the imaging optical system.
In this embodiment, as shown in FIG. 1, if the switches SW1, SW2 are made OFF condition, the nematic liquid crystals 20, 21 in the liquid crystal lens 4 become a homogeneous structure or alignment, that is, the major axis direction of the liquid crystalline molecule becomes an alignment orthogonal to an optical axis. In this case, the incident light from an object having a polarizing direction perpendicular to the aligned film 17 is subjected to a function due to an ordinary ray refractive index of the liquid crystal 20, rotated therein, and passed in the liquid crystal 21 through the aligned films 14, 15 having a polarizing direction orthogonal to each other. In this case, this incident light is subjected to a function due to an extraordinary ray refractive index of the liquid crystal 21, and passed therein, since the polarizing direction of the light and the major axis direction of the liquid crystal are coincident in the liquid crystal 21. While, the incident light having polarizing direction parallel to the aligned film 17 is, in the liquid crystal 20, subjected to the function due to the extraordinary ray refractive index of the liquid crystal 20 and passed therethrough, and also is, in the liquid crystal 21, subjected to the function due to the ordinary ray refractive index of the liquid crystal 21 and passed therethrough, in accordance with the above principle. In this case, the liquid crystals 20, 21 are enclosed in the plano-convex lenses 10 and 11 having equal absolute values and curvature of reverse signs, respectively, so that the liquid crystal lens 4 acts as a lens having a substantially the same refractive function to the full polarizing component of incident light flux.
While as shown in FIG. 2, if the alternating voltage is applied by making the switches SW1, SW2 ON state, the nematic liquid crystals 20, 21 in the liquid crystal lens 4 become a homeotropic structure or alignment, that is, the major axis direction of the liquid crystalline molecule becomes an alignment parallel to an optical axis. Therefore, the whole light incident on the liquid crystals 20, 21 are subjected to the function due to ordinary ray refractive index of the liquid crystals 20, 21 and transmitted through the liquid crystal lens 4.
The above liquid crystals 20, 21 have a bisymmetric shape for the plane-parallel lens 9 in order to obtain the same lens power in whole polarizing directions. For example, by using a concave lens having an absolute value |R| of radius curvature R of 27 mm and a liquid crystal having a birefringence difference Δn of 0.24, and by using a distance between the plane-parallel plate lens 10 and the plane-parallel plate lens 11 being a value from 0.1 mm to 0.4 mm (for example, 0.3 mm), a best object position can be changed from 8 mm to 18 mm. Moreover, the thickness of respective liquid crystals may be set to 20 μm by setting the liquid crystal lens 4 at the position of 0.15 mm after the aperture diaphragm 3, thereby improving the response speed.
In the present embodiment, the thickness of and the distance between the liquid crystal 20 and 21 of the liquid crystal lens 4, are set as described above, thereby preventing total image run-out due to polarizing direction, resulting in a possibility of suppressing run-out of the image on the end face of CCD 24 less than 3 μm. This run-out amount of the image is an amount of image run-out which can be ignored in case of considering sampling frequency of CCD. The liquid crystal 4 can be wired in a driving section without substantially occupying the space, by providing the electrodes on a D cutting portion provided on its side surface, because of the thickness of 1 mm or the like, so that the liquid crystal can be loaded without substantially changing the shape of the distal portion of the endoscope in the diametrical and longitudinal directions.
In the above descriptions, as a method of forming the aligned film for aligning the liquid crystals 20, 21, there can be utilized a method of rubbing an applied polyimide film, or a method of rhombic vaporizing silicon oxide. The method of forming the aligned film by the rhombic vaporizing can form a homogeneous and contactless uniform aligned film for a lens having minimized and curved surface as in this embodiment, so that it is preferable to obtain an objective lens for endoscope. Moreover, S i O 2 is coated between the glass material and the ITO film as a transparent electrode, so that alkaline component included in the glass material can be prevented from being flew out. In this case, in order to prevent a reflection at a boundary between the lens and the liquid crystal, it is desirable to hold the following relationship for the thickness of S i O 2 , ITO and polyimide, ds, di and dp:
10 (nm)≦ds≦50 (nm) (17)
80 (nm)≦di≦150 (nm) (18)
19 (nm)≦dp≦50 (nm) (19)
Sealing of liquid crystal is performed by forming a wall outside effective aperture of the lens with epoxy resin, in which spacers are inlaid, by pouring liquid crystals after providing substrate, and by sealing the injection inlet. In this case, the spacer has an insulating effect, in the same manner as the aligned film, so that on considering injection of the liquid crystal, it is desirable to utilize a ball shaped spacer of 4 μm or more. In this case, only considering two focus switching, if the liquid crystal is made a twistnematic structure, in order to make the polarized light incident on the liquid crystal rotated by 90 degree in the liquid crystal without depending the thickness of the liquid crystal to some extent. In the present embodiment, in order to make the incident light on the liquid crystal transmitted by rotating the polarized surface more than 95%, it is necessary to make the thickness of the liquid crystal more than 6 μm. In this case, on considering the thickness of the liquid crystal at the center of the lens, the increase of the spacer more than requirable makes the response speed slow.
As to the drive of the liquid crystal, it is desirable to drive the liquid crystal at an alternating field with the frequency of more than 50 Hz, and in case of considering increase of response speed, it is desirable to drive the liquid crystal with the frequency having largely variable relative permittivity (for example, high frequency of 1 kHz or more). Moreover, the voltage at the near point is set to about 1 V, instead of applying no voltage, thereby improving the response speed more. This embodiment utilizes the liquid crystal having positive anisotropy of dielectric constant, but negative anisotropy of dielectric constant may be utilized, instead thereof, so that this makes the liquid crystal homogeneous structure at the application of voltage, and makes the liquid crystal homeotropic structure at the application of no voltage. In this case, the liquid crystal is driven only in the observation of near point side. Moreover, in utilizing, if the liquid crystal adequately operates with two focus switchings of near point side and far point side, the liquid crystal may be operated with TN (twist nematic) structure. In this case, the alignment of liquid crystal at the application of no voltage is stabilized, and thus more sharp image can be obtained. Even in this case, it is necessary to make the alignment at both concave surface perpendicular to each other.
Moreover, the pint can be switched in accordance with the object point distance by providing a function of detecting the object point distance (the distance up to object position) based on catoptric light intensity from the object in self illuminating light such as trigonometric range finding method, image phase difference method or light guide and the like. In this case, the object position performing a pint switching from the far point infocusing condition to near point infocusing condition and the object position performing a pint switching from the near point infocusing condition to far point infocusing condition, are set to different position to each other, thereby preventing the pint switching from being caused frequently in case of presenting the object near the pint switching position, resulting in an acquirement of permanent sharp image. Particularly, the object position performing a pint switching from the far point infocusing condition to near point infocusing condition is set to a best switching position at the side of the near point infocusing condition (for example, 8 mm), and the object position performing a pint switching from the near point infocusing condition to far point infocusing condition is set to a best switching position at the side of the far point infocusing condition (for example, 18 mm), thereby decreasing frequency of pint switching from the far point infocusing condition to near point infocusing condition, resulting in an acquirement of permanent sharp image.
The imaging optical system according to the present embodiment has preferable conditions in case of being constructed as an imaging optical system for an electric endoscope which are as follows.
In the optical system having wide angle of view, such as an objective lens for the endoscope, an optical system of retrofocus type, in which back focus is also taken, is commonly used. Since in order to prevent the solid state imaging element from being photosensitized with infrared radiation, it is necessary to displace a filter having a function of cutting the infrared radiation. Then, if a substrate for constructing the liquid crystal lens is constructed by an infrared ray cutting filter, the liquid crystal lens can be arranged without newly providing a space for the lens.
Moreover, if the incident light for the liquid crystal lens is largely slanted to the optical axis, there is a cause for a double image or a coloring by ghost in the liquid crystal thereby. Then, as in the present embodiment, it is desirable to displace the liquid crystal near the aperture diaphragm, particularly, front or rear of the aperture diaphragm.
In the imaging optical system requiring a lens having small diameter, such as an endoscope, also, it is required for the liquid crystal lens to make the diameter of the liquid crystal small to some extent, so that the outer diameter φ of the liquid crystal 5 must be made lower than 5 mm.
Moreover, the thickness of the liquid crystal 20 and 21 must be made lower 0.05 mm by considering a scatter and absorption of the light for the liquid crystal into effect, and in the minimized lens for use in the endoscope, the absolute value |R| of the radius of curvature R of the plano-concave lens 10 and 11 must be made more than 1 mm and lower than 150 mm.
In this embodiment, moreover, as liquid crystals 20 and 21, there is used a liquid crystal having a birefringent difference Δn of the nematic liquid crystal being 0.24, but this birefringent difference Δn is a value corresponding to a focus variation amount of the liquid crystal lens 4, so that it is required to make the birefringent difference Δn of the nematic liquid crystal larger than 0.15 and smaller than 0.35, in order to obtain the variation of the focal length required for an endoscope.
If the distance d between the liquid crystals 20 and 21 is large, slight difference is caused in the light path of the liquid crystal lens due to the polarizing direction, resulting in a cause of generating the double image, so that the distance d between the liquid crystal lenses 20 and 21 must be made more than 0.1 mm and less than 0.4 mm.
FIGS. 3 and 4 show a construction of second embodiment of an imaging optical system according to the present invention, particularly, FIG. 3 shows the condition in which a voltage is not applied to the liquid crystal, and FIG. 4 shows the condition in which a voltage is applied to the liquid crystal. The image optical system of the second embodiment is intended to load on an endoscope for digestive organs. A liquid crystal 31 of this embodiment comprises a bi-concave lens 41 and two plane-parallel plate lenses 44, 45 and the other optical system (optical elements 32 38) of this embodiment are the same construction as in the first embodiment. In this embodiment, also, a solid state imaging element (CCD) 60 is disposed after a cover glass 39 for the solid state imaging element and an image is focused on the end surface of the CCD.
The both surfaces of the bi-concave lens 41 of the liquid crystal 31 are covered with transparent electrodes 44, 45 and aligned films 46, 47 disposed in the directions orthogonal to each other, in turn, respectively, and the surfaces at the side of the bi-concave lens, of the plane-parallel plate lenses 42, 43 are covered with transparent electrodes 48, 49 and aligned films 50, 51, respectively. Nematic liquid crystals 52, 53 are enclosed and sealed, respectively, in a concave lens shaped space (sell) formed by covered films of the bi-concave lens 41 and the plane-parallel plate lenses 42, 43 disposed so as to opposite to the both surfaces, respectively. The transparent electrodes 45, 49 and 44, 48 are connected to alternating supply sources P1, P2 (for example, 50 Hz, 10 V) through switches SW1, SW2, respectively, in the same manner as the first embodiment.
The distal section A of the endoscope is provided with an illuminating optical system consisting of a light guide 22 and an illuminating lens 23 in parallel to the imaging optical system. By constructing the liquid crystal lens 31 with the use of the above bi-concave lens 41, the distance or interval between the liquid crystals 52 and 53 can be made narrow rather than the case of the first embodiment in which the liquid crystal is disposed on the both sides of the plane-parallel plate, thereby decreasing the double image (total image run-out) caused by the difference of the polarizing direction.
FIG. 5 shows a construction of third embodiment of an imaging optical system according to the present invention. This embodiment is a modification of the second embodiment. In this embodiment, the bi-concave lens 41 for forming the liquid crystal lens 41 has its both concave surfaces with slightly different radius curvatures R, R'.
According to this embodiment, the image optical system is formed as the above construction, thereby compensating the above slight run-out of major ray (maximum image height) due to the polarizing direction on the end surface of the CCD.
FIG. 6 shows a construction of fourth embodiment of an imaging optical system according to the present invention, and designates the condition of applying no voltage on the liquid crystal. The imaging optical system of the fourth embodiment is intended to load on an electroscope for digestive organs. This embodiment can intensifies focal depth at near point side by providing a variable focusing function of the liquid crystal lens without substantially changing the lens length and the outer diameter of whole optical system with the use of conventional imaging optical system. Moreover, in the present embodiment, particularly, the light ray height is low near the aperture diaphragm, so that the liquid crystal having lens diameter of 2 mm or the like, thereby making the liquid crystal layer thin and making the response speed of the liquid crystal lens fast,
A liquid crystal 81 of this embodiment comprises a plant-parallel plate lenses 62, a bi-concave lens 63 and a plane-parallel plate lenses 64 and the other optical systems of this embodiment are the same construction as in the second embodiment. In this embodiment, also, a solid state imaging element (CCD) 66 is disposed after a cover glass 65 for the solid state imaging element, before which an optical element 82 is disposed, and an image is focused on the end surface of the CCD.
In FIG. 6, also, a plane-parallel plate 67 is an infrared cutting filter for correcting a spectral sensitivity of CCD, and plane-parallel plates 68, 69 are a filter coated by a coat for cutting a TAG laser light utilized for a diagnosis and a remedy. Plane-parallel plate lens or a concave lens which constitute the liquid crystal lens, therefore, is constructed by an infrared cutting filter. Moreover, the YAG laser cutting coat is coated on both surface of the liquid crystal lens, resulting in a compacting. The liquid crystal lens 81 is, also, provided with electrodes on a side surface of the lens, and both surfaces of the bi-concave lens and both of two plane-parallel plates are conductive, simultaneously, thereby driving the liquid crystal lens by only a pair of driving portion.
In the above respective embodiments, the imaging optical system is applied to the endoscope or the like, but the present invention is not limited to such an application, the imaging optical system may be applied to other optical system. Moreover, the above illuminating optical system can also be omitted.
Hereinafter, numerical values of the above first to fourth embodiments are explained, wherein OB is object position up to the best object point position, f is focal length, FNO is F number, IH is image height, r 1 , r 2 , . . . , is radius of curvature, d 1 , d 2 , . . . , is distances of respective surfaces, n 1 , n 2 , . . . , is refractive index at D line (587,56 nm ray) in respective optical members and ν 1 , ν 2 , . . . , is abbe's number thereof.
[First Embodiment]
(1) Numerical value of optical system (As to definition of respective numerical value, refer to FIG. 7)
______________________________________r.sub.1 = 30.655 d.sub.1 = 0.800 n.sub.1 = 1.88 ν.sub.1 = 40.78r.sub.2 = 2.206 d.sub.2 = 2.850r.sub.3 = 7.352 d.sub.3 = 0.700 n.sub.2 = 1.85 ν.sub.2 = 23.78r.sub.4 = 25.586 d.sub.4 = 0.850r.sub.5 = ∞ (aperture d.sub.5 = 0.154diaphragm)r.sub.6 = ∞ d.sub.6 = 0.480 n.sub.3 = 1.88 ν.sub.3 = 40.78r.sub.7 = 27.008 d.sub.7 = 0.020 n.sub.a (nematic liquid crystal layer)r.sub.8 = ∞ d.sub.8 = 0.300 n.sub.4 = 1.88 ν.sub.4 = 40.78r.sub.9 = ∞ d.sub.9 = 0.020 n.sub.b (nematic liquid crystal layer)r.sub.10 = -27.008 d.sub.10 = 0.480 n.sub.5 = 1.88 ν.sub.5 = 40.78r.sub.11 = ∞ d.sub.11 = 0.600r.sub.12 = ∞ d.sub.12 = 2.000 n.sub.6 = 1.59 ν.sub.6 = 61.18r.sub.13 = -2.439 d.sub.13 = 0.500 n.sub.7 = 1.85 ν.sub.7 = 23.78r.sub.14 = -4.515 d.sub.14 = 0.100r.sub.15 = 6.855 d.sub.15 = 1.420 n.sub.8 = 1.73 ν.sub.8 = 54.68r.sub.16 = -32.264 d.sub.16 = 0.100r.sub.17 = 5.532 d.sub.17 = 3.070 n.sub.9 = 1.73 ν.sub.9 = 54.68r.sub.18 = 4.295 d.sub.18 = 0.600 n.sub.10 = 1.85 ν.sub.10 = 23.78r.sub.19 = 21.640 d.sub.19 = 1.390r.sub.20 = ∞ d.sub.20 = 0.700 n.sub.11 = 1.52 ν.sub.11 = 64.15r.sub.21 = ∞ d.sub.21 = 0r.sub.22 = (image position)______________________________________
In this case, the refraction index of the nematic liquid crystal layer to be used at the ordinary ray is 1.52, the refraction index at the extraordinary ray is 1.76, the aperture diameter of the aperture diaphragm is 1.2 mm.
(2) Numerical value in case of applying the voltage on the nematic liquid crystal layer of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.52OB = 18.3 (mm) f = 1.4722 (mm)F.sub.NO = 2.795 IH = 1.135 (mm)______________________________________
(3) Numerical value in case of performing incidence of the polarized light having oscillating direction parallel to the major axis direction of liquid crystal molecule, under the state of applying voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.76 n.sub.b = 1.52OB = 8 (mm) f = 1.462 (mm)F.sub.NO = 2.78 IH = 1.135 (mm)______________________________________
(4) Numerical value in case of performing incidence of the polarized light having oscillating direction perpendicular to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.76OB = 8 (mm) f = 1.464 (mm)F.sub.NO = 2.79 IH = 1.135 (mm)______________________________________
[Second embodiment]
(1) Numerical value of optical system (As to definition of respective numerical value, refer to FIG. 8)
______________________________________r.sub.1 = ∞ d.sub.1 = 0.450 n.sub.1 = 1.88 ν.sub.1 = 40.78r.sub.2 = 1.007 d.sub.2 = 0.730r.sub.3 = 5.905 d.sub.3 = 2.120 n.sub.2 = 1.77 ν.sub.2 = 49.60r.sub.4 = 1.999 d.sub.4 = 0.100r.sub.5 = ∞ (aperture d.sub.5 = 0diaphragm)r.sub.6 = ∞ d.sub.6 = 0.370 n.sub.3 = 1.52 ν.sub.3 = 64.15r.sub.7 = ∞ d.sub.7 = 0.020 n.sub.a (nematic liquid crystal layer)r.sub.8 = 27.008 d.sub.8 = 0.300 n.sub.4 = 1.52 ν.sub.3 = 64.15r.sub.9 = 27.008 d.sub.9 = 0.020 n.sub.b (nematic liquid crystal layer)r.sub.10 = ∞ d.sub.10 = 0.370 n.sub.5 = 1.52 ν.sub.5 = 64.15r.sub.11 = ∞ d.sub.11 = 0.030r.sub.12 = ∞ d.sub.12 = 0.620 n.sub.6 = 1.51 ν.sub.6 = 75.00r.sub.13 = ∞ d.sub.13 = 0.160r.sub.14 = 5.781 d.sub.14 = 1.300 n.sub.7 = 1.70 ν.sub.7 = 55.53r.sub.15 = -1.442 d.sub.15 = 0.280 n.sub.8 = 1.85 ν.sub.8 = 23.78r.sub.16 = -5.018 d.sub.16 = 0.100r.sub.17 = ∞ d.sub.17 = 0.400 n.sub.9 = 1.52 ν.sub.9 = 59.89r.sub.18 = ∞ d.sub.18 = 0.871r.sub.19 = ∞ d.sub.19 = 1.000 n.sub.10 = 1.52 ν.sub.10 = 64.15r.sub.20 = ∞ d.sub.20 = 1.250 n.sub.11 = 1.53 ν.sub.11 = 59.89r.sub.21 = ∞ d.sub.21 = 0r.sub.22 (image position)______________________________________
In this case, the refraction index of the nematic liquid crystal layer to be used at the ordinary ray is 1.52, the refraction index at the extraordinary ray is 1.76, the aperture diameter of the aperture diaphragm is 1.4 mm.
(2) Numerical value in case of applying the voltage on the nematic liquid crystal layer of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.52OB = 15.0 (mm) f = 1.609 (mm)F.sub.NO = 7.39 IH = 1.63 (mm)______________________________________
(3) Numerical value in case of performing incidence of the polarized light having oscillating direction parallel to the major axis direction of liquid crystal molecule, under the state of applying voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.76 n.sub.b = 1.52OB = 8 (mm) f = 1.570 (mm)F.sub.NO = 7.37 IH = 1.63 (mm)______________________________________
(4) Numerical value in case of performing incidence of the polarized light having oscillating direction perpendicular to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.76OB = 8 (mm) f = 1.570 (mm)F.sub.NO = 7.37 IH = 1.63 (mm)______________________________________
[Third embodiment]
(1) Numerical value of optical system (As to definition of respective numerical value, refer to FIG. 8)
______________________________________r.sub.1 = ∞ d.sub.1 = 0.450 n.sub.1 = 1.88 ν.sub.1 = 40.78r.sub.2 = 1.007 d.sub.2 = 0.730r.sub.3 = 5.905 d.sub.3 = 2.120 n.sub.2 = 1.77 ν.sub.2 = 49.60r.sub.4 = 1.999 d.sub.4 = 0.100r.sub.5 = ∞ (aperture d.sub.5 = 0diaphragm)r.sub.6 = ∞ d.sub.6 = 0.370 n.sub.3 = 1.52 ν.sub.3 = 64.15r.sub.7 = ∞ d.sub.7 = 0.020 n.sub.a (nematic liquid crystal layer)r.sub.8 = -16.807 d.sub.8 = 0.300 n.sub.4 = 1.52 ν.sub.4 = 64.15r.sub.9 = 28.685 d.sub.9 = 0.020 n.sub.b (nematic liquid crystal layer)r.sub.10 = ∞ d.sub.10 = 0.370 n.sub.5 = 1.52 ν.sub.5 = 64.15r.sub.11 = ∞ d.sub.11 = 0.030r.sub.12 = ∞ d.sub.12 = 0.620 n.sub.6 = 1.51 ν.sub.6 = 75.00r.sub.13 = ∞ d.sub.13 = 0.160r.sub.14 = 5.781 d.sub.14 = 1.300 n.sub.7 = 1.70 ν.sub.7 = 55.53r.sub.15 = -1.442 d.sub.15 = 0.280 n.sub.8 = 1.85 ν.sub.8 = 23.78r.sub.16 = -5.018 d.sub.16 = 0.100r.sub.17 = ∞ d.sub.17 = 0.400 n.sub.9 = 1.52 ν.sub.9 = 59.89r.sub.18 = ∞ d.sub.18 = 0.871r.sub.19 = ∞ d.sub.19 = 1.000 n.sub.10 = 1.52 ν.sub.10 = 64.15r.sub.20 = ∞ d.sub.20 = 1.250 n.sub.11 = 1.53 ν.sub.11 = 59.89r.sub.21 = ∞ d.sub.21 = 0r.sub.22 (image position)______________________________________
In this case, the refraction index of the nematic liquid crystal layer to be used at the ordinary ray is 1.52, the refraction index at the extraordinary ray is 1.76, the aperture diameter of the aperture diaphragm is 0.54 mm
(2) Numerical value in case of applying the voltage on the nematic liquid crystal layer of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.52OB = 15.0 (mm) f = 1.608 (mm)F.sub.NO = 7.39 IH = 1.63 (mm)______________________________________
(3) Numerical value in case of performing incidence of the polarized light having oscillating direction parallel to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.76 n.sub.b = 1.52OB = 8 (mm) f = 1.571 (mm)F.sub.NO = 7.37 IH = 1.63 (mm)______________________________________
(4) Numerical value in case of performing incidence of the polarized light having oscillating direction perpendicular to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.76OB = 8 (mm) f = 1.547 (mm)F.sub.NO = 7.26 IH = 1.63 (mm)______________________________________
[Fourth embodiment]
(1) Numerical value of optical system (As to definition of respective numerical value, refer to FIG. 9)
______________________________________r.sub.1 = ∞ d.sub.1 = 0.460 n.sub.1 = 1.88 ν.sub.1 = 40.78r.sub.2 = 1.009 d.sub.2 = 0.830r.sub.3 = 5.908 d.sub.3 = 2.120 n.sub.2 = 1.77 ν.sub.2 = 49.60r.sub.4 = -2.000 d.sub.4 = 0.100r.sub.5 = ∞ (aperture d.sub.5 = 0diaphragm)r.sub.6 = ∞ d.sub.6 = 0.300 n.sub.3 = 1.56 ν.sub.3 = 60.67r.sub.7 = ∞ d.sub.7 = 0.014 n.sub.a (nematic liquid crystal layer)r.sub.8 = -16.304 d.sub.8 = 0.250 n.sub.4 = 1.56 ν.sub.4 = 60.67r.sub.9 = 16.304 d.sub.9 = 0.014 n.sub.b (nematic liquid crystal layer)r.sub.10 = ∞ d.sub.10 = 0.300 n.sub.5 = 1.56 ν.sub.5 = 60.67r.sub.11 = ∞ d.sub.11 = 0.030r.sub.12 = ∞ d.sub.12 = 0.400 n.sub.6 = 1.52 ν.sub.6 = 59.89r.sub.13 = ∞ d.sub.13 = 0.030r.sub.14 = ∞ d.sub.14 = 0.620 n.sub.7 = 1.51 ν.sub.7 = 75.00r.sub.15 = ∞ d.sub.15 = 0.079r.sub.16 = 5.772 d.sub.16 = 1.300 n.sub.8 = 1.70 ν.sub.8 = 55.53r.sub.17 = -1.273 d.sub.17 = 0.280 n.sub.10 = 1.85 ν.sub.10 = 23.78r.sub.18 = -5.020 d.sub.18 = 0.100r.sub.19 = ∞ d.sub.19 = 0.400 n.sub.11 = 1.52 ν.sub.11 = 59.89r.sub.20 = ∞ d.sub.20 = 0.890r.sub.21 = ∞ d.sub.22 = 1.000 n.sub.12 = 1.52 ν.sub.12 = 64.15r.sub.22 = ∞ d.sub.22 = 1.250 n.sub.13 = 1.52 ν.sub.13 = 59.89r.sub.23 = ∞ d.sub.23 = 0r.sub.24 (image position)______________________________________
In this case, the refraction index of the nematic liquid crystal layer to be used at the ordinary ray is 1.52, the refraction index at the extraordinary ray is 1.76, the aperture diameter of the aperture diaphragm is 0.37 mm.
(2) Numerical value in case of applying the voltage on the nematic liquid crystal layer of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.52OB = 10.0 (mm) f = 1.597 (mm)F.sub.NO = 11.14 IH = 1.63 (mm)______________________________________
(3) Numerical value in case of performing incidence of the polarized light having oscillating direction parallel to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.76 n.sub.b = 1.52OB = 3.7 (mm) f = 1.597 (mm)F.sub.NO = 11.14 IH = 1.63 (mm)______________________________________
(4) Numerical value in case of performing incidence of the polarized light having oscillating direction perpendicular to the major axis direction of liquid crystal molecule, under the state of applying no voltage on the nematic liquid crystal of the optical system.
______________________________________n.sub.a = 1.52 n.sub.b = 1.76OB = 3.7 (mm) f = 1.597 (mm)F.sub.NO = 11.28 IH = 1.63 (mm)______________________________________
FIG. 10 shows whole construction of the distal section for an endoscope described in respective embodiments. The endoscope 130 comprises an endoscope unit 120 having a distal section A accommodating therein an optical system for imaging and an optical system for illumination and a member for transmitting a picked-up image and the illuminating light, a monitor 125 and a light source 127. A subject imaged at the distal section A is displayed finally at the monitor 125 as an image for the endoscope and observed by an observer. The illuminating light from the light source 127 illuminates a field of view direction through a light guide cable 126, base section 123, an inserting section 122 and the distal section A (light guide 22 and the illuminating lens 23).
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An imaging optical system is disclosed. The system comprises a liquid crystal lens including a first body consisting of a substantially transparent birefringent liquid crystal member, a second body consisting of a substantially transparent birefringent liquid crystal member, and two pairs of electrodes for adding an electric field or a magnetic field onto the first body and the second body. A rear face of the first body is aligned perpendicular to a front face of the second body, the first body and the second body have substantially symmetrical shape against a plane perpendicular to an optical axis and plurality of optical elements are arranged front and after the liquid crystal lens.
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FIELD OF THE INVENTION
A detection device for piece goods, preferably textiles and/or textile articles, comprising an antenna device for inductive coupling of an operating voltage into an electronic marking which are in each case captively connected to the piece goods to be counted, and a reading unit for acquiring the signals sent by the electronic markings, as well as a counter connected downstream of the reader for determining the respective number of piece goods by evaluation of the signals of the electronic markings received by means of the reader.
BACKGROUND
Such a detection device for cleaning mops is previously known, for example, from German utility model DE 200 16 620 U1.
The cleaning mop previously known from this document is provided with a cleaning fabric on the side facing the floor to be cleaned in normal use and comprises, in the side end region on the opposite side, a respective open receiving pocket which is formed by means of attached pocket layers, it being possible for the end sections of a preferably foldable mop holder to be inserted into said receiving pockets.
Such cleaning mops have been commercially available for many years and are used to pick up contaminants from flat surfaces, such as floors or walls. Cleaning mops of this type are used, for instance, to clean floors in hospitals or clinics and other medical establishments. There are particularly strict hygiene requirements in these sectors, and thus the cited cleaning mops or mop coverings have to be cleaned and disinfected at prescribed time intervals. The mop cleaning intervals are regulated as a function of the surface that is treated by the respective mop. Firstly, there is therefore the problem that the mop cleaning intervals have to be monitored. Said mops are also only allowed to run through a prescribed number of cleaning intervals before they have to be replaced. A further considerable problem within the context of cleaning said mops accordingly consists in the fact that cleaning very often takes place outside of the cited establishments, in other words in special cleaning facilities. When monitoring the cleaning intervals, there is therefore an additional interest in being able to also detect and check the number of mops. This interest is especially intensified in that in the last few years, it has been found that there has been a virtually inexplicable loss of said mops in said establishments. It is largely unclear whether this loss is to be attributed to the hospital staff employed or to said cleaning establishments or to other causes entirely. This problem could previously only be adequately solved in that the mops handed over for cleaning were counted before dispatch and the cleaned mops counted again once they had been returned. It is understood that counting, in particular of the mops soiled from cleaning, is a time-consuming and not exactly pleasant manual task.
Starting from this prior art, DE 200 16 620 U1 proposes the use of the RFID tags that are known per se. A detailed description of these RFID tags and the engineering achieved in this regard can be found, for instance, in DE 101 55 935 A1.
The RFID (Radio Frequency IDentification) tags substantially consist of contactlessly scannable transponder systems. These are oscillating circuits with a defined resonant frequency. The tag substantially consists in this regard of an antenna coil with one or more windings, which is electrically coupled to a chip. As soon as said antenna coil is brought into the alternating magnetic field of a transmitting antenna, an inductive coupling between the transmitting antenna and the antenna coil of the tag is produced. An electric voltage is induced in the tag by the alternating electromagnetic field, which voltage ultimately ensures the voltage supply of the silicon chip integrated in the circuit, i.e. the so-called “transponder IC”. Alternatively, said silicon chip is omitted in the simple 1-bit transponders, and thus the RFID tag is only composed of said antenna coil and an oscillating circuit consisting of a coil and a capacitor, whereby owing to the excitation of this oscillating circuit, preferably with the resonant frequency thereof, the RFID tag for its part measurably weakens the alternating magnetic field generated by the transmitting antenna. Using the 1-bit transponder, the existence of a transponder of this type can substantially only be digitally detected and the contents of a silicon chip with additional individual data, for instance, cannot be read out. 1-bit transponders are used, for example, as an anti-theft device in large stores. In this case it is sufficient to actually detect whether a transponder of this type, which is firmly attached to an item of clothing for example, is moved past a reader, which is usually arranged in the exit region of a large store, in an unauthorised manner—in other words without making a corresponding payment.
This technology is advantageously used according to DE 200 16 620 U1 to count the cited mops. The aforementioned RFID tags are sewn for this purpose into a corresponding receiving pocket of the cleaning mop, the previously known solution not relating to 1-bit transponders but rather to transponders with an integrated memory chip. The data individualising the respective cleaning mop, for example a serial number, the date of manufacture, manufacturer's details, proprietor's details, for instance the name of the hospital, as well as details regarding the first, second and/or last chemical cleaning of the cleaning mop, is assigned to the chip. The memory chip is both readable and writable. For this purpose, the cleaning mop must be guided over a card reading device or over a reading/data input device, respectively.
This solution allows the process of counting the mops in question to be significantly simplified and, moreover, allows said cleaning intervals to be monitored using electronic means. The degree of automation of counting and/or acquiring the data stored in connection with the mops that is to be achieved with a reader of this type is nevertheless kept within limits. To be able to reliably detect an RFID tag arranged in the alternating electromagnetic field of a transmitting antenna, it must firstly be ensured that the distance between the antenna for coupling the operating voltage into the RFID tags and the RFID tag itself is not too large. It is currently assumed, using the field strengths that are still compatible with the surroundings, that the distance between RFID tag and antenna must not be greater than 30 cm.
Furthermore, the RFID tag must be arranged relative to the transmitting antenna while maintaining a specific orientation. The tag with the integrated coil is ideally moved past the reader such that the coil surface surrounded by the coil is moved past the coil surface of the transmitting/receiving antenna so as to be more or less parallel. This ensures that the field lines of the electromagnetic field generated by the transmitting/receiving antenna intersect the coil surface almost orthogonally. In any case, the angle between the coil surface and the surface enclosed by the antenna of the tag should not exceed 45 degrees since otherwise sufficient penetration of the antenna coil surface of the RFID tag, and thus the required inductive coupling into the relevant tag, is no longer ensured. Reliable identification and/or reliable reading out of the RFID tag by the respective transmitting/receiving antenna is no longer ensured in this case.
According to the closest prior art represented by DE 200 16 620 U1, in order to count and check the mops, it is therefore more or less still necessary to move the mops past a transmitting and receiving antenna, for instance by means of a conveyor belt or by hand, such that they are more or less exactly aligned. This is still regarded as being unsatisfactory, in particular in conjunction with a large number of mops.
SUMMARY OF THE INVENTION
The object forming the basis for the invention is therefore to produce a detection device for piece goods, preferably for textiles and/or textile articles, which avoids the aforementioned drawbacks and thereby allows largely fully automatic counting or detection of the piece goods to be counted.
The solution to this object is achieved by a detection device according to the features of the main claim. Advantageous embodiments of the detection device according to the invention can be found in dependent claims 2 to 24 .
The fact that the antenna device of the detection device comprises at least two antennas arranged at a, preferably orthogonal, angle to one another ensures that a plurality of electromagnetic fields of different orientation in each case is generated in a space. This in turn ensures that, independently of the respective orientation of the, preferably textile, piece goods to be counted, the RFID tags are intersected at least by the field lines of one of the involved fields and therefore the conditions necessary for activating the electronic marking are created. Owing to the detection device according to the invention, a specific spatial orientation of the piece goods and the electronic markings captively connected thereto is no longer decisive. The detection device works reliably even with a random arrangement of the piece goods in a space.
The antennas of the antenna devices consist of electrical conductors for generating an alternating electromagnetic field at a defined frequency. An alternating field is normally generated at 13.56 MHz.
In an advantageous embodiment, the detection device is provided with a counting cage, the individual antennas of the antenna devices overlapping the counting cage on at least two sides. Dimensioning the counting cage as a function of the field strength of the fields of the antennas used ensures that at least the electronic markings of the piece goods received in the counting cage may be activated and read out.
In an advantageous embodiment, the counting cage is cuboidal and comprises a floor plate that is delimited by four side walls, said counting cage being open towards the top. This enables the piece goods to be simply dropped or placed into the counting cage from the top before actual counting begins so that they can be detected. The detection device comprises an antenna device having two, preferably four, diagonal antennas, with each of the diagonal antennas including at least one, however preferably two, diagonal sections. These diagonal antennas are each assigned to one, preferably two, side walls of the counting cage. The name of the diagonal antennas and the diagonal sections of the diagonal antennas stems from the fact that in the diagonal section, these antennas each extend diagonally over the corresponding side wall. It has been shown that in the case of a random arrangement of piece goods in the counting cage, such diagonal antenna arrangements constitute a particularly advantageous arrangement since they ensure optimal field penetration in the case of randomly arranged piece goods and thus achieve these results alone, which although are not 100 percent accurate, are sufficiently accurate for many applications. If the piece goods are provided with RFID tags, a sufficiently accurate counting result with an error quotient of 5 to 10%, which is sufficient for most applications, can already be provided with 2 or 4 diagonal antennas. The fewer antennas there are, the fewer tuning problems there are and the quicker the counting results. The arrangement of two or ideally four diagonal antennas each with two diagonal sections, with each diagonal section being assigned to a side wall, thus represents a particularly advantageous and simple embodiment of the antenna device of the detection device according to the invention.
As an alternative to the closed cuboid shape, a further solution regarding the construction of the counting cage is to leave it open on two opposite sides and to hang the counting cage such that it is moveable per se. An embodiment is particularly preferred here, in which the counting cage can be moved vertically and the sides of the cuboid that are horizontal in this position are open. In this embodiment, counting is made possible in that a container holding the piece goods to be counted is placed underneath the counting cage, which is then lowered over the container such that the antenna device of the counting cage surrounds the container. The piece goods thus do not have to be reloaded again, but can rather remain in the container provided, for example, by the laundry.
In a specific development, the diagonal antennas are configured such that they each include two diagonal sections that are connected by two transverse members preferably arranged in the region of opposite edges of the cuboidal counting cage. Such a geometric arrangement ensures that the geometry of the counting cage is not affected by the diagonal antennas and thus a particularly easy anchoring of the diagonal antennas with the counting cage is possible.
A diagonal orientation of the generated fields is advisable also in the region of the diagonal antennas, and thus it is expedient for a pair of diagonal antennas or a pair of diagonal sections, which preferably intersect at an angle of at least approximately 90°, to be assigned to each side wall.
A further improvement in the counting result of the piece goods that can be achieved with the detection device can be obtained by additionally upgrading the antenna device by providing it with six further so-called frame antennas in addition to the aforementioned diagonal antennas. The frame antennas are substantially assigned to the x, y and z axes of the counting cage in such a manner that each frame antenna substantially surrounds a limiting surface of the counting cage. There are six frame antennas since two frame antennas are assigned to each orthogonal orientation, i.e. the x, y and z direction. These are normally one of each of a transmitting antenna and a receiving antenna.
The combination of the described diagonal and frame antennas in conjunction with the also described arrangement achieves an almost 100% accurate counting result for a random arrangement of piece goods having an electronic marking, preferably an RFID tag, inside the counting cage. The reason for this is that owing to the particular geometric arrangement of the antennas of the antenna device, it is ensured that the electronic markings or cited RFID tags are in any case penetrated to the required extent and angle by the field lines of the transmitting field.
In order to be able to achieve an overall tuning of the antenna device, it is, however, necessary for each antenna of the antenna device to be assigned at least one separate electronic tuning means.
In the case of the use of passive electronic markings, i.e. in particular RFID tags, which is preferred herein, it is necessary for the antenna device to comprise both transmitting and receiving antennas, with a receiving antenna being assigned to each transmitting antenna, and the two together forming in each case a transmitting/receiving antenna pair.
It has shown in practice that if the antennas are supplied with power at the same time, this results in almost insurmountable couplings and antenna detunings which are in turn reflected by undesirable errors in the counting result. These attenuating and detuning effects of the antennas can be effectively eliminated in that the antennas can be independently supplied with power via a multiplexer and thus a decoupling of the counting results of the individual antennas is also possible.
This effect is additionally enhanced in that the antennas are electrically separated by means of switching elements, for example, relays. An oscillation in the effective range of 13.56 MHz is thereby prevented and coupling of disturbing effects into adjacent antennas is avoided.
The multiplexer operation of the antennas is ideally organised by means of a central control unit of the detection device in such a manner that the transmitting antennas controlled via the multiplexer are supplied with power one after the other and the counting results received by the receiving antennas assigned to the respective transmitting antennas are detected one after the other. Switching through channel for channel and thus antenna for antenna occurs via the multiplexer and in each case the counting result detected on average for an antenna is detected, the adding up of the counting results then leading to the total number of piece goods contained in the counting cage.
It has also proven worthwhile to provide the detection device with so-called duplicate recognition, whereby not only the fact that a piece good has been identified is detected by the reader, but at the same time an individual identification assigned to each electronic marking of the piece goods is detected and evaluated in such a manner that the counting result is reduced by the number of duplicates that can be identified in this manner. When switching through the channels in the multiplex operation and gradually adding up the actual counting results, only those detected piece goods not already counted during a previous measurement are included in the counting result. This also makes a considerable contribution to the accuracy of the counting result that can be achieved.
A common problem as regards the operation of antennas is the connection thereof via a coaxial cable, in this case at the multiplexer. As a result, an asymmetric signal is transmitted to the symmetrically configured circuit via the coaxial cable, however the problems relating to antenna detuning occurring as a result hereof can be solved by inserting so-called baluns. The insertion of baluns represents circuit engineering that is known per se in the field of token ring technology.
In an advantageous embodiment, the detection device comprises a data processing means having a storage member so that the measurement results can be recorded and stored for a predetermined period of time by the data processing means in the sense of a data logger. This protocol function is decidedly helpful in particular when prosecuting theft.
Further sensors such as, for example, a moisture meter and/or a temperature detecting device, can additionally be added to the detection device. Possible sources of error in the measurement can be identified by means hereof. It may also be helpful for this reason to record the transmitting powers of the transmitting antennas used for the respective measurement in conjunction with the measuring result.
In an advantageous embodiment, the counting cage and the antenna device are each provided with a fixed part and a detachable part. Filling of the antenna cage and dismantling thereof can be simplified in this manner.
A precise tuning of the receiving antennas to the transmitting antennas and to the in each case quite different environmental conditions when using the detection device is made possible in that a receiving amplifier is allocated to each receiving antenna.
A more or less automatic tuning of the receiving amplifiers is made possible in that the central control device controls the receiving amplifiers of the receiving antennas as a function of the input level of the transmitting/receiving antennas.
In a specific embodiment, the detection device is used in particular for detecting mops placed in the counting cage in a simple manner. An RFID tag can be introduced into the mops as an electronic marking, the RFID tags normally being captively incorporated in sealed receiving pockets of the mops or the piece goods to be counted.
The transmitting/receiving antennas with a plurality of, preferably two, coils arranged in parallel are connected to the fixed part of the counting cage, whereas the simple receiving antennas are connected to the separable part of the counting cage.
The receiving antennas are additionally connected to a receiving amplifier to attain greater sensitivity of the antenna device for the signals sent by the electronic markings. The amplifier allows lower field strengths to be used to activate the electronic markings.
In another advantageous embodiment, the amplification factor of the receiving amplifier is selected as a function of the input level of the transmitting/receiving antenna, i.e. with correspondingly greater bit strength, the receiving amplifier may, if necessary, be adjusted downward to activate electronic markings.
In the case of the embodiment of the electronic markings as intelligent RFID tags with an integrated chip, monitoring of the cleaning intervals and other individual features may take place at the same time as counting.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail below by means of an embodiment illustrated only schematically in the drawings, in which:
FIG. 1 shows a basic circuit diagram of a detection device with an antenna device,
FIG. 2 shows a perspective view of the antenna device of the detection device shown in FIG. 1 in the closed state, and
FIG. 3 shows a separate perspective view of both the frame antennas and the diagonal antennas of the antenna device of the detection device shown in FIG. 1 .
DETAILED DESCRIPTION
According to the illustration in FIG. 1 , the detection device comprises a counting cage 1 for receiving a container with piece goods 2 to be counted, which are provided with a contactlessly evaluatable electronic marking 3 . The electronic marking 3 is preferably a transponder or an RFID tag. RFID tags are understood as passive oscillating circuits in which a silicon chip with a data storage medium is arranged. The oscillating circuit may be supplied with power via a transmitting antenna by the active coupling of an operating voltage into an alternating electromagnetic field. The inductive coupling then provides the operating voltage required for the silicon chip, which then transmits the stored data to a receiving antenna.
In the present case, an antenna device 4 is associated with the counting cage 1 for this purpose, said device comprising transmitting/receiving antennas 5 , 5 ′ and two pure receiving antennas 6 , 6 ′. The antennas 5 , 5 ′ and 6 , 6 ′ are arranged in the space with different orientations. In the present case, they are permanently connected to the side walls of the counting cage 1 in a manner that is not shown in more detail here. This ensures that the piece goods 2 disposed inside the counting cage 1 are exposed to a plurality of electromagnetic fields of different orientation. This in turn ensures that the piece goods 2 , independently of their random orientation in the space or, more precisely, in the counting cage 1 , are in each case penetrated by the field lines of the electromagnetic fields generated by means of the transmitting/receiving antennas 5 , 5 ′ such that the required operating voltage is reliably coupled into each RFID tag disposed inside the counting cage 1 . This in turn ensures that the signals sent by the RFID tags may be reliably received by both the receiving antennas 6 , 6 ′ and the transmitting/receiving antennas 5 , 5 ′.
The transmitting/receiving antennas 5 , 5 ′ are controlled by a common central control device 7 by way of a multiplexer 10 . The multiplexer 10 is connected to a transmitting channel 11 and receiving channel 12 of the central control device 7 . The multiplexer 10 is data-connected in each case by means of a bidirectional data connection 13 , 13 ′ to the connected transmitting/receiving antennas 5 , 5 ′. The pure receiving antennas 6 , 6 ′ are on the other hand connected to the central control unit 7 via a unidirectional data connection 14 , 14 ′ by way of an additional multiplexer 15 .
The alternating electromagnetic field required for coupling of the required operating voltage is first of all generated by the transmitting/receiving unit 5 , 5 ′. After the field has been switched off, the tags transmit the data contained in the chips for identifying the piece goods 2 , which data is received by the antennas 5 , 5 ′, 6 , 6 ′ of the antenna device 4 and is transmitted to the central control device 7 for further evaluation. A counter 16 for displaying the counting result is assigned to the central control unit 7 . The counter 16 has a display device 17 for this purpose.
A perspective view of the specific embodiment of the antenna device 4 is shown in FIG. 2 . The antenna device 4 substantially consists of four diagonal antennas 30 , 31 , 32 and 33 as well as six frame antennas 34 to 39 . The diagonal antennas thereby each consist of two diagonal sections 31 a and 31 b , that are connected with one another by transverse members 31 c and 31 d , as is shown, for example, for diagonal antenna 31 in FIG. 2 . The other diagonal antennas 30 , 32 and 33 , have an analogous construction.
The antenna device 4 thereby comprises a counting cage that is not shown in more detail in FIG. 2 and which normally has four side walls and is hung so as to be vertically moveable. The frame antennas 34 to 39 each surround the limiting surfaces of the cuboidal counting cage. The diagonal antennas are arranged such that the transverse members are each arranged in the region of the edges of the cuboid, with the length of the transverse members 31 c and 31 d slightly exceeding in each case the length of the limiting edges of the counting cage such that the diagonal sections 31 a and 31 b are respectively arranged outside of the side walls of the counting cage 1 . The diagonal antennas 31 to 33 are assigned to the counting cage 1 in such a manner that two diagonal sections intersecting at an angle of 90° are assigned to each side wall of the counting cage 1 .
An individual tuning device 40 is assigned to each individual antenna 30 to 39 . The geometric arrangement of the antenna device shown in a perspective view in FIG. 2 can be better understood from the separated view in FIG. 3 . As is indicated by the plus sign in FIG. 3 , the antenna device 4 thus consists of the arrangement of the frame antennas in the left-hand illustration and the arrangement of the diagonal antennas in the right-hand illustration.
The function of the antenna device in FIGS. 2 and 3 is explained below again in context.
As already explained above, in order to detect piece goods that have been labelled with RFID tags, it is necessary for the induction loop contained in the RFID tags to be penetrated by the field lines of the transmitting antennas at least at an angle of 45° to the coil surface distinguished by the coil of the RFID tag. This can only be achieved in the case of a random and disorderly arrangement of piece goods if a plurality of field lines are arranged at an angle to one another. Practical experiments have shown that very good counting results can be already achieved with a diagonal arrangement having only two diagonal antennas that are in an appropriate arrangement with respect to one another. However, in a further improvement, it is advisable to select an arrangement with four diagonal antennas in accordance with FIG. 3 . With this arrangement, accuracies are achieved in connection with the above-explained mop counting in a counting cage 1 , as shown in FIG. 1 , whose deviation lies in the single-figure percentage range.
In most cases, such a mop result should be entirely satisfactory. The counting result can be further improved by adding an arrangement of frame antennas according to the left-hand illustration in FIG. 3 to the arrangement of the diagonal antennas according to the right-hand illustration in FIG. 3 .
The antennas each have to be understood as antenna pairs of transmitting and receiving antennas. The passive oscillating circuits of the RFID tags are inductively supplied with power by means of the transmitting antennas, with this excitation of the inductive oscillating circuits of the RFID tags being sufficient to activate these, for their part, as transmitters so that the chip identifications contained in the RFID tags are inductively transmitted. These inductive RFID identifications can then be evaluated using the receiving antennas and supplied to a further data collection device. In the case of an antenna device according to FIG. 2 , an almost 100% counting result is achieved for the principal object within the framework of the invention, i.e. mop counting. The individual antennas are operated in this case via a multiplexer that assigns an individual channel to each antenna of the antenna device 4 such that the transmitting antennas can be supplied with power one after the other by the multiplexer. The receiving antennas are accordingly also activated one after the other, and thus the correct counting result is achieved in that the counting results of the individual receiving antennas are added up. The detection device is ideally provided with duplicate recognition, which also evaluates the individual identifications of the RFID tags and thereby determines whether an RFID tag has already been detected in connection with a previous count. Such duplicates are not included in the further counting result and thus errors due to corresponding duplicate counts are effectively avoided.
In an advantageous embodiment, the detection device can be provided with further sensors such as a temperature meter or moisture meter, which can be of additional importance in connection with the detection of the counting conditions, and also of the state of the mops. The arrangement is normally operated in conjunction with a storage member that records the measurements and the circumstances thereof. The recording of the counting results is important to thus be able to pursue in a targeted manner possible notices of loss for example in the entrance area of laundries and the like.
In contrast to the prior art, the advantage of the detection device according to the invention lies in the fact that the device in question also works reliably with a random arrangement of the piece goods 2 inside the counting cage 1 .
LIST OF REFERENCE NUMBERS
1 counting cage
2 piece goods
3 electronic marking
4 antenna device
5 , 5 ′ transmitting/receiving antennas
6 , 6 ′ receiving antennas
7 central control device
10 multiplexer
11 transmitting channel
12 receiving channel
13 , 13 ′ bidirectional data connection
14 , 14 ′ unidirectional data connection
15 additional multiplexer
16 counter
17 display device
31 a , 31 b diagonal sections
31 c , 31 d transverse members
30 to 33 diagonal antennas
34 to 39 frame antennas
40 tuning element
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The invention relates to a detection device for piece goods, in particular textiles. Starting from the marking of textiles with RFID tags that can be read out with the use of a reader, as is known from the prior art, a detection device for textiles is produced within the scope of the present invention, in which electromagnetic fields of different orientation are generated with the use of at least two antennas arranged at a defined angle to each other, and this ensures that the electronic markings of the piece goods disposed in a counting cage may be reliably read out independently of their relative arrangement in the space.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a CRC arithmetic unit for detecting a data transmission error by a CRC (cyclic redundancy check) system employed for transmitting a data string.
2. Description of the Background Art
In relation to communication of a data string, there is a method of determining whether or not the transmitted data string is normal by adding a check bit for an error detection check to an information bit to be transmitted and performing a prescribed operation in receiving. A method employing a parity bit is well known as a simple error detection system. In this method, a single parity bit is added in response to whether the number of “1” included in each transmitted data string is even or odd.
A cyclic redundancy check (hereinafter abbreviated as CRC) is a method enhanced in detectability. In the CRC, an operation with a generating polynomial is performed on an information bit to be transmitted.
A method of forming a CRC sign is briefly described. First, it is assumed that P(X) represents an information data string to be transmitted corresponding to an information bit, G(X) represents a generating polynomial, F(X) represents a transmitted data string and R(X) represents a remainder polynomial corresponding to a check bit. These are expressed in sign polynomials. In a sign polynomial, a binary number is expressed in a polynomial. For example, P(X)=“100 1011 0100 1011” is expressed as follows:
P ( X )= X 14 +X 11 +X 9 +X 8 +X 6 +X 3 +X 1 +1
When the generating polynomial G(X) is equal to X 8 +X 7 +X 6 +X 4 +X 2 +1, the transmitted data string F(X) is obtained by the following expressions (1) to (3):
First, the information data string P(X) is multiplied by the high-order term X 8 of the generating polynomial G(X) for obtaining P′(X) as follows:
P ′( X )= P ( X )× X 8 (1)
Then, P′(X) is subjected to mod2 division described later by the generating polynomial G(X) for obtaining the remainder polynomial R(X). It is assumed that “/” denotes the mod2 division described later.
R ( X )= P ′( X )/ G ( X ) (2)
The obtained remainder polynomial R(X) is added to P′(X) for obtaining the transmitted data string F(X) as follows:
F ( X )= P ′( X )+ R ( X ) (3)
FIG. 15 is a diagram for illustrating the mod2 division for obtaining the check bit from the information bit and the generating polynomial.
The operation of obtaining the check bit from the information bit when the generating polynomial G(X) is equal to X 8 +X 7 +X 6 +X 4 +X 2 +1 is described with reference to FIG. 15 . “1 1101 0101” corresponds to the generating polynomial, and the information bit is “100 1011 0100 1011”.
The number 0 of a bit number−1 in the generating polynomial is first added to the low order of the information bit. This processing corresponds to the operation shown in the expression (2).
The mod2 operation is performed on each bit of the generating polynomial in descending order. However, the mod2 operation generates no carry or negative carry dissimilarly to general division. In other words, the exclusive OR of each information bit and each bit of the generating polynominal is sequentially calculated. The most significant result is necessarily “0” and hence at least a single information bit is supplied to the lower result to match with the bit number of the generating polynomial. Referring to FIG. 15, symbol A denotes an intermediate result obtained in this stage.
The mod2 operation is thereafter similarly repeated, and terminated when the result is finally less than the bit number of the generating polynomial. The finally obtained remainder “00110001” is the obtained check bit. The operation of repeating the mod2 operation for obtaining the remainder is referred to as mod2 division in this specification.
The check bit obtained in the aforementioned manner is transmitted subsequently to the information bit when transmitting the data string. The receiving end confirms whether or not a transmission error occurs on the basis of the transmitted information and check bits.
FIG. 16 is a diagram for illustrating the operation for confirming whether or not a transmission error occurs.
Referring to FIG. 16, the mod2 division is performed on the data string transmitted with the check bit “0011 0001” added to the lower side of the information bit “100 1011 0100 1011” by the generating polynomial “1 1101 0101”. As to the mod2 division described with reference to FIG. 15, redundant description is not repeated.
When transmission is correctly performed, the remainder is zero and it is confirmable that no transmission error occurs.
FIG. 17 is a conceptual diagram showing the structure of a conventional CRC arithmetic unit 100 performing the division illustrated in FIGS. 15 and 16.
Referring to FIG. 17, the CRC arithmetic unit 100 includes XOR circuits 102 to 110 operating and outputting exclusive OR and registers 112 to 126 driven by a clock signal (not shown) for capturing and holding data.
The XOR circuit 102 operates and outputs the exclusive OR of a data string input in the CRC arithmetic unit 100 and a value held in the register 126 . The register 112 receives the output of the XOR circuit 102 and holds the same for a single clock period. The register 114 receives an output of the register 112 and holds the same for a single clock period. The XOR circuit 104 operates and outputs the exclusive OR of outputs of the registers 114 and 126 . The register 116 receives the output of the XOR circuit 104 and holds the same for a single clock period. The register 118 receives an output of the register 116 and holds the same for a single clock period.
The XOR circuit 106 operates and outputs the exclusive OR of the outputs from the registers 118 and 126 . The register 120 receives the output of the XOR circuit 106 and holds the same for a single clock period. The register 122 receives an output of the register 120 and holds the same for a single clock period. The XOR circuit 108 operates and outputs the exclusive OR of outputs from the registers 122 and 126 . The register 124 receives the output of the XOR circuit 108 and holds the same for a single clock period. The XOR circuit 110 outputs the exclusive OR of outputs from the registers 124 and 126 . The register 126 receives the output of the XOR circuit 110 and holds the same for a single clock period.
FIGS. 18 to 25 illustrate the process of operations in the CRC arithmetic unit 100 shown in FIG. 17 . The process up to the intermediate stage of the mod2 division shown in FIG. 15 is described with reference to FIGS. 18 to 25 .
Referring to FIGS. 15 and 18, the CRC arithmetic unit 100 is provided with the XOR circuits 102 to 110 in correspondence to positions where the bits of “1” of the generating polynomial are present. In other words, the structure of the CRC arithmetic unit 100 corresponds to the generating polynomial “1 1101 0101”.
First, it is assumed that all registers 112 to 126 initially hold “0”. Although not illustrated, it is general that values held in all registers 112 to 126 are initialized to “0” in response to a reset signal. While the register 126 holds “0”, the XOR circuits 102 to 110 output data received from preceding stages to subsequent stages intact. In other words, the CRC arithmetic unit 100 acts as a simple shift register until data “1” arrives at the register 126 .
After a lapse of a prescribed time, the registers 112 to 126 hold “1001 0110”. “1” is input in an input of the CRC arithmetic unit 100 .
Referring to FIG. 19, the registers 112 to 126 hold results operated in the XOR circuits 102 to 110 after a lapse of a single clock period. The next bit “0” is input in the input of the CRC arithmetic unit 100 . This state corresponds to the intermediate result A shown in FIG. 15 .
FIG. 20 shows the state in a next clock cycle. At this time, the registers 112 to 126 hold “0010 0101”.
FIG. 21 shows the state in a next clock cycle. At this time, the register 126 holds “0” and hence the values are shifted to the upper side one bit position. Thus, the registers 122 to 126 hold “0100 1010”.
FIG. 22 shows the state in a next clock cycle. The register 126 holds “0” in FIG. 21, and hence the CRC arithmetic unit 100 holds “1001 0101” shifted to the upper side one bit position. “0” is newly input in the input of the CRC arithmetic unit 100 . This state corresponds to an intermediate result B shown in FIG. 15 .
In a next clock cycle, the registers 112 to 126 hold “1111 1111” as shown in FIG. 23 . “1” is newly input in the input of the CRC arithmetic unit 100 . This state corresponds to an intermediate result C shown in FIG. 15 . In a next clock cycle, the registers 112 to 126 hold “0010 1010” as shown in FIG. 24 .
In a next clock cycle, the registers 112 to 126 hold “0101 0101” as shown in FIG. 25 . In a next clock cycle, the registers 112 to 126 hold an intermediate result D shown in FIG. 15 .
A plurality of systems employing different generating polynomials are present for the CRC operation. In the conventional CRC arithmetic unit 100 described above, the positions for inserting the XOR circuits 102 to 110 must be changed for changing the used generating polynomial, while it is difficult to change the positions when the generating polynomial is once decided.
Further, the conventional arithmetic unit 100 can handle only a 1-bit input in a single clock cycle, to disadvantageously result in a long operation time.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a CRC arithmetic unit capable of readily dealing with change of a generating polynomial and performing an operation at a high speed.
Briefly stated, the present invention is directed to a CRC arithmetic unit for performing error detection in a cyclic redundancy check system on object data on the basis of a generating polynomial, which comprises a main arithmetic circuit and a hold circuit.
The main arithmetic circuit sequentially receives a plurality of split data obtained by splitting signal bits included in the object data into a plurality of bits for performing arithmetic processing according to the generating polynomial. The main arithmetic circuit performs the arithmetic processing on first data included in the plurality of split data and second data obtained by performing the arithmetic processing on part of the object data received before receiving the first data and generating third data.
The hold circuit holds the second data and supplies the same to the main arithmetic circuit while holding the third data.
Accordingly, a principal advantage of the present invention resides in that the CRC arithmetic unit simultaneously batch-processing a plurality of bits in a clock cycle can perform a CRC operation at a high speed.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing the structure of a CRC arithmetic unit 1 according to a first embodiment of the present invention;
FIG. 2 is a circuit diagram showing the structure of a hold circuit 2 appearing in FIG. 1;
FIG. 3 is a circuit diagram showing the structure of an arithmetic circuit 6 appearing in FIG. 1;
FIG. 4 is an operation waveform diagram for illustrating operations of the CRC arithmetic unit 1 shown in FIG. 1;
FIG. 5 is a diagram for illustrating operations of the CRC arithmetic unit 1 in a clock cycle T 1 shown in FIG. 4;
FIG. 6 is a diagram for illustrating operations of the CRC arithmetic unit 1 in a clock cycle T 2 shown in FIG. 4;
FIG. 7 is a diagram for illustrating operations of the CRC arithmetic unit 1 in a clock cycle T 3 shown in FIG. 4;
FIG. 8 is a diagram for illustrating operations of the CRC arithmetic unit 1 in a clock cycle T 4 shown in FIG. 4;
FIG. 9 is a circuit diagram showing the structure of a CRC arithmetic unit 20 capable of readily dealing with change of a generating polynomial;
FIG. 10 is a schematic block diagram showing the structure of a CRC arithmetic unit 30 according to a second embodiment of the present invention;
FIG. 11 is a circuit diagram showing the structure of an arithmetic circuit 36 appearing in FIG. 10;
FIG. 12 illustrates a state setting set data S 7 to S 0 of the CRC arithmetic unit 30 ;
FIG. 13 is a circuit diagram showing the structure of a CRC arithmetic unit 60 obtained by modifying the CRC arithmetic unit 20 shown in FIG. 9 to be capable of changing the degree of a generating polynomial;
FIG. 14 is a circuit diagram showing the structure of an arithmetic circuit 66 employed in a CRC arithmetic unit according to a third embodiment of the present invention;
FIG. 15 is a diagram for illustrating mod2 division for obtaining a check bit from an information bit and a generating polynomial;
FIG. 16 is a diagram for illustrating an operation for confirming whether or not a transmission error occurs;
FIG. 17 is a conceptual diagram showing the structure of a conventional CRC arithmetic unit 100 performing the division shown in FIGS. 15 and 16; and
FIGS. 18 to 25 are first to eighth diagrams showing the process of operations performed by the CRC arithmetic unit 100 shown in FIG. 17 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention are now described in detail with reference to the drawings. In the drawings, parts identical or corresponding to each other are denoted by the same reference numerals.
[First Embodiment]
FIG. 1 is a schematic block diagram showing the structure of a CRC arithmetic unit 1 according to a first embodiment of the present invention.
Referring to FIG. 1, the CRC arithmetic unit 1 includes a hold circuit 2 capturing data X 4 1 to X 4 8 in response to a clock signal CLK and an arithmetic circuit 4 receiving data X 0 1 to X 0 8 held by the hold circuit 2 and data X 3 0 to X 0 0 input from inputs IN 0 to IN 3 and outputting data X 4 1 to X 4 8 .
The arithmetic circuit 4 includes an arithmetic circuit 6 receiving the data X 0 0 to X 0 8 and outputting data X 1 1 to X 1 8 , an arithmetic circuit 8 receiving the data X 1 0 to X 1 8 and outputting data X 2 1 to X 2 8 , an arithmetic circuit 10 receiving the data X 2 0 to X 2 8 and outputting data X 3 1 to X 3 8 and an arithmetic circuit 12 receiving the data X 3 0 to X 3 8 and outputting the data X 4 1 to X 4 8 .
FIG. 2 is a circuit diagram showing the structure of the hold circuit 2 appearing in FIG. 1 .
Referring to FIG. 2, the hold circuit 2 includes a register 2 # 0 receiving the data X 4 1 , capturing the same in response to the clock signal CLK and outputting the data X 0 1 , a register 2 # 1 receiving the data X 4 2 , capturing the same in response to the clock signal CLK and outputting the data X 0 2 , a register 2 # 2 receiving the data X 4 3 , capturing the same in response to the clock signal CLK and outputting the data X 0 3 and a register 2 # 3 receiving the data X 4 4 , capturing the same in response to the clock signal CLK and outputting the data X 0 4 .
The hold circuit 2 further includes a register 2 # 4 receiving the data X 4 5 , capturing the same in response to the clock signal CLK and outputting the data X 0 5 , a register 2 # 5 receiving the data X 4 6 , capturing the same in response to the clock signal CLK and outputting the data X 0 6 , a register 2 # 6 receiving the data X 4 7 , capturing the same in response to the clock signal CLK and outputting the data X 0 7 and a register 2 # 7 receiving the data X 4 8 , capturing the same in response to the clock signal CLK and outputting the data X 0 8 .
FIG. 3 is a circuit diagram showing the structure of the arithmetic circuit 6 appearing in FIG. 1 .
Referring to FIG. 3, the arithmetic circuit 6 includes a gate circuit 6 # 0 receiving the data Xn 0 and the data Xn 8 and outputting data Xn+1 1 , a gate circuit 6 # 1 receiving the data Xn 1 and the data Xn 8 and outputting data Xn+1 2 , a gate circuit 6 # 2 receiving the data Xn 2 and the data Xn 8 and outputting data Xn+1 3 and a gate circuit 6 # 3 receiving the data Xn 3 and the data Xn 8 and outputting data Xn+1 4 .
The arithmetic circuit 6 further includes a gate circuit 6 # 4 receiving the data Xn 4 and the data Xn 8 and outputting data Xn+1 5 , a gate circuit 6 # 5 receiving the data Xn 5 and the data Xn 8 and outputting data Xn+1 6 , a gate circuit 6 # 6 receiving the data Xn 6 and the data Xn 8 and outputting data Xn+1 7 and a gate circuit 6 # 7 receiving the data Xn 7 and the data Xn 8 and outputting data Xn+1 8 .
Each gate circuit has an XOR circuit arranged on a position corresponding to the generating polynomial, and receives data Xn k in the remaining position for outputting data Xn+1 k+1 intact (k: integer of 0 to 7). While the gate circuits 6 # 0 to 6 # 8 are simply connected by wires for outputting the data intact, circuits such as buffer circuits not changing the polarity of data may alternatively be arranged.
The arithmetic circuits 8 , 10 and 12 shown in FIG. 1 are similar in structure to the arithmetic circuit 6 . FIG. 3 shows the structure of the arithmetic circuit 6 when n=0, the structure of the arithmetic circuit 8 when n=1, the structure of the arithmetic circuit 10 when n=2, and the structure of the arithmetic circuit 12 when n=3. Therefore, redundant description is not repeated.
FIG. 4 is an operation waveform diagram for illustrating operations of the CRC arithmetic unit 1 shown in FIG. 1 .
Referring to FIG. 4, data D 12 to D 15 forming upper four bits of a data string are input in the inputs IN 0 to IN 3 in a clock cycle T 1 .
Then, data D 8 to D 11 are input in the inputs IN 0 to IN 3 in a clock cycle T 2 . In the clock cycles T 1 and T 2 , the hold circuit 2 is not filled with data and hence the data in the hold circuit 2 are shifted by four bits at a time. When data D 4 to D 7 are input in the inputs IN 0 to IN 3 in a clock cycle T 3 , the CRC arithmetic unit 1 starts an operation. When data D 0 to D 3 are input in the inputs IN 0 to IN 3 in a clock cycle T 4 , the CRC arithmetic unit 1 responsively outputs the remainder to the data X 4 1 to X 4 8 .
Operations of the CRC arithmetic unit 1 receiving the same data as those in the conventional circuit described with reference to FIGS. 18 to 25 are now described.
FIG. 5 is a diagram for illustrating the operation of the CRC arithmetic unit 1 in the clock cycle T 1 of FIG. 4 .
Referring to FIG. 5, reference numerals of the elements are simplified for simplifying the illustration. A register 14 corresponds to the register 2 # 0 shown in FIG. 2, and an XOR circuit 16 corresponds to the gate circuit 6 # 0 shown in FIG. 3 .
Referring to FIGS. 4 and 5, “0”, “1”, “0” and “0” are input from the inputs IN 3 , IN 2 , IN 1 and IN 0 as the data D 15 , D 14 , D 13 and D 12 respectively in the clock cycle T 1 . It is assumed that the hold circuit 2 initially holds data “0000 0000”. Although not illustrated, values held in all registers included in the hold circuit 2 are generally initialized to “0” in response to a reset signal, for example.
At this time, the arithmetic circuit 6 receives “0 0000 0000” as the data X 0 8 to X 0 0 . In response, the arithmetic circuit 6 outputs “0000 0000” as the data X 1 8 to X 1 1 .
The arithmetic circuit 8 outputs “0000 0001” as the data X 2 8 to X 2 1 in response to the output from the arithmetic circuit 6 and “1” input from the input IN 2 . The arithmetic circuit 10 outputs “0000 0010” as the data X 3 8 to X 3 1 in response to the output from the arithmetic circuit 8 and “0” input from the input IN 1 .
The arithmetic circuit 12 outputs “0000 0100” as the data X 4 8 to X 4 1 in response to the output from the arithmetic circuit 10 and “0” input from the input IN 0 . The hold circuit 2 captures the data X 4 8 to X 4 1 in the next clock cycle T 2 .
FIG. 6 is a diagram for illustrating the operation of the CRC arithmetic unit 1 in the clock cycle T 2 of FIG. 4 .
Referring to FIGS. 4 and 6, “1”, “0”, “1” and “1” are input as the data D 11 , D 10 , D 9 and D 8 respectively.
The hold circuit 2 captures and holds the data “0000 0100” output from the arithmetic circuit 12 in the clock cycle T 1 .
The arithmetic circuit 6 outputs “0000 1001” in response to the output from the hold circuit 2 and “1” input from the input IN 3 . The arithmetic circuit 8 outputs “0001 0010” in response to the output from the arithmetic circuit 6 and “0” input from the input IN 2 .
The arithmetic circuit 10 outputs “0010 0101” in response to the output from the arithmetic circuit 8 and “1” supplied from the input IN 1 . The arithmetic circuit 12 outputs data “0100 1011” in response to the output from the arithmetic circuit 10 and “1” input from the input IN 0 .
The hold circuit 2 outputs “0000” as the data X 0 8 to X 0 5 in the clock cycles T 1 and T 2 , and hence it is understood that the data input from the inputs IN 0 to IN 3 are shifted in the hold circuit 2 by four bits at a time.
FIG. 7 is a diagram for illustrating the operation of the CRC arithmetic unit 1 in the clock cycle T 3 of FIG. 4 .
Referring to FIGS. 4 and 7, the hold circuit 2 captures the data “0100 1011” output from the arithmetic circuit 12 in the clock cycle T 2 . The arithmetic circuit 6 outputs “1001 0110” in response to the output from the hold circuit 2 and “0” supplied from the input IN 3 . The arithmetic circuit 8 outputs “1111 1000” in response to the output from the arithmetic circuit 6 and “1” supplied from the input IN 2 .
The arithmetic circuit 10 outputs data “0010 0101” in response to the output from the arithmetic circuit 8 and “0” supplied from the input IN 1 . The arithmetic circuit 12 outputs data “0100 1010” in response to the output from the arithmetic circuit 10 and “0” supplied from the input IN 0 .
FIG. 8 is a diagram for illustrating the operation of the CRC arithmetic unit 1 in the clock cycle T 4 of FIG. 4 .
Referring to FIGS. 4 and 8, the hold circuit 2 captures the data “0100 1010” output from the arithmetic circuit 12 in the clock cycle T 3 . The arithmetic circuit 6 outputs “1001 0101” in response to the value held in the hold circuit 2 and “1” input from the input IN 3 . The arithmetic circuit 8 outputs “1111 1111” in response to the output from the arithmetic circuit 6 and “0” supplied from the input IN 2 .
The arithmetic circuit 10 outputs data “0010 1010” in response to the output from the arithmetic circuit 8 and “1” supplied from the input IN 1 . The arithmetic circuit 12 outputs data “0101 0101” in response to the output from the arithmetic circuit 10 and “1” input from the input IN 0 . When outputting the output of the arithmetic circuit 12 as the remainder, it follows that the CRC arithmetic unit 1 implements in the clock cycles T 1 to T 4 division similar to that of the conventional circuit shown in FIGS. 18 to 25 .
As described above, the CRC arithmetic unit 1 according to the first embodiment can simultaneously process multiple bits in a single clock cycle for performing a CRC operation at a high speed.
While the CRC arithmetic unit 1 shown in FIG. 1 receives and processes four bits at a time, the processing is speeded up as compared with the conventional CRC arithmetic unit performing processing bit by bit when processing a plurality of bits at a time, and hence the number of bits can be properly increased/decreased in response to the required speed so far as the number is at least two.
When the number of bits included in the data string to be processed cannot be divided by 4, i.e., the number of bits subjected to batch processing, “0” may be supplied to the upper side (most significant bit side) of the data string for separating the data string into a number corresponding to a divisor of 4. For example, data input in order of “abcdefghij” can be processed by inputting the same as “00ab”, “cdef” and “ghij”.
[Second Embodiment]
Several types of systems employing different generating polynomials are present for the CRC operation. In this case, the positions for arranging the XOR circuits must be varied with the generating polynomials in the arithmetic unit 1 shown in FIG. 3 . However, it is not easy to change hardware in a highly integrated semiconductor device or the like.
FIG. 9 is a circuit diagram showing the structure of a CRC arithmetic unit 20 capable of readily dealing with change of a generating polynomial.
Referring to FIG. 9, the CRC arithmetic unit 20 includes AND circuits 22 # 0 to 22 # 7 , XOR circuits 24 # 0 to 24 # 7 and registers 26 # 0 to 26 # 7 .
The AND circuit 22 # 0 receives an output of the register 26 # 7 and a set value “1” input as set data S 0 . The XOR circuit 24 # 0 receives an output of the AND circuit 22 # 0 and data input from an input IN. The register 26 # 0 captures an output of the XOR circuit 24 # 0 in response to a clock signal (not shown).
The AND circuit 22 # 1 receives the output of the register 26 # 7 and a set value “0” input as set data S 1 . The XOR circuit 24 # 1 receives outputs of the register 26 # 0 and the AND circuit 22 # 1 . The register 26 # 1 captures and holds an output of the XOR circuit 24 # 1 in response to the clock signal (not shown).
The AND circuit 22 # 2 receives the output of the register 26 # 7 and a set value “1” input as set data S 2 . The XOR circuit 24 # 2 receives outputs of the register 26 # 1 and the AND circuit 22 # 2 . The register 26 # 2 captures and holds an output of the XOR circuit 24 # 2 in response to the clock signal (not shown).
The AND circuit 22 # 3 receives the output of the register 26 # 7 and a set value “0” input as set data S 3 . The XOR circuit 24 # 3 receives outputs of the AND circuit 22 # 3 and the register 26 # 2 . The register 26 # 3 captures and holds an output of the XOR circuit 24 # 3 in response to the clock signal (not shown).
The AND circuit 22 # 4 receives the output of the register 26 # 7 and a set value “1” input as set data S 4 . The XOR circuit 24 # 4 receives outputs of the AND circuit 22 # 4 and the register 26 # 3 . The register 26 # 4 captures and holds an output of the XOR circuit 24 # 4 in response to the clock signal (not shown).
The AND circuit 22 # 5 receives the output of the register 26 # 7 and a set value “0” input as set data S 5 . The XOR circuit 24 # 5 receives outputs of the AND circuit 22 # 5 and the register 26 # 4 . The register 26 # 5 captures and holds an output of the XOR circuit 24 # 5 in response to the clock signal (not shown).
The AND circuit 22 # 6 receives the output of the register 26 # 7 and a set value “1” input as set data S 6 . The XOR circuit 24 # 6 receives outputs of the AND circuit 22 # 6 and the register 26 # 5 . The register 26 # 6 captures and holds an output of the XOR circuit 24 # 6 in response to the clock signal (not shown).
The AND circuit 22 # 7 receives the output of the register 26 # 7 and a set value “1” input as set data S 7 . The XOR circuit 24 # 7 receives outputs of the AND circuit 22 # 7 and the register 26 # 4 . The register 26 # 7 captures and holds an output of the XOR circuit 24 # 7 in response to the clock signal (not shown).
Thus, the CRC arithmetic unit 20 can deal with change of the generating polynomial by changing the set values supplied as the set data S 0 to S 7 .
When supplying set values “1101 0101” as the set data S 0 to S 7 , the generating polynomial is as follows:
G ( X )= X 8 +X 7 +X 6 +X 4 +X 2 +1
Therefore, the CRC arithmetic unit 20 can perform operations similar to those of the conventional CRC arithmetic unit 100 shown in FIG. 17 .
A CRC arithmetic unit capable of readily dealing with change of a generating polynomial and batch-processing multiple bits is studied.
FIG. 10 is a schematic block diagram showing the structure of a CRC arithmetic unit 30 according to a second embodiment of the present invention.
Referring to FIG. 10, the CRC arithmetic unit 30 includes an arithmetic circuit 34 in place of the arithmetic circuit 4 in the structure of the CRC arithmetic unit 1 shown in FIG. 1 .
The arithmetic circuit 34 includes arithmetic circuits 36 , 38 , 40 and 42 in place of the arithmetic circuits 6 , 8 , 10 and 12 respectively in the structure of the arithmetic circuit 4 shown in FIG. 1 . The arithmetic circuits 37 , 38 , 40 and 42 are capable of dealing with change of a generating polynomial in response to set values input as set data S 0 to S 7 . The remaining connection is similar to that of the CRC arithmetic unit 1 shown in FIG. 1, and hence redundant description is not repeated.
FIG. 11 is a circuit diagram showing the structure of the arithmetic circuit 36 appearing in FIG. 10 .
Referring to FIG. 11, the arithmetic circuit 36 includes a gate circuit 36 # 0 receiving data Xn 0 and Xn 8 and the set data S 0 and outputting data Xn+1 1 , a gate circuit 36 # 1 receiving data Xn 1 and Xn 8 and the set data S 1 and outputting data Xn+1 2 , a gate circuit 36 # 2 receiving data Xn 2 and Xn 8 and the set data S 2 and outputting data Xn+1 3 and a gate circuit 36 # 3 receiving data Xn 3 and Xn 8 and the set data S 3 and outputting data Xn+1 4 .
The arithmetic circuit 36 further includes a gate circuit 36 # 4 receiving data Xn 4 and Xn 8 and the set data S 4 and outputting data Xn+1 5 , a gate circuit 36 # 5 receiving data Xn 5 and Xn 8 and the set data S 5 and outputting data Xn+1 6 , a gate circuit 36 # 6 receiving data Xn 6 and Xn 8 and the set data S 6 and outputting data Xn+1 7 and a gate circuit 36 # 7 receiving data Xn 7 and Xn 8 and the set data S 7 and outputting data Xn+1 8 .
The gate circuit 36 # 0 includes an AND circuit 52 # 0 receiving the data Xn 8 and the set data S 0 and an XOR circuit 54 # 0 receiving an output of the AND circuit 52 # 0 and the data Xn 0 and outputting the data Xn+1 1 .
The gate circuit 36 # 1 includes an AND circuit 52 # 1 receiving the data Xn 8 and the set data S 1 and an XOR circuit 54 # 1 receiving an output of the AND circuit 52 # 1 and the data Xn 1 and outputting the data Xn+1 2 .
The gate circuit 36 # 2 includes an AND circuit 52 # 2 receiving the data Xn 8 and the set data S 2 and an XOR circuit 54 # 2 receiving an output of the AND circuit 52 # 2 and the data Xn 2 and outputting the data Xn+1 3 .
The gate circuit 36 # 3 includes an AND circuit 52 # 3 receiving the data Xn 8 and the set data S 3 and an XOR circuit 54 # 3 receiving an output of the AND circuit 52 # 3 and the data Xn 3 and outputting the data Xn+1 4 .
The gate circuit 36 # 4 includes an AND circuit 52 # 4 receiving the data Xn 8 and the set data S 4 and an XOR circuit 54 # 4 receiving an output of the AND circuit 52 # 4 and the data Xn 4 and outputting the data Xn+1 5 .
The gate circuit 36 # 5 includes an AND circuit 52 # 5 receiving the data Xn 8 and the set data S 5 and an XOR circuit 54 # 5 receiving an output of the AND circuit 52 # 5 and the data Xn 5 and outputting the data Xn+1 6 .
The gate circuit 36 # 6 includes an AND circuit 52 # 6 receiving the data Xn 8 and the set data S 6 and an XOR circuit 54 # 6 receiving an output of the AND circuit 52 # 6 and the data Xn 6 and outputting the data Xn+1 7 .
The gate circuit 36 # 7 includes an AND circuit 52 # 7 receiving the data Xn 8 and the set data S 7 and an XOR circuit 54 # 7 receiving an output of the AND circuit 52 # 7 and the data Xn 7 and outputting the data Xn+1 8 .
The arithmetic circuits 38 , 40 and 42 shown in FIG. 10 are similar in structure to the arithmetic circuit 36 . FIG. 11 shows the structure of the arithmetic circuit 36 when n=0, the structure of the arithmetic circuit 38 when n=1, the structure of the arithmetic circuit 40 when n=2, and the structure of the arithmetic circuit 42 when n=3. Therefore, redundant description is not repeated.
FIG. 12 illustrates a state of setting the set data S 7 to S 0 of the CRC arithmetic unit 30 .
Referring to FIG. 12, set values “1101 0101” are supplied as the set data S 7 to S 0 . In this structure setting the set values “1101 0101” as the set data S 7 to S 0 , the CRC arithmetic unit 30 is equivalent to the CRC arithmetic unit 1 according to the first embodiment described with reference to FIGS. 1 to 8 and can perform similar operations. Further, the CRC arithmetic unit 30 can flexibly deal with change of the generating polynomial by properly changing the set data S 7 to S 0 .
[Third Embodiment]
The CRC arithmetic unit 30 according to the second embodiment can deal with change of a generating polynomial having the highest degree of X 8 . In a third embodiment of the present invention, a CRC arithmetic unit capable of changing the degree of a generating polynomial is studied.
FIG. 13 is a circuit diagram showing the structure of a CRC arithmetic unit 60 obtained by modifying the CRC arithmetic unit 20 shown in FIG. 9 to be capable of changing the degree of a generating polynomial.
Referring to FIG. 13, the CRC arithmetic unit 60 further includes switching circuits 62 # 0 to 62 # 6 in the structure of the CRC arithmetic unit 20 shown in FIG. 9 .
The switching circuit 62 # 0 supplies either an output of a register 26 # 0 or data input from an input IN to an XOR circuit 24 # 1 . The switching circuit 62 # 1 supplies either an output of a register 26 # 1 or the data input from the input IN to an XOR circuit 24 # 2 . The switching circuit 62 # 2 supplies either an output of a register 26 # 2 or the data input from the input IN to an XOR circuit 24 # 3 . The switching circuit 62 # 3 supplies either an output of a register 26 # 3 or the data input from the input IN to an XOR circuit 24 # 4 .
The switching circuit 62 # 4 supplies either an output of a register 26 # 4 or the data input from the input IN to an XOR circuit 24 # 5 . The switching circuit 62 # 5 supplies either an output of a register 26 # 5 or the data input from the input IN to an XOR circuit 24 # 6 . The switching circuit 62 # 6 supplies either an output of a register 26 # 6 or the data input from the input IN to an XOR circuit 24 # 7 .
Referring to FIG. 13, the switching circuits 62 # 0 and 62 # 1 select the input IN and supply the input to the next-stage XOR circuits 24 # 1 and 24 # 2 . The switching circuits 62 # 2 to 62 # 6 select the outputs of the registers 26 # 2 to 26 # 6 respectively and supply the same to the next-stage XOR circuits 24 # 3 to 24 # 7 . Thus, the CRC arithmetic unit 60 can set the highest degree of the generating polynomial to X 6 . When setting set data S 0 to S 7 to “11010100”, the generating polynomial is as follows:
G ( X )= X 6 +X 5 +X 4 +X 2 +X 0
At this time, the set data S 0 and S 1 may be not “0” but “1”.
Description is now made on a CRC arithmetic unit according to the third embodiment of the present invention enabling change of the degree when batch-processing multiple bits.
FIG. 14 is a circuit diagram showing the structure of an arithmetic circuit 66 employed in the CRC arithmetic unit according to the third embodiment.
Referring to FIG. 14, the arithmetic circuit 66 includes gate circuits 68 # 1 to 68 # 7 in place of the gate circuits 36 # 1 to 36 # 7 in the structure of the arithmetic circuit 36 shown in FIG. 1 .
The gate circuit 68 # 1 is different in structure from the gate circuit 36 # 1 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 1 supplying either data Xn 1 or data Xn 0 to an XOR circuit 54 # 1 . The gate circuit 68 # 2 is different in structure from the gate circuit 36 # 2 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 2 supplying either data Xn 2 or the data Xn 0 to an XOR circuit 54 # 2 .
The gate circuit 68 # 3 is different in structure from the gate circuit 36 # 3 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 3 supplying either data Xn 3 or the data Xn 0 to an XOR circuit 54 # 3 . The gate circuit 68 # 4 is different in structure from the gate circuit 36 # 4 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 4 supplying either data Xn 4 or the data Xn 0 to an XOR circuit 54 # 4 .
The gate circuit 68 # 5 is different in structure from the gate circuit 36 # 5 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 5 supplying either data Xn 5 or the data Xn 0 to an XOR circuit 54 # 5 . The gate circuit 68 # 6 is different in structure from the gate circuit 36 # 6 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 6 supplying either data Xn 6 or the data Xn 0 to an XOR circuit 54 # 6 .
The gate circuit 68 # 7 is different in structure from the gate circuit 36 # 7 shown in FIG. 11 in a point that the same further includes a switching circuit 70 # 7 supplying either data Xn 7 or the data Xn 0 to an XOR circuit 54 # 7 .
The remaining structures of the gate circuits 68 # 1 to 68 # 7 are similar to those of the gate circuits 36 # 1 to 36 # 7 respectively, and hence redundant description is not repeated.
The switching circuits 70 # 1 and 70 # 2 select the data Xn 0 and output the same to the XOR circuits 54 # 1 and 54 # 2 respectively in the example shown in FIG. 14 . The switching circuits 70 # 3 to 70 # 7 select the data Xn 3 to Xn 7 respectively and output the same to the XOR circuits 54 # 3 to 54 # 7 .
When employing the arithmetic circuit 66 shown in FIG. 14 in place of the arithmetic circuits 36 to 42 shown in FIG. 10, the degree of the generating polynomial can be changed by changing setting of the switching circuits 70 # 1 to 70 # 7 . Further, the generating polynomial can be changed by changing setting of set data S 7 to S 0 .
The switching circuits 70 # 1 to 70 # 7 may be switched by re-coupling wires, while gate circuits each selecting either one of two inputs with a selection signal, for example, may be employed.
As hereinabove described, the CRC arithmetic unit according to the third embodiment, capable of batch-processing multiple bits for attaining a high speed and changing the generating polynomial as well as the degree of the generating polynomial, can be flexibly employed for various systems.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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A hold circuit holds results of processing in an arithmetic circuit collectively receiving four bits from inputs. The inventive arithmetic unit collectively processes an input data string, which has generally been processed bit by bit, by four bits at a time, whereby a CRC arithmetic operation can be speeded up. More preferably, the arithmetic unit can flexibly deal with change of a generating polynominal set in the arithmetic circuit when rendering set data corresponding to the generating polynomial changeable.
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CROSS REFERENCE TO A PROVISIONAL APPLICATION
[0001] This patent application claims priority on Provisional Application Ser. No. 60/362,026, filed on Mar. 5, 2002, the entirety of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to sewn articles and sewing operations and, more particularly, to sewn attachment of different pieces of material by gussets.
[0003] In the sewn construction of padded articles, such as mattresses and furniture cushions, a padded layer or layers may be enclosed in upholstery and attached by a gusset to an accompanying pad or spring unit. For example, in a pillow-top style mattress, a pillow-top is attached to a panel by a gusset, which in one form is a folded band of material sewn along a fold line to the panel, and then sewn to a flange (which is subsequently stapled to the mattress) along the first edge opposite the fold and sewn to the pillow-top along the second edge opposite the fold, thereby attaching the pad to the mattress. At corners of the panel to which the gusset is sewn, the gusset is mitered at a seam to allow the gusset to turn the ninety degree corner of the mattress. The mitering of the gusset at the corners requires at least one miter cut to be made in the gusset at each right angle corner of the adjoining panel. Each of the mitered corner cuts must be precisely measured and individually sewn so that the gusset forms a closed structure between the mattress and the pillow-top. In a manual assembly process, the gusset is separately constructed by sewing together each leg of the gusset at the mitered corners to form a gusset frame which matches the mattress panel. The gusset is then sewn to the edges of the panel of the mattress by a tape edge. Thereafter, the pillow-top is attached to the other free edge of the gusset by a second tape edge. If the miter cuts at the corners of the gusset are not made at the correct angles, the gusset corner will not have a smooth contour or appearance. Also, in articles where the gusset remains visible, the multiple seams in the gusset are unsightly and vulnerable to separation. Constructing a gusset this way is a tedious manual production process which adds significantly to the cost of producing pillow-top mattresses and similar sewn articles.
[0004] Therefore, there is a need for a mattress having a continuously cornered gussets. There is also a need for a system for producing mattresses having continuously cornered gussets. There is also a need for a system that combines the process for sewing the flange and the gusset to the panel, or for a system the eliminates the need for a flange.
SUMMARY OF THE INVENTION
[0005] The disadvantages of the prior art are overcome by the present invention which, in one aspect, is an apparatus for attaching a gusset to a panel that includes a gusset folder that receives and folds a gusset material to form the gusset for attachment to the panel. The panel is received on and supported for sewing by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guide guides the gusset fed to the sewing machine toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.
[0006] In another aspect, the invention is a method of sewing a gusset to a panel, in which the gusset is sewn to the panel along a first substantially linear path with a sewing machine. A corner of the panel is detected. The panel is turned when the corner of the panel approaches the sewing machine so that the gusset follows a curved path adjacent the corner of the panel. The gusset is sewn to the panel along a second substantially linear path, angularly divergent from the from the first substantially linear path, after the gusset has been sewn around the corner of the panel.
[0007] In another aspect, the invention is an apparatus for sewing a gusset and a flange to a panel. The apparatus includes a first reel holding a gusset material and a second reel holding a flange material. A folding device folds the gusset material from the first reel along a substantially linear path. A first sewing machine receives the gusset material from the folding device and the flange material from the second reel and sews the gusset material to the flange material, thereby forming a gusset-flange. A second sewing machine receives the gusset-flange from the first sewing machine and sews the gusset-flange to the panel.
[0008] In another aspect, the invention is a gusset for attachment to a panel that has at least one first corner. The gusset includes a strip of gusset material having a first edge and a second edge. The strip of gusset material is folded substantially along a centerline and the first edge of the gusset material is sewn to the first panel. The gusset defines at least one pleat that causes the gusset material to change direction. The pleat is placed adjacent to the first corner.
[0009] In another aspect, the invention is a mattress having a first panel over one side of a mattress inner-spring. The mattress includes a gusset attached substantially about a perimeter of the first panel. The gusset is made of an elongated piece of material folded along a length dimension. The gusset is attached to the first panel proximate to a fold in the gusset material. A first edge of the gusset opposite the fold is attached to a perimeter of the first panel. A second edge of the gusset is adapted for attachment to a second panel. The gusset includes at least one corner that has at least one pleat forming a ruffled gusset corner.
[0010] In another aspect, the invention is an outer layer for attaching a pillow-top to a mattress that includes a panel having at least one outer end. A gusset includes a strip of gusset material that has a first edge and an opposite second edge and that has been folded substantially in half along a fold line so the first edge is substantially adjacent the second edge. The gusset is sewn to panel along a line adjacent the fold line and near the outer end of the panel so that the outer end extends beyond the first edge and so that the second edge has sufficient distance to provide an attachment surface on the panel to enable attaching the outer layer to the mattress.
[0011] These and other aspects of the invention will become apparent from the following description of the preferred embodiments taken in conjunction with the following drawings. As would be obvious to one skilled in the art, many variations and modifications of the invention may be effected without departing from the spirit and scope of the novel concepts of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a cross-sectional view of a mattress constructed according to an illustrative embodiment of the invention.
[0013] FIG. 2 is a top plan view of a portion of a ruffled gusset according to an illustrative embodiment of the invention.
[0014] FIG. 3 is a top plan view of a gusset manufacturing machine according to an illustrative embodiment of the invention.
[0015] FIG. 4 is an elevational view of the gusset manufacturing machine shown in FIG. 3 , as viewed from lines 4 - 4 .
[0016] FIG. 5A is a top plan view of a portion of the gusset manufacturing machine shown in FIG. 4 , as viewed from line 5 - 5 , while in the process of sewing a gusset to a strait edge of a panel.
[0017] FIG. 5B is a top plan view of a portion of a gusset manufacturing machine shown in FIG. 4 , as viewed from line 5 - 5 , while in the process of sewing a gusset to a corner of a panel.
[0018] FIG. 6 is a top perspective view of a sewing table employing several aspects of the invention.
[0019] FIG. 7 is an exploded top perspective view of an air table employed in one embodiment of the invention.
[0020] FIG. 8 is a top perspective view of a mechanism for rotating a panel about a corner, according to one aspect of the invention.
[0021] FIG. 9 is a top perspective view of a ruffler, according to one aspect of the invention.
[0022] FIG. 10 is a side cross-sectional view of an air table employing directional air jets, according to one aspect of the invention.
[0023] FIG. 11 is a side elevational view of an apparatus for sewing both a gusset and a flange to a panel, according to one aspect of the invention.
[0024] FIG. 12 is a top plan view of a panel with a recessed gusset, according to one aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] A preferred embodiment of the invention is now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,” “an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.”
[0026] As shown in FIG. 1 , a pillow-top mattress 100 , according to one illustrative embodiment of the invention, includes a main mattress body 102 and a pillow-top portion 108 attached to the mattress body 102 with a gusset 110 . The gusset 110 is folded in half along a centerline 116 and sewn to a panel 106 along a stitch line 120 so as to have a first edge 112 and a second edge 114 . A strip of flange material 122 is sewn to the periphery of the panel 106 , along stitch line 120 . The flange is also attached to the first edge 112 by stitches 127 . The flange material 122 extends from the outermost edge of the panel 106 and is stapled to a spring unit 125 of the mattress body 102 . A strip of fabric tape 126 is sewn to the first edge 112 , along stitch line 128 , the side wall 124 along stitch line 128 , thereby securing the gusset 110 to the mattress body 102 .
[0027] The second edge of the gusset is aligned with the outermost edge of the pillow-top 108 and a strip of fabric tape 132 is sewn around the junction of the gusset 110 and the pillow-top 108 along a stitch line 134 , thereby securing the panel 106 (and thus the mattress body 102 ) to the pillow-top.
[0028] As shown in FIG. 2 , as the gusset 110 is being sewn to the panel 106 , when a corner 204 of the panel 106 nears the point of sewing, a plurality of ruffles 216 are stitched into the gusset 110 so that the gusset 110 is a continuous piece of gusset material. This eliminates the need for mitering the gusset material.
[0029] A gusset sewing system 300 is shown in FIG. 3 . The sewing system 300 includes an air table 310 , a sewing machine 320 , a supply reel 312 for the gusset material 314 , a folding device 316 , a ruffler 318 (also referred to as a pleat generator) and a turning device 330 for turning the panel 106 as the corner 214 approaches the sewing machine 320 . The air table 310 includes a plurality of openings 340 through which air is forced to provide an air cushion between the table 310 and the panel 106 , thereby facilitating movement of the panel 106 .
[0030] As shown in FIG. 4 , the turning device 330 includes a frame 422 that supports a first pneumatic actuator 424 and a second pneumatic actuator 428 . The frame 422 is affixed to a support 434 that is coupled to the table 310 . A cornering actuator 432 is coupled to the frame 422 so as to be able to rotate the frame 422 between a first position and a second position. The first pneumatic actuator 424 is capable of raising and lowering a first arm 426 and the second pneumatic actuator 428 is capable of raising and lowering a second arm 430 . The first arm 428 and the second arm 430 work in concert to engage and turn the panel 106 at the corners of the panel.
[0031] A conveyor 412 moves the panel 106 along a linear path when the corners are not being sewn. A guide wheel 450 keeps the panel 106 running along a substantially straight line during sewing. The guide wheel 450 is controlled by an optical sensor (not shown) that directs the edge of the panel 106 to a predetermined point when the edge of the panel 106 deviates from the predetermined point.
[0032] The sewing machine 320 includes a needle 442 and a sewing foot 444 for holding the gusset material 314 against the panel 106 . The ruffler 318 includes a plunger assembly 446 and a ruffler foot 440 . The plunger assembly 446 is capable of driving the ruffler foot 440 back and forth to push ruffles (also referred to as pleats) into the gusset material 314 . The plunger assembly 446 , in one embodiment, includes a pneumatic piston that is controlled so as to push the gusset material 314 into a ruffle when the needle 442 is in an “up” position and to retract the ruffler foot 440 when the needle is in a down position.
[0033] The turning device 330 , as shown in FIGS. 5A and 5B , can include a transverse arm 434 extending from second arm 430 . The transverse arm 430 helps to prevent the panel 106 from becoming bunched-up during a turn. Straight sewing is shown in FIG. 5A , whereas the turning operation is shown if FIG. 5B . Essentially, the turning device 330 causes the arms 426 , 430 and 434 to engage the panel 106 and the frame 422 is rotated in the direction of arrow A as the corner ruffling is sewn into the panel 106 .
[0034] As shown in FIG. 6 , the gusset sewing system can include a gusset-cutting knife 610 that can extend outwardly from the sewing machine 320 at the termination of the gusset sewing process. The knife 610 can include a pneumatically-driven blade that cuts the gusset material. To allow an operator to gain access to the sewing machine 320 while the knife 610 is in the retracted position, a trap door 612 is included in the table 310 . The trap door 612 may be driven by a pneumatic piston and controlled so that the trap door 612 is in the “up” position during the automatic part of the sewing process and when the knife 610 is in the extended cutting position. The trap door 612 is driven to the down position when the operator is needed to control the sewing machine 320 at the termination of the sewing process, after the gusset has been cut by the knife 610 .
[0035] A plurality of controllable directional air jets 630 are included in the air table 310 to provide directional jets of air when the panel is being moved so as to prevent bunching up of the panel. The directional jets of air are aimed toward the direction of intended movement, which can include along the normal linear path taken by the panel and along the turning direction of the panel while the corners are being ruffled. Air flow to the directional air jets 630 can be controlled to provide more or less force on the panel, depending on the needs of the panel. For example, heavier panel materials would require more force, as would more porous panel materials. Also, as a panel becomes heavier as a result of gusset material being sewn thereto, the airflow may be increased. Air flow control may be accomplished either by controlling the speed of the blowers that provide the air supply for the air table and the directional air jets or by opening or shutting louvers at the intake to the blowers.
[0036] An accumulator 620 may be included to ensure that sufficient gusset material is available to complete an entire panel. At the start of the sewing process, a clamp 626 holds the gusset material in a fixed position as the accumulator 620 pays out from the reel 312 onto a plurality of rollers 622 (two rows of which expand away from each other) a length of gusset material required for a given panel. An optical sensor 624 detects whether the gusset material covers all of the rollers 622 (the last one of which may be covered with a reflective material). If the last roller is not covered with gusset material, then the operator is notified through an alarm. If insufficient gusset material exists for a panel, the operator can determine, by counting the number of rollers that are interleaved with the gusset material, the operator can determine if there is sufficient gusset material to edge a smaller-sized panel (e.g., a twin-size mattress panel, rather than a full-size panel).
[0037] An exploded view of a section 700 of an air table is shown in FIG. 7 . The section 700 includes a surface portion 710 that defines a plurality of openings 712 passing there through. The surface portion 710 is sealed to a manifold 720 that includes at least one passage 714 to an air supply (not shown), which could comprise one of many types of blowers generally available. A baffle 716 is disposed above the passage 714 to prevent local high concentrations of air flow through the surface portion 710 .
[0038] The turning mechanism 330 is shown in greater detail in FIG. 8 and the ruffler 318 is shown in greater detail in FIG. 9 . A detail of a directional air jet 630 and the air table 310 is shown in FIG. 10 . The directional air jet 630 is supplied by an air supply 1112 and controlled remotely by a solenoid 1110 .
[0039] In one embodiment, as shown in FIG. 11 , the gusset material 1120 and the flange material 1130 may be sewn to the panel 106 in a single operation. To do this, the system requires a first sewing machine 1150 for sewing the flange material 1130 to the gusset material 1120 and a second sewing machine 1140 for sewing the combined gusset/flange to the panel 106 .
[0040] In one embodiment of a panel/gusset combination, as shown in FIG. 12 , the gusset 1210 may be sewn to the panel 1200 so as to leave a predetermined width of panel 1200 extending away from the gusset 1210 . In this embodiment, the extra panel material eliminates the need for a flange, as the periphery of the panel 1200 is attached directly to the side wall of the mattress body.
[0041] The above described embodiments are given as illustrative examples only. It will be readily appreciated that many deviations may be made from the specific embodiments disclosed in this specification without departing from the invention. Accordingly, the scope of the invention is to be determined by the claims below rather than being limited to the specifically described embodiments above.
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An apparatus for attaching a gusset to a panel includes a gusset folder that receives and folds a gusset material to form the gusset. The panel is supported by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guide guides the gusset toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/061,332 filed Jun. 13, 2008 entitled Resettable Safety System for Upgraded Occupant Survivability, the contents of which are incorporated in their entirety herein.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to the protection of military vehicle occupants from the high forces encountered during a crash event, specifically from secondary impacts within the vehicle.
[0003] In automobiles, crash energy mitigation has focused on protection of occupants through passive occupant restraints and by limiting secondary impact forces using load-attenuating deformable structures such as padded dashboards, collapsible steering columns, and airbags. This approach has dramatically reduced both serious and fatal injuries in the modern automobile.
[0004] Unfortunately, deformable structures are less applicable to military aircraft and ground vehicles. The large volume of vehicle controls and mission-related equipment located in the cabins of these vehicles make it impossible to surround the occupants with deformable structure. The occupants of these vehicles are also exposed to rapid vertical accelerations which are not present in automobiles, further complicating the protection of these occupants from secondary impacts within the vehicle. In the case of military aircraft, these vertical accelerations result from the crash event itself, while ground vehicles are subjected to these accelerations by anti-vehicle mines or other explosive devices encountered in combat.
[0005] To counter the effects of rapid vertical accelerations on the occupant's spine, vertically stroking seats are used in both military ground and air vehicles. While this approach reduces spinal injuries, the vertical motion of the seat makes the occupant more likely to strike other objects within the vehicle cabin.
[0006] During a crash, mine blast or rollover event, the seat and restraint are designed to protect a fully upright occupant whose upper torso is resting against the seat back. In the moments immediately before many crash or blast events, occupants are diligently taking measures to prevent their vehicle from crashing or performing their normal duties within the vehicle.
[0007] While performing these tasks the occupant's body position can deviate significantly from the most survivable orientation. The occupant's body can further deviate due to maneuver loads. At the moment of impact, the vehicle can permanently deform and absorb the crash- or blast-related kinetic energy. This deceleration causes the occupant to move and slump in his seat.
[0008] As the crash proceeds the occupant will accelerate forward relative to the seat. This increases the tension on the restraint's shoulder straps, causing the webbing to pack down within the shoulder harness retractor and stretch, effectively loosening the restraint and causing the occupant's upper torso and head to rotate forward into close proximity with hard structures within the vehicle. This combination of slump and rotation can be aggravated by some crashworthy designs that allow continued head and body travel as part of the load attenuation process. The slump, rotation and energy attenuation makes secondary cabin impacts more likely and, in vehicles with small cabins, can even result in the occupant's head or body protruding through the vehicle window or door.
SUMMARY OF THE INVENTION
[0009] In a preferred embodiment, the present invention limits secondary impacts within the vehicle cabin in two ways: first, it prepares the occupant for a crash or blast event prior to the moment of impact, and second it limits an occupant's movement relative to the seat after the blast or crash event has begun. These actions are preferably achieved with a restraint system that monitors sensor data and adjusts the restraint on the occupant accordingly. Generally, this monitoring and adjusting is achieved with an active restraint system, an active headrest, and a crash recognition module (CRM).
[0010] Preferably, the active restraint includes two lap belts (also known as straps or webbing), two shoulder belts, and a tie-down strap attached to a rotary buckle. Attached to each lap and shoulder strap is a webbing retractor with an integral pyrotechnic pretensioner, a reversible pretensioner, and a spool position encoder. The reversible and resettable nature of the reversible pretensioners greatly increase the ability of the restraint to keep the occupant in a safe and survivable orientation without interfering with their duties. The pyrotechnic pretensioner allows for quicker retraction and therefore can be activated after a crash has begun. In this respect, the combined use of both the reversible electric pretensioner and the pyrotechnic pretensioner provides the best attributes of both devices in a single retractor.
[0011] When the occupant buckles the restraint, sensors within the buckle allow the CRM to determine that the restraint is fully donned. The CRM establishes a baseline position for each retractor's webbing spool which is stored by the CRM until the restraint is unbuckled. Each retractor repeatedly samples the spool position and communicates the position to the CRM.
[0012] When a shoulder strap is extended significantly beyond the baseline position for any length of time, the occupant is reminded to sit up straight by a gentle, haptic, “out of position” tug on the shoulder strap caused by momentarily energizing the retractor's reversible pretensioning motor. If the CRM's predictive algorithms determine that the vehicle is maneuvering aggressively or erratically, each retractor's reversible pretensioner is energized to supplement the passive spring retraction force and eliminate slack from the shoulder and lap straps. The elimination of belt slack significantly reduces occupant slump and rotation during a blast or crash event. Additionally, keeping the occupant upright and close to the seat back during aggressive maneuvers may improve his or her ability to maintain control of the vehicle.
[0013] If a crash does not occur and the vehicle resumes a more stable operation, the CRM de-energizes each retractor's reversible pretensioner to relax the straps back to their baseline positions and allow the occupant to pay out additional strap. Once the CRM determines that a crash or blast event is occurring, it activates the pyrotechnic pretensioners in each retractor. This holds the occupant firmly upright in the seat, compensating for any packdown inside of the retractor and for webbing stretch due to increasing belt forces, limiting both torso rotation and lateral movement of the occupant.
[0014] While the shoulder strap pretensioners are effective at controlling lateral torso motion, the occupant's head can still experience enough lateral motion to cause a secondary impact with a side window or other primary structure, especially in vehicles with small cabins. To effectively control this, an active headrest is used in the preferred embodiment of this invention. To avoid limiting the occupant's field of vision during routine vehicle operation, the lateral supports are stowed in an aft or retracted position.
[0015] When a crash event is likely to occur, the CRM pivots the lateral supports of the active headrest forward. The lateral supports include deformable padding to limit the maximum impact force imparted to the occupant's head. The spring-biased lateral supports ratchet forward, limiting the travel of the occupant's head and providing a cushioned lateral impact surface. If the vehicle returns to a stable mode of operation the lateral supports are electrically retracted to their stowed position after a reasonable delay, restoring the occupant's field of view and resetting the headrest for a future crash or aggressive maneuver event.
[0016] In addition to assessing an occupant's position within his or her seat, the CRM contains an inertial monitoring unit consisting of multi-axis accelerometers (e.g., X, Y and Z dimensions) and rate gyros (e.g., roll, pitch and yaw) to determine vehicle rotational and linear acceleration rates. Algorithms running on the CRM analyze the sensor data and determine that the vehicle is in one of three operating states: stable operation, aggressive maneuvering, or crashing.
[0017] During stable vehicle operation the CRM simply monitors the retractors for excessive deviations from their baseline strap positions, issuing haptic “out of position” warnings if necessary. If the vehicle is maneuvering aggressively, the CRM activates the resettable features of the present invention, deploying the active headrest and commanding the reversible pretensioner in each retractor to remove slack from each lap and shoulder strap. Some of the conditions that determine this state include excessive yaw rates, combined pitch and roll angles that are excessive, and sustained acceleration rates above a preset G level.
[0018] After the CRM determines that the vehicle is once again in stable operation, it commands the retractors to return to baseline position and the headrest to retract its lateral supports. If at any time the algorithms determine that a crash is occurring, the CRM deploys the active headrest (if it is currently stowed) and sends a firing signal to each retractor pretensioner, causing it to retract additional webbing within 50 milliseconds of activation. The quick reaction time can be especially achieved with the pyrotechnic pretensioner which is ignited by electrical energy above a threshold value. The electrical energy is stored in a capacitor bank inside the CRM and released by closing a switch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which:
[0020] FIG. 1A is an isometric view of a preferred embodiment of a vehicle restraint system according to the present invention;
[0021] FIG. 1B illustrates a magnified view of a buckle from FIG. 1B ;
[0022] FIG. 2 is an isometric rear view of the embodiment of FIG. 1A ;
[0023] FIG. 3 is an exploded view of a rotary buckle according to a preferred embodiment of the present invention;
[0024] FIG. 4A is a detailed top view of an active headrest in the stowed orientation according to the present invention;
[0025] FIG. 4B is a detailed top view of the active headrest of FIG. 4A in the deployed orientation;
[0026] FIG. 5 is a detailed exploded view of the active headrest in the stowed orientation according to the present invention;
[0027] FIG. 6 is a schematic representation of a crash recognition module according to the present invention; and,
[0028] FIG. 7 is a system flow diagram of restraint system behavior according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0029] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, 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. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.
[0030] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0031] FIG. 1A illustrates a preferred embodiment of a resettable combat vehicle restraint system 10 that secures an occupant within a vehicle. In addition to simply maintaining the position of the occupant, the vehicle restraint system 10 prepares the occupant for a crash or extreme movement and limits the occupant's movement after the crash event has begun. Hence, the occupant is better protected from injuries.
[0032] The resettable combat vehicle restraint system 10 preferably includes an active five-point restraint 12 and an active headrest 11 for actively restraining an occupant's body. A crash recognition module (CRM) 13 monitors sensor data from the active five-point restraint 12 and active headrest 11 and appropriately controls the behavior of each.
[0033] The active five-point restraint 12 , best seen in FIGS. 1A , 1 B and 2 , preferably includes two lap straps 15 that are arranged to extend over the occupant's lap, two shoulder straps 16 arranged to extend over the occupant's shoulders and a tie-down strap 17 arranged to extend between the occupant's legs. An example of such a strap arrangement can be seen in U.S. Pat. Nos. 6,367,882 and 4,967,985, the contents of which are hereby incorporated by reference.
[0034] The lap straps 15 and shoulder straps 16 are each coupled to a retractor 18 that winds the straps 15 and 16 around a spool. The retractor 18 includes a mechanical, reversible pretensioner that provides a rotational bias to the winding spool and further locks movement of the spool during rapid unwinding of the spool (i.e., sudden pull out of the strap). Additionally, the reversible pretensioner includes a motor for electrically winding the spool at a desired time. Examples of reversible pretensioners can be seen in U.S. Pat. Nos. 5,765,774; 5,558,370; 5,076,609; and 5,005,777; the contents of which are hereby incorporated by reference.
[0035] Additionally, an integral pyrotechnic pretensioner is included in the retractor 18 to provide electronic control of locking and winding of the spool more quickly than the electronic reversible pretensioner. Hence, the pyrotechnic pretensioner is better suited to causing retraction after a crash has begun. Examples of integral pyrotechnic pretensioners can be seen in U.S. Pat. Nos. 5,443,222 and 5,415,431; the contents of which are hereby incorporated by reference.
[0036] The rotation position of the spool of each retractor 18 is monitored with a sensor, such as a rotary position encoder. Examples of such position encoders can be seen in U.S. Pat. Nos. 4,819,051; 4,567,467 and 5,736,865; the contents of which are hereby incorporated by reference.
[0037] As seen in FIGS. 1B and 3 , each of the five straps 15 , 16 and 17 has an end fitting 19 attached to its free end to interlock with rotary buckle 14 . Preferably at least one of the end fittings 19 are nonremovably connected to the rotary buckle 14 , such as on the tie-down strap 17 or to either lap strap 15 of five-point restraint 12 .
[0038] The rotary buckle 14 detects when the user buckles the straps 15 , 16 and 17 and communicates this information to the crash recognition module 13 . As seen in FIG. 3 , at least one sensor 22 is included to detect the insertion of the end fitting 19 into the rotary buckle 14 . Sensor 22 can be of a hall-effect type, a proximity switch type, optical, or any other technology to sense the presence or absence of end fitting 19 .
[0039] When all four of the removable end fittings 19 are inserted into rotary buckle 14 , electrical data signals are communicated through a buckle wire harness 23 which is connected to the CRM 13 . The seat occupant can release the five-point restraint 12 by rotating the cover 24 of the rotary buckle 14 , disengaging the four non-permanently attached end fittings 19 and thereby allowing each of the four retractors 18 to retract each lap strap 15 and shoulder strap 16 .
[0040] During a crash or extreme maneuver, the occupant's head can still experience enough lateral motion to cause a secondary impact with a side window or other primary structure. To reduce the effects of these forces, the active headrest 11 (seen best in FIGS. 1A , 2 , 4 A, 4 B and 5 ) includes two lateral supports 26 with deformable padding 32 disposed over at least a front surface (i.e., facing out and towards an occupant) to limit the impact force imparted to the occupant's head.
[0041] When a crash event is likely to occur, the CRM 13 pivots the lateral supports 26 forward on each side of the occupant's head (e.g. as seen in FIG. 4B ). If the vehicle returns to a stable mode of operation, the lateral supports 26 are electrically retracted to their stowed position (e.g., FIG. 4A ) after a predetermined delay, restoring the occupant's field of view and resetting the headrest 11 for a future crash or aggressive maneuver event.
[0042] The active headrest 11 is mounted to the top of the bucket 20 and connected to the CRM 13 by a headrest wire harness (see FIG. 6 ). Preferably, the active headrest 11 consists of at least one lateral support 26 that is pivotally mounted on a frame 30 . An electric motor 27 is coupled to the frame 30 and a reduction gearset 28 , allowing the motor 27 to drive movement of the gearset 28 . The gearset 28 is further coupled to the lateral supports 26 , selectively moving their position between the normal, retracted position ( FIG. 4A ) and the forward, crash position ( FIG. 4B ). The position of the lateral supports 26 can be determined by a sensor such position encode 29 . In this respect, the CRM 13 can monitor the position of the headrest 11 and change the position of the lateral supports 26 at an appropriate time.
[0043] Generally, the CRM 13 monitors sensors that provide data on the occupant (e.g., the rotary position encoder of the retractor 18 and the buckle sensor 22 ) and data on the movement of the vehicle. The CRM 13 uses this data to determine how the straps 15 , 16 and active headset 11 should be adjusted at any given time.
[0044] As seen in FIG. 6 , the CRM 13 includes a main circuit board 33 that receives sensor data, processes the data with algorithms, and controls the restraint system 10 . Sensor data from the retractors 18 and active headrest 11 is communicated to the main circuit board 33 over a retractor wire harness 36 and headrest wire harness 25 , respectively.
[0045] Preferably, a power/vehicle bus connector 35 can also be connected to the main circuit board 33 to provide sensor data from the vehicle (e.g., speed, ground proximity, external air pressure, engine speed, antilock braking system activation) and power for operation. This vehicle sensor data can be used in conjunction with other sensor data to determine behavior of the restraint system 10 . However, the CRM 13 may operate in a “stand alone” mode without this vehicle sensor data. Note that the types of sensor data will vary between vehicle types. For example, antilock braking systems may be specific to ground vehicles while external air pressure may be specific to aerial vehicles.
[0046] The main circuit board 33 is also in communication with an inertial measurement unit 34 which provides information on the movement of the vehicle. Preferably, the inertial measurement unit 34 includes a longitudinal accelerometer for providing longitudinal acceleration data, a rate gyro pitch sensor for providing vehicle pitch data, a lateral accelerometer for providing lateral acceleration data, a rate gyro roll sensor for providing vehicle roll data, a vertical accelerometer for providing vertical acceleration data and a rate gyro yaw sensor for providing vehicle yaw data. In other words, these sensors provide the main circuit board 33 with data on how the vehicle is moving in three dimensions.
[0047] The main circuit board 33 accepts the sensor data through various analog or digital inputs and stores this data (at least temporarily) in non-volatile memory over a data bus. A microprocessor on the main circuit board 33 executes a plurality of algorithms on this data to determine the desired behavior of the restrain system 10 . Example algorithms include crash/blast detection algorithms, aggressive maneuver detection algorithms, and occupant out-of-position (OOP) algorithms based on the sensor data. In a more specific example, the crash/blast algorithm can be watch for either roll, pitch, or yaw exceeding threshold values, accelerations exceeding threshold values, freefall (vertical accelerations equal to gravity) or any combination of the above. In another more specific example, the out-of-position algorithm can watch for belt payout exceeding a nominal value above a baseline value.
[0048] Preferably these algorithms use at least some of the sensor data from vehicle accelerations and angular rates from inertial measurement unit 34 , the spool position of each retractor 18 , the connection status of each removable end fitting 19 into rotary buckle 14 and the position of each lateral support 26 contained in active headrest 11 .
[0049] When the occupant buckles the straps 15 and 16 , the CRM 13 receives data from sensors 22 within the buckle 14 and determines that the occupant is buckled in. The CRM 13 then establishes a “baseline position” (e.g., a normal, stationary position) for each webbing spool of the retractors 18 . This baseline position is stored until the CRM 13 detects that the straps 15 and 16 are unbuckled.
[0050] When a strap 15 or 16 is extended significantly beyond the baseline position for a predetermined length of time (e.g., 30 seconds), the CRM 13 reminds the occupant to sit up straight by a gentle, haptic, “out of position” tug on the strap 15 or 16 caused by momentarily energizing pretensioning motor of the retractor 18 . Since moving away from the normal sitting or standing position reduces the ability of the restraint system 10 to protect the occupant, this tug reminds the user to quickly return to their baseline position.
[0051] FIG. 7 illustrates a flow chart showing a preferred behavior of the restraint system 10 during different vehicle operation situations. During stable flight, the active headrest 11 remains in a retracted position, the retractors 18 allow the straps 15 and 16 to unwind and the CRM 13 sends haptic warning tugs when the user is out of the established baseline position.
[0052] If predictive algorithms within the CRM 13 determine that the vehicle is maneuvering aggressively or erratically, each reversible pretensioner in the retractors 18 is energized to supplement the passive spring retraction force and eliminate slack from the shoulder and lap straps. The elimination of belt slack significantly reduces occupant slump and rotation during a blast or crash event. Additionally, keeping the occupant upright and close to the seat back during aggressive maneuvers may improve his or her ability to maintain control of the vehicle. The CRM 13 also deploys the two lateral supports 26 of the active headrest 11 to provide support and protection to the occupant's head.
[0053] If a crash does not occur after a predetermined period of time and the vehicle resumes a more stable operation, the CRM 13 de-energizes each retractor's reversible pretensioner to relax the straps back to their baseline positions and allow the occupant to pay out additional strap. The CRM 13 continues monitoring data for aggressive maneuvering or crash conditions.
[0054] If the CRM 13 determines that a crash or blast event is occurring, it activates the pyrotechnic pretensioners (by igniting a gas generator) in each retractor 18 and removes all slack in the straps 15 and 16 , preferably within about 50 milliseconds. This holds the occupant firmly upright in the seat, compensating for any packdown inside of the retractor and for webbing/strap stretch due to increasing belt forces, limiting both torso rotation and lateral movement of the occupant. If the lateral supports 26 of the headrest 11 have not already been deployed (e.g., triggered by an aggressive maneuvering algorithm), then they are deployed.
[0055] Once a crash has occurred, the occupant releases the buckle 14 , allowing the straps 15 and 16 to be fully retracted. The occupant can then quickly egress from the restraint system 10 and the vehicle.
[0056] It should be understood that in another preferred embodiment, the previously described active headrest may not be appropriate or necessary. For example, some (but not all) ground or air vehicle types may only see marginal safety benefit from the headrest and therefore may not be cost or weight effective.
[0057] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
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A resettable combat vehicle restraint system prevents secondary impacts within the vehicle cabin during crash, mine blast, or rollover events by positioning the occupant within a load attenuating seat to best survive the dangerous event. The preferred embodiment of the restraint system includes a five point restraint, webbing retractors for each lap and shoulder belt with the capability for both reversible and pyrotechnic pretensioning, an active headrest, and a crash recognition module to electrically activate the pyrotechnic pretensioners and to electrically modulate the actions of the reversible pretensioning retractors and the active headrest.
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PRIORITY AND RELATED APPLICATIONS
The present invention claims priority to U.S. Provisional Patent Application Ser. No. 61/902,851 filed on Nov. 12, 2013, entitled “Walker Stabilization Device”, and U.S. Provisional Patent Application Ser. No. 61/979,487 filed on Apr. 14, 2014, entitled “Walker Docking Station” both of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to devices and methods to assist a person who requires the use of a walker to transition from a sitting position to a standing position.
BACKGROUND OF THE INVENTION
Walkers are common moving aids to assist limited mobility people in moving around. These people also have difficulty in transitioning from a sitting position to a standing position and thus often need assistance, which can be difficult, such as requiring the assistance of another person or the assistance of a power device. There are existing devices to assist limited mobility people to sit and to rise. However, these devices are complicated and in general, difficult to utilize. Thus there is a need for a portable device used in conjunction with a walker that enables a person to transition from a sitting to a standing position, which is easy to use, simple in construction and easily adjustable.
SUMMARY OF THE INVENTION
The present invention relates to walkers and methods to stabilize a walker when a person using the walker transitions from a sitting position to a standing position.
The Walker Docking Station (WDS) is an apparatus to assist the user of a walker when transitioning from a sitting to a standing position. The lifting of the walker's front legs poses a significant problem when a user tries to make this transition because the user will be pulling on the walker handles and, without stabilization, the walker's front legs often lift and/or move backwards towards the user. Any unsteadiness of the walker could cause the user to lose his or her balance and fall. This could result in injury to the user or even injuring an aide or caregiver who may be trying to assist the user. The WDS minimizes the lifting or backwards movement of the front legs of a walker when the user transitions from a sitting to a standing position.
The WDS is primarily designed to be used with walkers that have wheels attached to its front legs via an axle and where there is a small amount of space between the walker's leg and the wheels.
Although a walker without front wheels could be modified to work with the WDS, the intent is to use the WDS with a walker that has wheels attached to its front legs.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be further understood from the following description in conjunction with the drawings:
FIG. 1 is an illustration of an isometric view of a walker.
FIG. 2 is an illustration of front view of a walker that is captured or secured on a WDS.
FIG. 3 is an illustration of the side view of a walker that is captured or secured on a Walker Docking Station.
FIG. 4 is an illustration of a Walker Movement Restrictor Assembly (WMRA).
FIG. 5 is an illustration of WCP's in a down or horizontal position.
FIG. 6 is an illustration of WCP's in an upright or vertical position relative to the base.
FIG. 7 is an illustration of the top view of a Self-Closing Hinge.
FIG. 8 is an illustration of the front view of a Self-Closing Hinge.
FIG. 9 is an illustration of the side view of a Self-Closing Hinge.
FIG. 10 is an illustration of the top view of an Elastic-Band based WDS.
FIG. 11 is an illustration of the front view of an Elastic-Band based WDS.
FIG. 12 is an illustration of the side view of an Elastic-Band based WDS.
FIG. 13 is an illustration of the top view of a Wedge based WDS.
FIG. 14 is an illustration of the front view of a Wedge based WDS.
FIG. 15 is an illustration of the side view of a Wedge based WDS.
FIG. 16 is an illustration of the top view of a Spring based WDS.
FIG. 17 is an illustration of the front view of a Spring based WDS.
FIG. 18 is an illustration of the side view of a Spring based WDS.
FIG. 19 is an illustration of the WDS Universal Base with holes.
FIG. 20 is an illustration of the WDS Universal Base with slots.
FIG. 21 is an illustration of the side view of a walker just prior to being captured, and
FIG. 22 is an illustration of the side view of a walker that has been captured or secured on a WDS.
DETAILED DESCRIPTION OF THE INVENTION
There are four versions of the WDS that will be discussed. They are the Self-Closing Hinge based WDS, the Elastic-Band based WDS, the Wedge based WDS and the Spring based WDS. All four WDS's operate on the same principle and consist of a base and a Walker Movement Restrictor Assembly (WMRA). FIG. 1 is an illustration of an isometric view of a Walker ( 1 ) that is captured or secured on a WDS ( 5 ). The walker's front leg ( 2 ) has a wheel ( 3 ) that is attached to the walker via an axle ( 4 ). The base ( 6 ) of the WDS has a WMRA attached to it. The base may be a portable surface or a floor. The WMRA consists of a hinge ( 9 ) and a flat plate ( 7 ) and the flat plate has a cutout ( 8 ). The flat plate with its cutout is also known as the Walker Capture Plate (WCP). The cutout is used to partially surround the walker's axle when the walker is being captured or secured by the WDS. The hinge is used to couple the WCP to the base and allows the WCP to rotate or pivot on the base.
The natural position of the WCP is in the down or horizontal position relative to the base as shown in FIG. 5 . When the WCP is in the upright or vertical position relative to the base, the WCP has either captured or is in the process of capturing a walker. Each WDS's WCP functions the same in that they capture or secure the walker's axle and holds the walker to the base. The difference is in the mechanism that is used in transitioning the WCP from its upright or vertical position to its down or horizontal position. Each of these mechanisms will be described later in the details of each WDS.
Although it is possible to construct a WDS using only one WCP, the WDS is more effective when each front wheel's axle is captured and secured by its own WCP.
The following section describes the operational setup and use of a WDS that has a portable base and two WMRA's. The walker is the type that has wheels on each of its front legs.
An aide or caregiver is expected to perform all tasks associated with getting the WDS ready for the user.
1. The aide or caregiver places the WDS in front of the user while he or she is sitting. The WCP's are in their down or horizontal position relative to the base with the WCP cutouts facing away from the user. 2. The aide or caregiver places the walker on the base of the WDS so that each walker's front leg is positioned in front of its corresponding WCP and the WCP can be rotated to a vertical or upright position without interference from the walker's leg. The aide or caregiver operates on one walker's front leg at a time. 3. The aide or caregiver lifts the first WCP to an upright or vertical position and moves the walker's leg backwards towards the user, so that the WCP lies between the walker's leg and wheel, and the WCP's cutout is partially surrounding the walker's axle. 4. The aide or caregiver performs the same procedure as in step 3 on the other front leg. 5. The aide or caregiver pushes the walker backwards until the walker's axles make contact with and are firmly seated in the cutouts of each of the WCP's. 6. The user places his or her feet on the base, grips the handles of the walker and pulls himself or herself up. If necessary, the aide or caregiver can step on the front of the base as the user pulls up. This helps to minimize any lifting of the WDS and walker. 7. Once the user is standing on the base, the user moves forward with the walker and as the walker's front legs leaves the WCP's, the WCP's rotate down and end up in a horizontal position relative to the base. The user is then able to go in any direction he or she desires.
Although it is desirable for the WCP to lie between the walker's front leg and wheel, the WDS can be designed to capture the end of the axle or an extending rod that is attached to the front legs of a walker without wheels; however, the walker is more secured when the WCP is positioned to lie between the walker's leg and wheel.
The Self-Closing Hinge based WDS uses a self-closing or a spring-loaded hinge, ( 10 ) that is normally closed unless there are forces trying to keep it open. When the WCP is in the upright or vertical position and positioned between the walker's leg and wheel, the self-closing hinge pulls on the WCP and keeps the WCP against the walker's leg. The walker's leg prevents the WCP from rotating or pivoting down and closing. When the walker's leg leaves the WCP, the self-closing hinge is free to close and the WCP transitions from an upright to a down position.
In the following three Self-Closing Hinge based WMRA figures, the WMRA is between the walker's front leg and wheel and the plate's cutout is partially surrounding the walker's axle.
FIG. 7 is an illustration of the top view of a Self-Closing Hinge based WDS's WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 8 is an illustration of the front view of a Self-Closing Hinge based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 9 is an illustration of the side view of a Self-Closing Hinge based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
The Elastic-Band based WDS has an elastic band, ( 11 ) such as a rubber band or bungee cord, where one end of the elastic band is secured to the base of the WDS and the other end of the elastic band is secured to the WCP. When the WCP is in the upright or vertical position and positioned between the walker's leg and wheel, the elastic band pulls on the WCP and keeps the WCP against the walker's leg. The walker's leg prevents the WCP from rotating or pivoting down and closing. When the walker's leg leaves the WCP, the elastic band pulls on the WCP and transitions the WCP from an upright to a down position. The Elastic-Band based WDS uses a standard or conventional hinge.
In the following three Elastic-Band based WMRA figures, the WMRA is between the walker's front leg and wheel and the plate's cutout is partially surrounding the walker's axle.
FIG. 10 is an illustration of the top view of an Elastic-Band based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 11 is an illustration of the front view of an Elastic-Band based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 12 is an illustration of the side view of an Elastic-Band based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
The Wedge based WDS has a wedge ( 12 ) that is mounted on the side of the WCP that faces the wheel. The wedge is positioned so when the walker's leg leaves the WCP, the wedge is the very last part of the WCP that the wheel makes contact with and when the wheel makes contact with the wedge, the wheel pushes the WCP away and this action causes the WCP to rotate or pivot down. The Wedge based WDS uses a standard or conventional hinge.
In the following three Wedge based WMRA figures, the WMRA is between the walker's front leg and wheel and the plate's cutout is partially surrounding the walker's axle.
FIG. 13 is an illustration of the top view of a Wedge based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 14 is an illustration of the front view of a Wedge based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 15 is an illustration of the side view of a Wedge based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
The Spring based WDS has a spring ( 13 ) at the base or bottom of the WCP. When the WCP is in the upright position, the spring makes contact with the base and the spring pushes on the WCP. When the WCP is in the upright or vertical position and positioned between the walker's leg and wheel, the spring pushes the WCP against the walker's leg. The walker's leg prevents the WCP from rotating or pivoting down and closing. When the walker's leg leaves the WCP, the spring, pushing on the WCP causes the WCP to rotate from an upright to a down position. The Spring based WDS uses a standard or conventional hinge.
In the following three Spring based WMRA figures, the WMRA is between the walker's front leg and wheel and the plate's cutout is partially surrounding the walker's axle.
FIG. 16 is an illustration of the top view of a Spring based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 17 is an illustration of the front view of a Spring based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
FIG. 18 is an illustration of the side view of a Spring based WDS' WMRA with the lower portion of a walker's front leg that has a wheel attached to it.
The spacing between the front legs may vary from walker manufacturer to walker manufacturer. It is possible to make a universal WDS that will accommodate different size walkers. One method to accomplish this is to have multiple holes drilled in the base ( 14 ). The holes would allow the spacing between the WMRAs to vary and support numerous manufacturer walkers. FIG. 19 is an illustration of the WDS Universal Bases with predrilled holes that would allow the space between WMRAs to vary. Another method to accomplish this would be to have one or more slots ( 15 ) that would also allow the spacing between the WMRAs to vary and support numerous manufacturer walkers. FIG. 20 is an illustration of the WDS Universal Bases with slots that would allow the space between the WMRAs to vary.
There are walker users who need help in getting up from a sitting to a standing position; however, they are not so incapacitated that they require an aide or caregiver in helping them make this transition. For those walker users, a WDS that has a semi-automated loading system (SALS) could help them in the sitting to standing transition. See FIG. 21 . The WDS SALS allows the user to back their walker into the docking station without the need of an aide or caregiver. This system uses a cable ( 17 ) where one end of the cable is tied to the WCP and the other end of the cable is tied to a sliding back-leg foot catch (BLFC) ( 16 ). The BLFC catches the walker's back leg ( 18 ) as the walker is sliding backwards and via the cable, the BLFC pulls on the WCP, rotating the WCP to an upright or vertical position at the same time securing the walker into the WDS.
FIG. 21 is an illustration of the side view of a walker just prior to being captured or secured by the SALS with the WCP in the down or horizontal position, and
FIG. 22 is an illustration of the side view of a walker that has been captured or secured on a WDS by the SALS with the WCP in the upright or vertical position.
While the present invention has been described with reference to the above embodiments, this description of the preferred embodiments and methods is not meant to be construed in the limited sense. It should also be understood that all aspects of the present invention are not to be limited to the specific descriptions, or to configurations set forth herein. Variations in the present invention will be apparent to a person skilled in the art upon reference to the present disclosure. It is therefore contemplated that the following claims will cover any such modifications or variations of the described embodiment as falling within the true spirit and scope of the present invention.
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A walker stabilizing platform including a movement restrictor assembly for assisting a user of a walker in transitioning from a sitting position to a standing position wherein the movement restrictor assembly automatically moves from a position of engagement with the walker to a position of disengagement with the walker, and further includes means for allowing the user of the walker to move the movement restrictor assembly from the disengaged position to the engaged position without assistance.
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TECHNICAL FIELD
The present invention relates to a cloth beam arrangement in a weaving machine for weaving tubular felts (cloths) which comprise an overfelt and an underfelt. The arrangement also comprises, for effecting the feed of the woven overfelt and underfelt in the weaving machine, a first beam or upper beam, against which the woven underfelt runs, a second beam or intermediate beam, against which the woven overfelt runs, and a third beam or lower beam, against which the woven underfelt runs. The arrangement further comprises driving members for driving the beams. The weaving machine is of the type which has a sley or reed which, during weaving, acts against a weaving edge or weaving edges which has/have been established.
The term felt is to be understood in its widest sense. Terms such as cloths, material, products are also used and are in this connection equivalent to the term felt.
BACKGROUND OF THE INVENTION
The woven product is to be used in a paper machine, that is in a machine for production of paper/paper pulp. The felt is placed in a given roller group in the paper machine. The tubular felt is in the form of a hose, the circumference of which is adapted in the weaving machine to the roller group in the paper machine in which it is to run. When the woven felt is mounted in the paper machine, the side walls of the machine are dismantled so that the ends of the rollers are freed and the woven felt can then be pushed in over the roller group. To produce the tubular felts, a weaving machine is required, which has a working width corresponding to half the circumference of the felt. As a roller group in the paper machine may have a large circumference, the working width of the weaving machine becomes considerable and working widths of roughly 30 meters may be cited by way of example. Production of tubular felt is a difficult process as there are in principle two felts which lie loosely one on top of the other in the weaving machine, which may give rise to problems.
It is previously known use cloth beam arrangements with three beams. The feed of the arrangement is adjusted in such a manner that each time a shuttle passes across the width of the weaving machine, the beam system is rotated forward by a given amount which is to correspond to the thread pitch in the felt. Reference may also be made to the current system sold on the open market by TEXO AB. The system is described in, for example, Swedish patent 8703865. In this known system. all are gearwheel-synchronized and the beams are advanced by the same distance. In so-called flat-woven products with only one felt ply, the known system functions excellently.
In the weaving of the tubular felts with an overfelt and an underfelt, problems arise when the known cloth beam arrangement is used. This is because the overfelt and the underfelt can be displaced in relation to one another. As is described in greater detail below, the underfelt and the overfelt have different driving radii in the cloth beam arrangement. During advance of the cloth beams, the overfelt is moved a slightly greater distance than the underfelt as a result of the radius of movement being longer for the overfelt than for the underfelt. This has such an effect that a noticeable displacement occurs between the two felt plies at the weaving edge or beating-up edge. This means that differences arise in the sett of the two felts. The underfelt, which by means of the cloth beam arrangement has the correct adjustment, has the expected sett while the overfelt has a looser sett. This has consequences in the paper machine in connection with paper production because the tubular felt has a sett which varies around its circumference. The invention aims to solve this problem.
It is important that the identical feed of the overfelt and the underfelt during weaving can take place irrespective of the felt thickness in the woven material. The cloth beam system/weaving machine is thus to be adjustable for different felt thicknesses and still effect the desired felt feed in the case of tubular felts. The invention solves this problem also.
The main characterizing feature of the new arrangement is considered to be use of driving members which bring about driving of the beams which prevents mutual longitudinal displacement movements between the overfelt and the underfelt and thus ensures during weaving that the overfelt and underfelt edges remain opposite one another at the weaving edge(s). The term opposite means that the overfelt and the underfelt are to cover or overlap one another (completely) at the weaving edge or weaving edges respectively.
In developments of the inventive idea, the driving members are designed to effect an unsynchronized rotation of at least the first and second beams. The driving members may comprise, for the first beam or upper beam, first driving members which drive the first beam via its two ends by means of first a.c. servo-motors. The first beam is in this connection designed freely programmable with regard to the sett in the woven material.
In a further embodiment, the second beam or intermediate beam is assigned second driving members which drive the second beam at a reduced speed of rotation in relation to the third beam. The second and third beams may form part of a common driving assembly which is driven by second driving members via the two ends of each beam of the second and third beams. The second driving members may comprise gearwheels mechanically interconnecting the second and third beams. The gearwheels bring about, by means of synchronization, a slightly higher driving speed of the third beam in relation to the second beam, resulting in a desired tensile stress being maintained in the overfelt. The second and third beams which form the common driving assembly can be driven by means of second a.c. servo-motors arranged at the two ends of the driving assembly (or of the beams). The overdriving of the third beam in relation to the second beam is brought about by the gearwheel of the third beam having fewer teeth than the gearwheel of the second beam.
In a further embodiment, the driving members are designed to drive the three beams in an entirely unsynchronized manner so that there is complete programming freedom for the drive functions of the beams.
The a.c. servo-motors mentioned above may, in a known manner, be made controllable from a unit, which controls the weaving, on or close to the machine.
By means of the above proposals, the process of weaving tubular felts in a weaving machine is made easier and the sley or reed can attack a common edge of the woven felt plies, which guarantees a uniform sett around the entire circumference of the tubular felt. By the beams different speeds, the feed of the overfelt and the underfelt can be coordinated in an entirely different manner from that which has been possible previously using the known equipment. The feed is also independent of the thickness of the woven material. Differences in radius which give rise to the felt displacement are compensated by differences in speed of the beams which have essentially the same diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
A presently proposed embodiment of a cloth beam arrangement according to the invention is to be described below with simultaneous reference to the attached drawings, in which:
FIG. 1 shows in perspective obliquely from above an example of a tubular felt,
FIG. 2 shows in vertical section from the side an example of a weaving machine which can use the novel cloth beam system,
FIG. 3 shows very generally in vertical section the felt feed in a cloth beam system,
FIG. 4 shows from the front the cloth beam system with associated driving members of a first embodiment, and
FIG. 5 shows from the front the cloth beam system with driving members in a second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the principle of a tubular felt. By means of patterning by the warp threads 1, a hose-shaped product is obtained in a weaving machine with a weaving width VB. In order to obtain a finished felt, a length is required which corresponds to a roller width PM in a given paper machine. The felt runs in a paper machine in a direction 2. A shuttle is shown by 1a and a weft thread connected to the latter is shown by 1b.
FIG. 2 shows the basic construction of a felt-weaving machine FV. The machine comprises one or more warp beams 3 where warp threads 4 are unwound. The warp passes around a guide beam 5 and over a whipe-roll beam 6 and on through the patterning arrangement 7 which may consist of up to 24 heald frames 8. The warp threads then pass through the sley (reed) 9 which is mounted on a reciprocating lay-beam 10 which bears a shuttle race 11. At a weaving edge 12, a tubular felt 13 is formed, which in principle consists of two loose felts which lie one on top of the other, the lower felt 14 here being called the underfelt and the upper felt 15 being called the overfelt. From the weaving edge, the tubular felt then extends over a breast beam batten 16 and then on over the breast beam 17. In the cloth beam system, which in most cases consists of three beams, the upper beam is indicated by 18, the intermediate beam by 19 and the lower beam by 20. The sett of the woven product is adjusted using the cloth beam system. Each time a shuttle passes across the width of the weaving machine, the beam system is rotated forward a given amount which corresponds to the thread pitch in the felt. The felt edges at the beating-up edge 12 are indicated by 14a and 15a.
FIG. 3 shows a partial enlargement of the cloth beams 18, 19 and 20 and it can be seen from this figure that the underfelt runs against the surface 18a of the main beam 18 and against the surface 20a of the lower beam 20. The overfelt 15 runs against the surface 19a of the intermediate beam 19. In FIG. 3, the upper and lower beams 18 and 20 respectively rotate in the anticlockwise directions 18b and 20b respectively. The intermediate beam 19 rotates in the clockwise direction 19b. In the exemplary embodiment, all three beams have the same size diameters D. In other respects, the beams are constructed in a known manner. It can be seen from the figure that the underfelt 14 is driven forward with a driving radius Ru and the overfelt is driven forward with a driving radius Ro. The driving radius Ro is in this connection greater than the driving radius Ru. This means that, during advance of the cloth beams, the overfelt travels a slightly greater distance than the underfelt because of the greater radius. The result is that, during weaving according to previously known principles, a clear displacement between the two surface plies occurs at the weaving edge (see 12 in FIG. 2). This results in a lower sett in the overfelt compared with the underfelt.
According to FIG. 4, the new cloth beam system or cloth beam arrangement has the same number of beams as in previous cases, that is there are three beams,--18, 19 and 20 according to the above--in the exemplary embodiment shown. In this case, the beams are not synchronized with one another. The upper beam 18 is driven at its two ends by means of a planetary gear, a worm gear and an a.c. servo-motor 21, 21'. In FIG. 4, the planetary gears are indicated by 21" and 21'" respectively. The worm gears have the designations 21"" and 21'"" respectively. The motors 21, 21' are freely programmable with regard to the sett in the felt. The programming can be carried out in a known manner via the connections 21a and 21a' respectively. In this connection, programming can take place on the control unit SE of the weaving machine, which unit is indicated only symbolically and can be constituted in a known manner known. The control unit is assumed to have control outputs U1 and U2 respectively which are connected to the connections 21a and 21a' respectively. According to the above, direct driving contact is thus made with the underfelt (see 14 in FIG. 3) and the latter thus has the correct sett. In order that both the underfelt and the overfelt lie directly one above the other at the beating-up point (see 12 in FIG. 2), the overfelt (see 15 in FIG. 3) must be braked in relation to the radial difference indicated in FIG. 3. In the exemplary embodiment according to FIG. 4, this is carried out with the aid of the intermediate beam 19 which drives the overfelt. The intermediate beam is also programmable and can be driven separately by a driving arrangement 22, 22' similar to the driving arrangement 21, 21' for the upper beam. The units 22, 22' may consist of a.c. servo-motors which are programmable from the control unit SE like the corresponding motors for the upper beam. In the case shown, the intermediate beam and the lower beam are interconnected at both ends by gearwheels 23, 24 and 23', 24' respectively. The intermediate beam and the lower beam thus together form a driving assembly, the main function of which is to control and adjust the advance of the overfelt (15 according to FIG. 3) by the intermediate beam. The lower beam 20 has been made, by gearwheel synchronization, with a small overfeed so as not to lose the tensile stress in the cloth. In FIG. 4, the drive 22, 22' has been placed on the shaft of the lower beam for purely practical, namely reasons of space in the machine concerned. Alternatively, the drive 22, 22' may be placed on the shaft of the intermediate beam. In this case, overfeed is brought about by the gearwheel 24, 24' of the lower beam having fewer teeth than the gearwheel 23, 23' of the intermediate beam. This overfeed is thus fixed and cannot be subsequently adjusted. By way of example of actual braking distances for the overfelt in relation to the underfelt, when the driving radius Ro of the overfelt is 1 mm greater than the driving radius of the underfelt, the overfelt is braked 6.0-6.6 mm, preferably about 6.3 mm, for each revolution of the cloth beam. A more precise value is 2×π(or 6.28) mm. When Ro is 2 mm greater, the exact braking distance is 12.56, and so forth.
In the embodiment according to FIG. 5, all three cloth beams 18, 19 and 20 have been assigned separate drives 25, 25', 25", 25'", 25"", 25'"", 26, 26', 26", 26'", 26"", 26'"" and 27, 27', 27", 27'", 27"", 27'"" respectively. By means of this embodiment, complete programming freedom is obtained for all the cloth beams, that is also overfeed of the lower beam 20 also. In FIGS. 4 and 5, the weaving machine itself has been symbolized by VS.
The equipment described above and the principles thereof have proved to function very well in practice. The setts are essentially the same in the two felts. In a practical test, the necessary different peripheral speeds were brought about by means of applying layers to the beams in accordance with the previously known cloth beam system. The beams were thus made with different diameters in the known system. By means of changes in diameter, the desired effect is obtained, namely that the sett in the underfelt is controlled by the, upper beam (with an increased diameter) and the intermediate beam slows down the overfelt to the correct position thanks to a slightly smaller diameter, and the lower beam, made with the same diameter as the upper beam, has a small overfeed in relation to the intermediate beam. Adjustment of the beam diameters does not represent a solution on weaving machines if the possibility of making the weaving machine easily adjustable for weaving different thicknesses is required. Varying the cloth beam diameters in accordance with the practical test may in practice be used on machines which are intended for only one type and thickness of felt.
The invention is not limited to the embodiment shown above by way of example but may be subjected to modifications within the scope of the following patent claims and the inventive idea.
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A cloth beam arrangement for tubular felts or cloths in a weaving machine brings about feed in the weaving machine of the overfelt and the underfelt. The arrangement comprises an upper first beam, an intermediate second beam and a lower third beam. The underfelt runs against the first and the third beam and the overfelt runs against the second beam. The arrangement comprises driving members for the beams. The weaving machine includes a sley which during weaving acts against a weaving edge which has been established. The driving members drive the beams in a way which prevents mutual longitudinal displacement movements between the overfelt and the underfelt. It is thus ensured during weaving that the overfelt and underfelt edges remain completely overlapping one another at the weaving edge.
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FIELD OF THE INVENTION
[0001] The invention relates to a novel apparatus for use in the door framing industry. Particularly, the apparatus of the invention is an adjustable device which equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all doors, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed.
BACKGROUND OF THE INVENTION
[0002] Carpenters use a wide variety of tools to help them with repetitive tasks. Where the construction of a plurality of doors is concerned, one of the critical tasks is spreading the door bucks to the proper spacing prior to securing the doors' sides and the bottom of the bucks to the floor and other securing members of the frame. Ordinarily, a door spreader is fashioned for each door on each new job from wood or other like material, taking time and using materials.
[0003] In the past, several tools designed to mitigate the need for crafting new spreaders on each job have been disclosed, however, they generally are complicated, clumsy, expensive, or insufficiently adjustable to accommodate the requirements of most door-framing jobs. For example, U.S. Pat. No. 5,340,095 discloses a door spreader with myriad moving parts, connections, and clamps, but it has disadvantages in that it requires tools such as wrenches to adjust the spread width. Likewise, U.S. Pat. No. 3,851,868 discloses a spreader employing bolts, magnets, and sliding members which allows for adjustability, but is limited in its ability to accommodate doors of different sizes, because the largest spread it can accommodate is somewhat less than twice the smallest spread owing to the nature of the sliding members. Further, at wider spreads, the device is insufficiently stable because its sliding members are extended to their fullest and are secured by only a single bolt.
[0004] U.S. Pat. No. 5,775,036 discloses a spreader employing grooves and slots to enable spreading of doors in a range likewise limited by the spread of its sliding members to less than twice the smallest range. Additionally, the lateral ends of the spreader are a single size, such that adaptation to a variety of door buck width sizes is not possible without building additional units.
[0005] The art is therefore in need of a superior door spreading apparatus which is useful on a variety of door spread widths and buck sizes, which may be carried by the carpenter to each job and used on the variety of doors in a repetitive fashion such that each door requires only a simple adjustment of the spreader apparatus.
SUMMARY OF THE INVENTION
[0006] The door spreader of the invention satisfies the needs in the art for a spreader which is reuseable on a variety of door framing jobs, which may be carried by individual carpenters to such jobs, and is both inexpensive and particularly well-adapted to its function.
[0007] In one aspect, the invention comprises an adjustable door spreader having (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0008] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. However, where the desired door bucks' separation width is greater than that of the base member, the slideable member is extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck.
[0009] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0010] In another aspect, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts.
[0011] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof. The measurement indicators are optional because the recesses are spread at precise increments. In use, the door spreader is adjusted to these incremental spread widths.
[0012] In another aspect, then, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally from 24 to 48 inches in 2 inch increments. Any desired increment may be accomplished by spacing the recesses on the slideable member at the desired distance. Preferably, the door spreader may be locked to a variety of common door frame widths, typically in 2 inch increments. Where the base member is 30 inches in its longest dimension, the spread widths are generally variable from 24 inches (using the slideable member only where the slideable member is 24 inches in its longest dimension), 30 inches (using a 30 inch base member with or without the slideable member affixed to the base member, but unextended therefrom), and from 30 to 48 inches in increments of 2 inches. Again, other increments are easily adapted by designing alternative space increments between the recesses on the slideable member.
[0013] In another aspect, the adjustable door spreader has an additional adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, a 9 inch extension member allows for additional extension up to 4 inches.
[0014] In one aspect, an adjustable door spreader with a 30 inch base member, a 24 inch slideable member, and a 9 inch extension member may thus be extended to accommodate spread widths of from 24 to 52 inches in increments of 2 inches, or any combination of at least two of such widths.
[0015] In another aspect, an adjustable door spreader with a 24 inch base member, a 20 inch slideable member, and a 7 inch extension member may thus be extended to accommodate spread widths of from 20 to 44 inches in increments of 2 inches, or any combination of at least two of such widths.
[0016] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0017] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths, as described more fully below.
[0018] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like.
[0019] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention.
[0020] These and other features of the invention are exemplified and further described in the Detailed Description of the Invention below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic diagram showing an embodiment of the adjustable door spreader of the invention.
[0022] FIG. 2 is a schematic diagram showing an overhead view of an embodiment of the adjustable door spreader of the invention.
[0023] FIG. 3 is a schematic diagram showing a side view of an embodiment of the slideable member of the invention, with an extension member affixed thereto.
[0024] FIG. 4 is a schematic diagram showing an edge-on view of an embodiment of the adjustable door spreader of the invention.
[0025] FIG. 5 is a schematic diagram showing the base member, the slideable member, and the extension member of an embodiment of the adjustable door spreader of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The door spreader of the invention comprises a base member having a smooth bottom surface, and lateral ends with notches adapted to fit standard door buck widths. The notches may be of a fixed width, or may be adjustable as described below to fit a variety of door buck widths.
[0027] The base member may be used by itself for the smallest door frame sizes, as it is designed to precisely fit the smallest standard door sizes, such as 24 inches or 30 inches. To accommodate larger door spread widths, the base further comprises a longitudinal spline running down the middle of the upper surface, and longitudinal rails running down the sides of the base. These features allow a slideable member having a lower and an upper surface, the lower surface having a groove sized to fit along the spline of the base member, and the slideable member being of width such that it fits within the two rails of the base member. The slideable member has its own set of notches on its longitudinal ends to accommodate the door bucks' width. The carpenter using the spreader simply slides the slideable member along the base member until the desired spread width is achieved.
[0028] The upper surface of the slideable member optionally has an adjustable third member adjustably affixed thereto to allow further extension and additional spreader width.
[0029] Measurement indicators are optionally present on one or more of the upper surface of base member, one or both of the side surfaces of the base member, the upper surface of the slideable member, and the upper surface of the adjustable third member. In one embodiment, the indicators provide markings spaced in intervals of, for example, 2 inches.
[0030] Once the desired spread width is achieved, the width of the spreader is secured by securing means which pass through holes through the entire thickness of the sliding member into recesses in the upper surface of the base member adapted to receive the securing means. Generally, a pair of securing means are used, positioned advantageously in opposition on the slideable member. The securing means may be dowels, pins, bolts, or preferably spring bolts which may be released and secured with a simple twist-and-pull action. The recesses in the upper surface of the base member are positioned such that each will engage a securing means, which have been passed through the holes. In the case of spring bolts, a simple twist-and-pull action recedes the spring bolt from being engaged, allowing the sliding member to slide against the base member, whereupon the desired width is achieved. The spring bolts are then twisted back to reengage the recesses at the desired position, achieving a secure engagement of the sliding and base members at the desired width.
[0031] Thus, in one embodiment of the invention, an adjustable door spreader has (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0032] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. For example, a base member having a longest dimension of 30 inches accommodates a standard 30 inch door frame, while the slideable member of 24 inches in longest dimension may be used by itself for smaller frames, such as those in smaller closets. However, where the door bucks' separation width is greater than that of the base member, the slideable member is slid within the base member, and extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck. This allows for spread widths of, for example, 24 inches to 48 inches in desired increments of, for example, 2 inches. In another embodiment, where the base member is 24 inches in width, the door spreader accommodates spreads of 20 to 44 inches.
[0033] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0034] In one embodiment, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts, such as those available from McMaster-Carr (e.g., “Pull-Ring” Hand-Retractable Spring Plungers, found in the online catalog at mcmaster.com), and may be made of brass, steel, or the like.
[0035] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof.
[0036] In an embodiment of the invention, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally 24 to 52 inches, in desired increments. Preferably, the door spreader may be locked to all these common door frame widths. Further, the recesses in the base member may be more numerous to allow for locking of the slideable member at additional, less common, widths.
[0037] In another embodiment, the adjustable door spreader has an adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, an extension member of 9 inches provides for additional extension of 4 inches.
[0038] In another embodiment, then, the adjustable door spreader with a 30 inch base member may thus be extended to accommodate spread widths of 24 to 52 inches, or any desireable combination of at least two of such widths. Preferably, the door spreader is capable of accommodating all such widths, and may be optionally machined to allow for less common widths in between these standard widths. For example, where a 2 increment is desired, the door spreader accommodates spread widths of 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, and 52 inches. In another embodiment, where the base member is 24 inches long, the door spreader accommodates door buck spread widths of 20 to 44 inches when the slideable member and extension members are utilized. Preferably a 2 inch increment is used, thus allowing for spread widths of 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, and 44 inches.
[0039] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0040] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths. For example, in one embodiment, the notches, as defined by their protruding sides are 2½ inches wide, but may be adjusted to greater or lesser width by adapting one of the protruding sides defining the notches to be movably adjustable, thereby allowing for door buck widths of from about 1 inch to about 3 inches.
[0041] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like. Each of the base member, the slideable member, and the extension member may be constructed from a single piece of material, or may be constructed from separate pieces which, when appropriately joined, formed the respective member. Preferably the door spreader is made of wood or fiberglass.
[0042] The dimensions of the door spreader are chosen for the particular spread of widths intended to be accommodated. Preferably, the door spreader is capable of spreading from 24 inches to 52 inches including a plurality of 2 inch increments thereof, more preferably including a majority of 2 inch increments thereof, more preferably including substantially all 2 inch increments thereof, and most preferably including all 2 inch increments thereof.
[0043] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention. In these methods, the carpenter lays the door spreader between the door bucks and adjusts the door spreader to the desired width, either by using the notches in the base member alone, or by extending the slideable member to a greater width, engaging one of the slideable member's notches with the first door buck and the base member's notch with the other, or by extending the extension member to achieve greater widths than possible with the slideable member alone.
EXAMPLES
[0044] The present invention will be further understood by reference to the following non-limiting examples.
Example 1
Adjustable Door Spreader with 30 Inch Base Member
[0045] With specific reference to the Figures, this Example illustrates an embodiment of the invention wherein the base member is 30 inches in its longest dimension. Made from wood, the door spreader is 30 inches wide, 7 inches across, and 2 inches high (including the height of the rails). The base member ( 1 ) as depicted in FIG. 1 is constructed from ¾ inch thick wood. The rails ( 2 ) are a total of 2 inches high and ½ inch thick, and, as shown in FIG. 4 , at the top ¼ inch of the rails, extend medially ¾ inches from the edge of the base member toward the center of the base member to retain the slideable member ( 4 ) in a flange-like manner, thereby providing a ¼ inch overhanging retaining portion of the rail.
[0046] The notches on the base member ( 3 ) are defined by tongs extending outward from the base member by ¾ inches, though they may alternatively extend outward by ½ inch to about 1 inch. The tongs are each 1¾ inches across. The notches defined by the tongs extended from the base member are therefore 2½ inches across, accommodating door bucks of up to 2½ inches in width.
[0047] The top surface of the base member has a 2 inch across spline ( 6 ), either side of which are recesses ( 7 ), beginning from between about 4 and 6 inches from either end of the base member, preferably between 5 and 5½ inches, and spaced in an interval of every 2 inches. The recesses ( 7 ) are set about 1 inch from the rails in order to match with the pair of holes ( 9 ) in the slideable member.
[0048] The slideable member ( 4 ) depicted in FIG. 3 is 24 inches in width, 5⅞ inches across, and 11/16 inches thick. The slideable member ( 4 ) has notches ( 3 ) such that the space defined by the tongs thereof are of similar width to those of the base member ( 1 ). The thickness of the notches ( 3 ) shown in FIG. 3 may be less than the full thickness of the slideable member ( 4 ), or the notches ( 3 ) may be fully as thick as the slideable member ( 4 ) itself. In this example, a groove matching the dimensions of the spline ( 6 ) (which in this example is ⅛ inch thick) is provided on the lower surface of the slideable member ( 4 ). As depicted in FIG. 5 , the slideable member ( 4 ) has two pairs of recesses towards one end for adjustably affixing the extension member ( 5 ), only one pair of recesses being utilized at a particular time depending on the desired door buck spread width. The slideable member may have three pairs of recesses, 2 inches apart, to allow for adjusting the extension member to extend by 0, 2, or 4 inches. Towards the opposite end of the slideable member, at a position about 2½ inches from the end of the slideable member, is a pair of holes ( 9 ) through which the locking pins ( 8 ) (shown in FIGS. 2 , 3 , and 4 ) are passed, for securing the slideable member ( 4 ) to the base member ( 1 ). The pair of holes ( 9 ) are each set back from the edge of the slideable member by 15/16 inches. The locking pins ( 8 ), after passing through the holes ( 9 ), pass into the recesses ( 7 ) of the base member. A handle ( 10 ) is also provided on the slideable member ( 4 ).
[0049] The extension member ( 5 ) as depicted in FIG. 5 is 9 inches in width, 5½ inches across, and ½ inch thick. It has a notch at only one end, the tongs of which define a space having dimensions as in the notches of the base member and slideable member, although the space defined by the tongs may be less, such as 2¼ inches. Two pairs of holes ( 12 ) are positioned on the extension member ( 5 ) such that it may be affixed to the slideable member ( 4 ) at either an unextended position (see FIG. 2 ), or in an extended position. The affixing is accomplished by means of wingnuts ( 11 ) which pass through the holes ( 12 ) and into the recesses in the slideable member ( 4 ). As shown in the Figures, the extension member ( 5 ) has two pairs of holes for extension purposes, however, if desirable, the extension member ( 5 ) may have additional pairs of holes for additional extension width possibilities. For example, three pairs of holes may be used to accommodate extension by 0, 2, and 4 inches.
[0050] FIG. 1 depicts the fully assembled adjustable door spreader, showing the base member ( 1 ), the slideable member ( 4 ) in unextended position, and the extension member ( 5 ) in unextended position. FIG. 5 depicts the unassembled door spreader, indicating the manner in which it is assembled for use.
[0051] The door spreader is used by placing it between door bucks and adjusting the door spreader so that the notches present in the appropriate member define the desired spread width. For example, a 30 inch spread width is accomplished by merely keeping the slideable member and extension member in unextended positions. A 36 inch spread width is accomplished by releasing the spring-bolts, sliding the slideable member 6 inches, and resecuring the spring-bolts. One notch of the base member abuts one of the door bucks, while one notch of the slideable member abuts (or defines the position) for the other door buck. The door bucks are then affixed to form a door frame of precise desired width. Similarly, a 52 inch spread width may be accomplished by extending the slideable member by 18 inches, and then the extension member to its fully extended position (yielding an additional 4 inches of extension), bringing the total width of the adjusted spreader to 52 inches.
Example 2
Adjustable Door Spreader with 24 Inch Base Member
[0052] This example differs from Example 1 in that the base member ( 1 ) is 24 inches wide, the slideable member is 20 inches wide, and the extension member is 7 inches wide. This example apparatus is capable of spreading from 24 inches to 44 inches.
[0053] It will be apparent to persons skilled in the art that numerous enhancements and modifications can be made to the above described apparatus without departing from the basic inventive concepts. All such modifications and enhancements are considered to be within the scope of the present invention, the nature of which is to be determined from the foregoing description and the appended claims. Furthermore, the preceding Examples are provided for illustrative purposes only, and are not intended to limit the scope of the invention. All references cited herein are expressly incorporated by reference herein.
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The invention relates to an adjustable door spreader apparatus for use in the door framing industry. The apparatus equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all common door sizes, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed.
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This is a division, of application Ser. No. 414,539 , filed Nov. 9, 1973 now Pat. No. 3,888,314.
BACKGROUND OF THE INVENTION
The present invention relates generally to a sprinkler system, and more particularly to a sprinkler system construction and to a method of operating the same.
Various types of sprinkler systems are already well known in the art. One type which is of particular interest in the context of the present invention involves a sprinkler conduit (which may be composed of a plurality of conduit sections) which is filled with gas under pressure and separated from a water supply conduit by a valve which is normally closed. Such systems are well known and may include a so-called "pre-action" system. In the type of sprinkler system which uses only a pressurized sprinkler conduit, the valve connecting the sprinkler conduit with the water supply conduit opens when it senses a pressure drop in the sprinkler conduit, for instance because pressurized gas can escape from the same due to the fact that one or more of the sprinklers of the sprinkler conduit have opened, if, however, the system is of the type using a "pre-action" system, then the valve connecting the sprinkler conduit with the water supply conduit is not opened when a pressure drop occurs in the sprinkler conduit itself, but instead is opened only in response to the operation of a separate fire alarm system. In this case, the opening of one or more sprinklers of the sprinkler conduit will result only in the giving of a signal indicative of the fact that the pressure in the sprinkler conduit has dropped. The operation of the fire alarm system also produces a signal, and at the same time opens the valve which separates the sprinkler conduit from the water supply conduit. However, only if two conditions are met can the sprinkler system operate in these circumstances, namely one or more sprinklers must be open and the fire alarm system must detect a fire and open the valve separating the sprinkler conduit from the water supply conduit.
This type of combined system is used only for certain purposes, for the simple reason that the additional pre-action system with its fire alarm imposes a check upon the operation of the sprinkler system which does not exist in prior-art sprinkler systems that do not have a pre-action system. Of course, this combined type of system has its advantages, namely if it is for instance installed in structures housing computer installations or the like, where it is absolutely essential that water damage be incurred only if a fire is actually present, not if for some reason one of the sprinklers of the system should malfunction and open without the presence of a fire. The disadvantage of this type of system is, of course, the fact that if the fire alarm system should not properly operate, either as an actual malfunction or because the electrical energy required for its operation should not be available, the sprinkler system cannot operate at all, even if one or more of the sprinklers themselves should open. This means, in other words, that a fire might conceivably occur which would not be put out by operation of the sprinkler system, because the latter would be prevented from operating (even though its sprinklers should open) by the fact that the valve separating it from the water supply conduit is maintained closed due to the failure of the pre-action system to operate.
SUMMARY OF THE INVENTION
It is, accordingly, a general object of the present invention to overcome the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an improved sprinkler system of the type discussed above, provided with a pre-action system, which avoids the aforementioned disadvantages.
Another object of the invention is to provide such a sprinkler system which is highly reliable in its operation.
An additional object of the invention it to provide a sprinkler system of the type outlined above which is relatively simple in its construction.
In keeping with the above objects, and with others which will become apparent hereafter, one feature of the invention resides, in a sprinkler system, in a combination which comprises a sprinkler conduit and a water supply conduit. A diaphragm valve is interposed between the sprinkler conduit and the water supply conduit, and a pressure conduit communicates with a source of pressurized gas and with the diaphragm valve for the purpose of normally maintaining the latter closed by the pressure of the gas. A bypass conduit has one end portion communicating with the pressure conduit intermediate the source and the diaphragm valve, and another end portion which communicates with the sprinkler conduit. A magnetic valve is interposed in the bypass conduit, and a venting valve is interposed in the pressure conduit. A permanently energized electrical fire alarm circuit is connected with the magnetic valve and the venting valve and normally maintains both of them closed. This circuit is operative for opening the venting valve when detecting a fire, and for opening the magnetic valve in automatic response to the circuit becoming deenergized.
The electrical fire alarm circuit may be part of a fire alarm system that is of electrical, pneumatic or mechanical type.
By using the present invention, the sprinkler system is converted from an operation in which it depends upon the signals derived from the pre-action system, into a conventional sprinkler system in which it does not require such dependence for its operation and is completely reliable independently of whether or not the pre-action system may be malfunctioning or may not function at all due to a lack of electrical energy.
If, for instance, the supply of electrical energy is interrupted, or if the system is otherwise malfunctioning, this would inherently prevent the valve which separates the sprinkler conduit from the water supply conduit from opening even though a fire may have been detected by one or more of the sprinklers of the sprinkler conduit. The present invention, however, assures that as a result of the interruption of the electrical energy supply the magnetic valve which is interposed in the bypass conduit will automatically open, and provide for a connection between the sprinkler conduit and the pressure conduit, so that if a sprinkler of the sprinkler conduit opens under these circumstances, the pressure drop which occurs in the sprinkler conduit can be communicated via the now open magnetic valve to the diaphragm valve which will open as soon as the pressure drop has reached the operating level of the diaphragm valve, so that water can now enter the sprinkler conduit and issue from the same via the open sprinkler or sprinklers.
Of course, as pointed out above, the alarm system can be operated not only electrically, but also pneumatically or mechanically, in which case the magnetic valve would be replaced with a different type of control valve, that is a control valve which is either a pneumatically operated valve or a mechanically operated valve.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic illustration of a sprinkler system according to the present invention, with the separate fire alarm system having been omitted;
FIG. 2 shows in a diagrammatic presentation the fire alarm system which is used in conjunction with the embodiment of FIG. 1 and
FIG. 3 is a diagram, showing details of a component of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly to FIG. 1, it will be seen that in this embodiment the so-called pre-action system is illustrated, which utilizes a system of sprinkler conduits 18 (only one fragmentarily shown) provided with normally closed non-illustrated sprinklers of any type known per se. These sprinklers are provided with heat sensors which will open when they sense an increase in the ambient temperature above a preselected level. The system has a pre-action valve 1 which is interposed between the conduit system 18 and a water supply conduit 19. This valve 1 is of course normally closed, and is opened not by a pressure drop in the system 18 resulting from opening of one or more of the non-illustrated sprinklers, but by a separate fire alarm system.
The valve 1 is provided with a separate chamber 2 which is subdivided into two compartments by the diagrammatically illustrated diaphragm which, in turn, is connected via a linkage 20 with a valve member 21 that is maintained in closed position under normal operating circumstances. Removal of water takes place via a conduit or conduit system 22.
A conduit 17 is connected with the chamber 2 at the pressure side of the diaphragm therein and, in turn, communicates with a further conduit 15 which communicates with a non-illustrated source of pressurized gas, for instance air, which is diagrammatically identified with character A. A conduit 28 communicates with the conduit 15 and with the conduit system 18, and a further conduit 23 also communicates with the conduit 15 and with the conduit system 18. The direction of air flow from the source is identified by the arrow adjacent the character A.
A manually operable valve 3 is interposed in the conduit 15, as are a throttle valve 4 and a one-way valve 5. These may be combined into a single unit in known manner, if desired. In any case, the valves 3, 4 and 5 are located upstream of the conduit 17, insofar as the direction of flow of the incoming compressed air or gas is concerned. A further shutoff valve 6, throttle valve 7 and one-way valve 8 are interposed in the conduit 23. In addition, a conduit 14 branches off conduit 17 and has interposed in it a magnet valve 11 which is electrically connected with the fire alarm system shown in FIG. 2.
A conduit 16 communicates at its one end via the conduit 23 with the conduit system 18, and at its other end with the conduit 17, intermediate the conduit 15 and the chamber 2. A normally closed magnet valve 15 and a one-way valve 25 are interposed in the conduit 16. The magnet valve 12 is also connected with the fire alarm system shown in FIG. 2.
The conduit 23 which communicates with the conduit system 18, is also connected with a pressure measuring gauge 9 and a pressure switch 10. A further pressure switch 13 is provided which is connected with the valve 1 to provide a signal when the latter opens.
In operation of the system thus far described, it will be appreciated that in standby condition the pre-action valve 1 is closed. It is maintained closed by the pressure of compressed gas which is derived from the source A via the conduits 15 and 17 and exerts enough pressure in the chamber 2 upon the diaphragm therein to maintain the valve member 21 in closed position. This compressed gas is contantly supplied via the valves 3, 4 and 5 at the level necessary to maintain the valve member 21 in closed position, and at the same time additional compressed gas is supplied via the valves 6, 7 and 8 into the conduit system 18 so that the latter is pressurized, given the fact that its sprinklers are normally closed unless they detect an increase in ambient temperature. The pressure at which the conduit system 18 is to be maintained, can be determined from the gauge 9 and if a dangerous drop in the pressure in the conduit system 18 should take place, the pressure switch 10--which has been set to provide a signal before the level of pressure in the conduit system 18 can drop to the level where the sprinkler system can operate-- will provide such a signal to alert a user. In this operating condition the valves 11 and 12 are closed, as are the valves 26 and 27.
If, now, the separately installed fire alarm system of FIG. 2 should operate, indicating that it has a detected a fire, it will provide an impulse to the valve 11, causing the same to open. This vents the conduits 15, 17 via the valve 8, causing a pressure drop in these conduits. When a certain pressure drop has occurred, for instance by one atmosphere, the diaphragm in the chamber 2 is no longer sufficiently deflected, and the spring which biases it in opposition to the pressure exerted upon it by the pressurized gas, will now deflect the diaphragm (to the left in FIG. 1) and cause the valve member 21 of the valve 1 to open. This permits water to flow from the conduit 19 into the sprinkler conduit system 18. Assuming that the fire detected by the fire alarm system of FIG. 2 was sufficiently significantly so that one or more of the sprinklers of the conduit system 18 have also opened, water will now issue from these sprinklers to put out the fire.
When the valve 1 opens, a normal alarm will be given as in the case of other systems of this type, by means of one or more non-illustrated components such as bells or the like. At the same time, the pressure switch 13 can supply a signal to an indicating board at a fire station or the like.
Should only one sprinkler in the system 18 open, then a pressure drop will occur in the system 18 since the amount of gas that can escape through the sprinkler which has opened is substantially greater than the amount of gas that can re-enter via the throttle valve 7. This pressure drop will be observable, because it will cause the pressure switch 10 to originate a signal indicative of the existence of a pressure drop.
If, as is of course inevitable, the alarm system of FIG. 2 should malfunction or its energy supply (assuming it is electrically energized) should be interrupted, then the valve 1 would not properly operate even though a fire might be present because it is maintained close by the gas pressure. However, in the case of a malfunction or in the event the electrical energy supply should be interrupted, the normally energized and normally closed magnet valves 11 and 12 will become deenergized and as a result will immediately open. This produces a communication between the sprinkler conduit system 18 on the one hand, and the control conduit system composed of the conduits 14, 15 and 17 on the other hand. This, in turn, means that the system now operates as a normal sprinkler system known from the art, in that if a sprinkler in the conduit system 18 should now open, a pressure drop will take place in the conduit system 18. Unlike the previously described result of such a pressure drop, however, in this instance the pressure drop will be communicated to the chamber 2 resulting in a drop of pressure in the chamber 2 also, and permitting an automatic opening of the valve member 21 of the valve 1 as soon as the pressure acting upon the diaphragm in the chamber 2 has dropped sufficiently.
FIG. 2 shows the fire alarm system which is used in conjunction with the embodiment of FIG. 1 and which here is of an electrical type. Reference numeral 29 identifies a source of electrical energy, and reference numeral 30 identifies a conductor which connects the source 30 with a detector arrangement 31. The conductor 34 is also electrically energized and will be seen to be connected with the valve 12, to maintain the same in closed position.
In the event a fire is detected, the arrangement 31 produces an electrical communication between the conductors 30 and 32, which results in the development of an electrical signal at the control box 35 which, in turn, supplies electrical energy via the conductor 33 to the magnetic valve 11, causing the same to open so that the conduits 15, 17 can vent and the pressure in them drop. At the same time, the control box 35 cuts off electrical energy to the conductor 34, and this causes the valve 12 to open also.
The above operation is the one which takes place if the system in FIG. 2 operates in its intended manner. If, however, the system should malfunction or the supply of electrical energy from the source 29 should be interrupted for any reason, then the conductor 34 will no longer carry electrical energy and this will cause the valve 12 to immediately open and to switch over the system to pressure-controlled operation as described earlier.
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 type described above.
The elements designated with numerals 101-109 in FIG. 1 are well known per se in this field of art: they have therefore been shown only diagrammatically. Elements 101, 102 and 103 are valves which are manually operated and serve to drain water from the system. Element 104 is a water pipe with an associated pressure indicator 105 to permit monitoring of the water supply pressure in the system. Elements 106 and 108 are alarm conduits and element 107 a test valve for testing of the alarm conduits. Normally, the valve 107 will be in the illustrated position. In the event of fire, valve member 21 moves to open position and water flows into conduit system 18. At the same time, water can now also flow into conduit 106 and from the same via valve 107 into conduit 108. The latter may have a bell or other signalling device interposed in it, which is activated by the entry of the water and provides an alarm signal. Element 109, finally, is a filter which prevents the entry of contaminants into the (not illustrated) signalling device, since this could render the device inoperative. Details of the element 35 of FIG. 2 are shown by way of example in FIG. 3. Such elements are well known per se, being for instance manufactured by the General Electric Co. The elements 31 are contact-type sensors which complete an electric circuit when they sense fire, smoke, etc. When this takes place, current can flow from source 29 via line 32 and open valve 11. Element 35 uses a relay (see FIG. 3) which operates when current flows in this manner, closing the switch a and raising the switch b (see FIG. 3). This causes current to flow in line 33 and to be interrupted in line 34. The latter result causes the magnetic valve 12 to open. If current supply is interrupted, current ceases to flow in line 30 and line 34, so that in this case also the valve 12 will open.
While the invention has been illustrated and described as embodied in a sprinkler system, 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 and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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A sprinkler system having a pressurized sprinkler conduit which is separated from a water supply by a normally closed valve, and a fire alarm system having a circuit which is connected with this valve and opens the same in response to the detection of a fire by the circuit, is operated by detecting the absence of electrical energization of the fire alarm circuit, and thereupon operating the sprinkler system as a function of pressure losses in the sprinkler conduit rather than as a result of the operation of the fire alarm system.
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This application is a continuation of application Ser. No. 062,550 filed July 31, 1979 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a seat belt retaining device for an automotive vehicle or the like.
2. Description of the Prior Art
The tendency toward higher speeds of automotive vehicles has come to require seat occupants to wear seat belts. It is usually the practice to manually operate the seat belt each time one gets into and out of the vehicle, but it has recently become desirable to mount a passive device which automatically fastens or releases the belt in response to the opening or closing of a door or to entering and leaving the seat to eliminate the trouble to manually operate the seat belt. Such passive devices, however, typically have suffered from a disadvantage that when an impact is exerted on the vehicle by collision or overturning of the vehicle or when a sudden acceleration or deceleration is applied to the vehicle, the seat occupant maybe thrown out of the vehicle due to the opening of the door and consequent releasing of the belt as a result of the shock of collision or the like. It may occur to mind to provide the belt moving mechanism with an emergency locking device to prevent the belt from being loosened during such impacts, but if this device is operatively associated with a door latch, it could slip out when the door is opened by accident. If the device is made independent of the door latch, the door cannot be opened from outside when locked.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the various disadvantages as noted above and to provide a simple seat belt emergency locking device which can positively retain the seat belt during an impact and which prevents the seat belt from being released even when the belt moving mechanism is pulled intensely or the door is opened.
If the seat belt system is of the passive type which is operatively associated with opening and closing of a door, engaging means connected to the seat belt is constructed as a moving device movable between a seat occupant non-restraining position and a seat occupant restraining position in response to opening and closing of the door, and this moving device is retained in the seat occupant restraining position by retaining means provided on the vehicle body side.
It is an object of the present invention to provide a moving device of simple construction in such a passive type seat belt system.
Further, there is an undesirable possibility that a strong force exerted on drive means for driving such a moving device may destroy the moving device and the retaining means therefor.
It is therefore an object of the present invention to provide a seat belt system in which the moving device and its retaining means are not destroyed irrespective of any strong force exerted on the drive means.
The invention will become fully apparent from the following detailed description thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an example of the passive type seat belt system.
FIG. 2 is an exploded view of the moving device according to an embodiment of the present invention.
FIG. 3 is an exploded view of the vehicle body side retaining means of the embodiment of FIG. 2.
FIG. 4 is a schematic cross-sectional view showing the moving device retained by the retaining means.
FIG. 5 is a bottom view corresponding to FIG. 4.
FIG. 6 is a view similar to FIG. 4 and showing the moving device retained by an emergency locking means.
FIG. 7 is a bottom view corresponding to FIG. 6.
FIG. 8 is a view showing the moving device released from the retaining means.
FIG. 9 is a bottom view corresponding to FIG. 8.
FIG. 10 is a partial illustration of the pendulum type inertia sensing means.
FIG. 11 shows the operative state of the inertia sensing means.
FIG. 12 is an illustration of a standing pendulum inertia sensing means.
FIG. 13 illustrates the operation thereof.
FIG. 14 is an illustration of an inertia sensing means using a ball.
FIG. 15 illustrates the operation thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will hereinafter be described with reference to the drawings.
FIG. 1 illustrates a mechanism in which the present invention is carried out in a passive type seat belt in which mounting and dismounting of a belt is effected in response to the opening and closing of a door. The safety belt 6 is connected to a conventional retractor 7 attached to a seat in a vehicle, and the belt 6 is attached to the tongue 5 of an emergency release buckle 3. The buckle 3, the tongue 5 and a tongue portion 2 extending integrally from the tongue together form a runner R. The runner R is pulled by a wire 8 passed over a drive pulley 9 driven by opening and closing of the door, and is movable on a guide (not shown) in the direction of the arrow. When the door is open, the runner R is moved leftwardly as viewed in FIG. 1 and the belt is released to permit a seat occupant to come freely in and out from under the belt, and when the door is closed, the runner R is moved rightwardly by operation of the pulley 9 to tighten the seat belt 6 against the seat occupant. The tongue portion 2 comes into a latch portion 4 attached to the inner wall of the vehicle to hold the seat belt 6 in its tightened condition. An emergency locking device operable during an impact or the like is attached to the latch portion 4, as will hereinafter be described. Of course, the device of the present invention is applicable not only to the passive type seat belt system but also the so-called active seat belt system in which the seat occupant inserts the tongue portion into the latch portion each time he gets into and out of the vehicle.
FIG. 2 is an exploded view of the tongue portion 2. The tongue portion 2 comprises three parts which are a central base tongue 21 and lateral covers 22 and 23 lying on the opposite sides of the base tongue. The base tongue 21 is connected to the belt 6 through the tongue 5 secured to the emergency release buckle 3 and retained by this buckle. The first lateral cover 22 and the second lateral cover 23 are attached to the opposite sides of the base tongue 21. The two lateral covers 22 and 23 are fastened by caulking pins 31 extending through holes 22b and 23b formed therein and slots 21b formed in the base tongue 21, and the base tongue 21 may thus move slidably between the two lateral covers 22 and 23. The side of the lateral cover 23 adjacent mounting portion 24 having a recess 25 in which the projected portion 26' of a wire fastener 26 is fitted. The wire 8 has a part thereof securely fastened to the wire fastener 26 by means of a wire keeper member 27. Shear pins 30 are passed through holes 22a in the cover 22, slots 21a in the base tongue 21, holes 23a in the cover 23 and holes 26a in the projected portion 26 to secure the wire fastener 26 to the cover 23. These shear pins may be broken when a strong force of a predetermined magnitude is exerted on the wire, to permit separation between the cover 23 and the wire fastener 26 and thereby prevent any further force from being exerted on the tongue portion 2 by the wire. A spring support 28 is secured to the base tongue 21 by inserting a pin (not shown) through a hole 28c in the spring support and a hole 21c in the base tongue 21. A spring 29 is interposed between the mounting portion 24 and the spring support 28 to bias rightwardly the fasteners for the lateral covers 22 and 23 relative to the base tongue 21. Thus, the shear pins 30 and caulking pins 31 normally contact the right end of the slots 21a, 21b of the base tongue 21 (see FIGS. 4 and 5).
FIG. 3 shows the details of the latch portion 4 and emergency locking device E. A housing 41 into which the tongue portion 2 is to be inserted is in the form of a box having an open lower end and having an outer plate 41' and a base 41" attached to the inner wall of the vehicle. The outer plate 41' has a sector hole 41a into which a pallet 43 is fitted and holes 41b for receiving pins 49 holding a lateral member 42 in position, and the base 41" also has a hole 41d for mounting the same onto the vehicle.
The lateral member 42 may be attached to the housing 41 by inserting it into the lower open end of the housing 41 and inserting the pins 49 into the holes 41b of the base and 42b of the lateral member. A spring 44 is provided in a cavity formed by the pallet 43 in the sector hole 41a of the housing and the recess 42c of the lateral member. A bottom plate 45 is mounted on the opposite side of the base 41" and a slider 46 is placed within the bottom plate, and a pulley 47 for turning back the wire 8 is contained in a recess 46a of the slider. Springs 48 are interposed between an end wall 45' at the side of the bottom plate 45 which is adjacent to the belt (the left side as viewed in FIG. 3) and the slider 46. This end wall 45' is formed with a hole 45a through which the wire may pass. Thus, the wire 8 is turned back by the pulley 47 from the drive pulley 9 through the wire fastener 26 and guided by the drive pulley 9. Accordingly, when the drive pulley 9 drives the wire 8 in accordance with the opening and closing of the door, the runner R including the tongue portion 2 moves leftwardly or rightwardly.
Further, a lever supporting bed 50 is attached to that side of the base 41' which is adjacent to the belt (the left side as viewed in FIG. 3) as by inserting screws into holes 50c. A lever 55 is tiltably mounted on projected portions 58 of the supporting bed 50 by means of a pin 52 passing through holes 50b in the projected portions 58. A rod 51 is passed through a hole 50a in the supporting bed 50 and a pendulum 53 is attached to the lower end of the rod 51, and a semi-spherical head 56 of the lever 55 rests on the upper flat head 51' of the rod 51. When the pendulum swings upon an impact exerted on the vehicle, the head 56 of the lever is pushed by the flat head 51' so that the lever 55 is tilted to cause the end 57 thereof to move into a cut-away 41c formed in the upper wall of housing 41.
On the upper side edges of the three pieces 21, 22 and 23 of the tongue portion 2, there are provided similarly configured teeth 21d, 22d and 23d which are engageable with its end 57 of the lever through the cut-away 41c. On the opposite side, the base tongue 21 has teeth 21e engageable with the pallet 43, and the covers 22 and 23 have teeth 22c and 23c each having a gently inclined cam surface for releasing the engagement between the tooth 21e and the pallet 43, as will be described below.
Operation of the device of the present invention will now be described.
FIG. 4 shows a position in which the tongue portion 2 has come into the housing 41 but the lever end 57 of lever 55 has not yet come into the cut-away 41c. FIG. 5 is a bottom view of the structures shown in FIG. 4. When the tongue portion is assembled, as described previously, the spring 29 presses the portion between the spring support 28 attached to the base tongue 21 and the thick-walled portion of the second lateral cover 23, whereby the second lateral cover 23 and the first lateral cover 22 fastened thereto are pushed relative to the base tongue 21 rightwardly as viewed in the Figure, and as shown in FIGS. 4 and 5, the shear pins 30 and the caulking pins 31 are in contact with the right end of the slots 21a and 21b of the base tongue 21. As already mentioned, when the door is opened, the wire 8 on that side which is held to the cover 23 of the tongue portion 2 is directly pulled toward the pulley 9 and, when the door is closed, the wire is pulled by the drive pulley 9 through the pulley 47 and therefore, the runner R including the tongue 2 is pulled rightwardly and the tongue portion 2 is inserted into the housing 41 of the latch portion 4, so that the belt 6 restrains the seat occupant.
Even if the belt 6 is pulled and the base tongue 21 tries to move leftwardly in the Figure, a tooth 21e of the base tongue 21 is engaged with the pallet 43 inwardly forced by the spring 44, to thereby prevent the tongue portion 2 from slipping out (see FIG. 6). When the door is opened, the wire now pulls leftwardly the runner including the tongue portion. When the wire pulls the two covers 22 and 23, in FIGS. 8 and 9 which are similar to FIGS. 4 and 5, the base tongue 21 is held by the tooth 21e thereof engaged with the pallet 43, so that the two covers 22 and 23 leftwardly move relative to the base tongue 21 through the slots 21a and 21b against the force of the spring 29, and the gently inclined teeth 22c and 23c slide over the pallet 43 to force the pallet 43 outwardly against the force of the spring 44, and thus the engagement between the pallet 43 and the tooth 21e is released and the entire tongue portion 2 is leftwardly disengaged from the housing 41, whereby the runner is moved leftwardly to bring about a seat occupant non-restraining position.
FIGS. 10 and 11 show an embodiment of the inertia device of the emergency locking device of the present invention. FIG. 10 shows the device in a normal position in which the pendulum 53 depends to vertically and FIG. 11 shows the device in a position in which the pendulum has swing due to an impact. When the pendulum swings due to an impact as shown in FIG. 11, the head 56 of the lever 55 is pushed by the flat head 51' of the rod 51 of the pendulum 53 and the lever tilts about the pin 52 so that the end 57 of the lever comes into the cut-away 41c and engages the teeth 21d, 22d and 23d of the tongue portion as shown in FIGS. 6 and 7. The tongue portion is thus held in position even if the door should be flung open. A torsion spring 54 is wound on the pin 52 and secured to the lever and the supporting bed. By selecting the strength of the torsion spring, design can be such that the pendulum does not operate unless an impact greater than 1 G is exerted and the emergency locking device is not operated during the stoppage of the vehicle on a steep slope or during the overturn of the vehicle when a great shock such as that during collision is not exerted.
FIGS. 12 through 15 show further embodiments of the inertia device. In the embodiment shown in FIGS. 12 and 13, a vertical weight 153 stands upright on a supporting bed 150 attached to the base 41" and the head 56 of the lever 55 rests on top of the weight 153. When the weight is tilted by an impact, the head of the lever 55 is pushed to tilt the lever. In the embodiment shown in FIGS. 14 and 15, the supporting bed 250 attached to the base 41" has a cavity 250' having an inclined surface 250" and contains a steel ball 253 therein. The head 56 of the lever 55 rests on the steel ball with a pressing member 251' interposed therebetween. Normally, the steel ball 253 is located in the lowermost bottom of the cavity, but when subjected to a shock, the steel ball moves on the inclined surface 250" due to inertia to thereby raise the pressing member 251' and accordingly, raises the head 56 of the lever 55 upwardly as shown in FIG. 15. By this, the lever 55 is tilted.
Description will now be made of the action of the shear pin 30. As shown in FIG. 6, during an impact, the end 57 of the lever 55 comes into the cut-away 41c to hold the teeth 21d, 22d and 23d to prevent to tongue portion 2 from slipping out and prevent the belt from being released even if the door should be flung open violently. If the lever is made of a metal material, it will be sturdy but heavy so that a large pendulum or the like will be required to operate the lever, whereas if the lever is made of synthetic resin, it will be light in weight but not sufficiently strong so that if a great impact load greater than a certain degree is exerted by the door being flung open violently, the lever itself might be destroyed. Therefore, the shear pin 30 is inserted through the hole 22a of the first lateral cover 22, the hole 21a of the base tongue 21 and the hole 23a of the second lateral cover 23 to thereby fix the projected portion 26' of the wire fastener 26 in the recess 25 of the mounting portion 24 of the cover 23. The shear strength of the shear pin 30 is selected to a level weaker than that of the lever 55. If the wire 8 is pulled by a force stronger than the shear strength of the shear pin, the shear pin will be broken and only the wire fastener 26 will slip out of the recess 25 of the cover 23 by being pulled by the wire 8, so that no more force will be exerted on the tongue portion 2. In this manner, the shear pin will first be broken if the door should be flung open violently and therefore, the lever 55 will never be broken.
In the emergency locking device according to the present invention, as has hitherto been described, when subjected to a sudden impact during collision or the like, the inertia device such as a pendulum or the like is operated to tilt the lever and prevent the tongue portion from slipping out of the latch portion due to the impact and when the inertia device restores its horizontal position upon stoppage of the impact, the lever becomes disengaged so that the seat occupant may open the door to release the seat belt or if the opening-closing mechanism operatively associated with the door has gone wrong, the seat occupant may depress the button of the emergency release buckle 3 attached to the tongue portion to remove the safety belt. Since the slider 46 containing therein the pulley 47 on which one end of the wire 8 is wound is supported by the spring 48, the slider 46 and accordingly, the tongue portion 2 may move when a great force is exerted on the wire 8, so that application of an unreasonable force is generally avoided and the engagement of the teeth of the tongue may be well effected.
The present invention provides a simple seat belt emergency locking device of the above-described construction which is reliable in operation. It will be apparent that the present invention is applicable to various embodiments without departing from the spirit of the invention as defined in the appended claims.
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A seat belt latch device has latch means for retaining an engaging member coupled to a seat belt. The latch means includes inertia sensing means for sensing a predetermined variation in speed of a vehicle, and a retaining member responsive to the sensing operation of the inertia sensing means. The retaining means retains the engaging member when there is a predetermined variation in speed of the vehicle.
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