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This is a continuation of Ser. No. 951,709 filed Oct. 13, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sewing machine for sewing pieces of cloth.
2. Description of the Prior Art
When pieces of cloth are sewn together to make clothing, it is necessary, even in the making of a single article of clothing, to select the way of sewing suitable for a variety of sewing types. That is, for example, when an edge of a piece of cloth is stitched, overedge stitching is employed, and on the other hand, when a plurality of pieces of fabric are sewn together, lockstitching is employed. Because of such stitching requirements, if two sewing machines, one for the lockstitching and the other for the overlock sewing, have to be accommodated for example in an ordinary household, it poses a problem that these machines occupy a very large space when they are put in a house-work room.
In addition, when articles of clothing are made in the household, there is often involves the procedure of applying the overedge stitching to a first portion thereof, thereafter the overedge stitching to a second portion, and the overlock sewing to a third portion, and thereafter again the lockstitching thereto. In such case, if an attempt is made to perform sewing using two different sewing machines, the operation, in which an operator leaves one seat and takes the other seat where sewing takes place and thereafter the operator returns to the first seat for sewing, must be repetitiously conducted.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a sewing machine in which two modes of sewing, one for lockstitching and the other for overedge stitching can be achieved by a single sewing machine.
It is a further object of the present invention to provide a sewing machine in which even in the case where the two modes of sewing as described above are alternately carried out, either way of sewing may be immediately conducted by only slight movement of the hand.
It is another object of the present invention to provide a sewing machine of a compact style externally similar to conventional sewing machines which can merely perform a single way of sewing, despite the fact that the proposed sewing machine may perform two modes of sewing as previously mentioned.
Other objects and advantages of the invention will become apparent during the following discussion of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view, partly in section, of a sewing machine;
FIG. 2 is a side view on the right side;
FIG. 3 is a longitudinal sectional view of a selecting mechanism;
FIG. 4 is a front view showing the state of the sewing machine in the case of overedge stitching;
FIG. 5 is a side view on the left side, partly in section, showing the state similar to that of FIG. 4;
FIG. 6 is a plan view showing the state where lockstitching and overedge stitching are alternately carried out;
FIG. 7 is an exploded perspective view showing a modified form of embodiment;
FIG. 8 is a front view, partly in section, showing the state where the overedge stitching is carried out by the sewing machine shown in FIG. 7;
FIG. 9 is a perspective view of a cloth holding section;
FIG. 10 is a perspective view of a cover for covering an overedge stitching mechanism;
FIG. 11 is a front view showing the state where the overedge stitching mechanism is covered with the cover; and
FIG. 12 is a front view showing the state where an upper mechanism in a lockstitching mechanism is covered by a cover.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 6, the reference numeral 10 designates a machine frame of the entire sewing machine. This machine frame 10 comprises a bed 11, an upright support 12 uprightly extended from the bed 11, and an arm frame 13 extended parallel with the upper surface of the bed 11 from the upper end of the upright support 12. The arm frame 13 comprises an arm frame body 14 integral with the upright support 12 and a head 15 connected to the foremost end of the arm frame body 14. The head 15 is rotatably mounted on the arm frame body 14. That is, the arm frame body 14 is formed at its foremost end with a bearing hole 16 whereas the head 15 has a shank 17, which is rotatably received in the bearing hole 16. In a connection between the arm frame body 14 and the head 15, the arm frame body 14 has a projection 18 extended therefrom, which projection 18 threadedly receives an adjusting screw 19. On the other hand, the head 15 has a stop 20 attached thereto. When the stop 20 bears on the tip of the adjusting screw 19, a needle in the lockstitching mechanism later described herein is properly opposed to a shuttle also later described herein. It should be noted that the arm frame body 14 is provided with a fastening handle 21 used to lock the head 15 which is in turn provided with a handle 22 for rotation and operation thereof.
Next, a lockstitching mechanism 24 will be described. The lockstitching mechanism 24 comprises an upper mechanism 25 disposed in the head 15 and a lower mechanism 26 disposed interiorly of the bed 11. These are constructed similarly to a conventional sewing machine. Namely, in the upper mechanism 25, an arm shaft 28 for lockstitching is inserted in a hole 27 bored in a central position of the shank 17, and a thread take-up cam 29 is mounted on one end of the arm shaft 28. The cam 29 has a thread take-up lever 30 connected thereto. The head 15 has a needle bar 31, with a needle 33 attached to a lower end thereof, mounted thereon and movable up and down. The needle bar is needle-bar connected to the cam 29 through a connecting rod 32. The head 15 is provided with a presser bar 34 movable up and down, the presser bar 34 having a presser foot 35 attached to a lower end thereof. The head 15 further has a thread tension regulator 36 mounted on the outer surface thereof. Next, in the lower mechanism 26,a shuttle 37 is positioned below the needle bar 31 in the upper mechanism 25. The shuttle 37 has a shuttle driving mechanism 38 connected thereto, which in turn has an oscillating driving shaft 39 connected thereto. The driving shaft 39 is connected to the arm shaft 28 through connecting rods 40 and 41. Accordingly, when the shaft 28 rotates, the needle bar 31 moves up and down and the shuttle 37 also turns in association therewith, whereby a needle thread passed through the needle 33 cooperates with a bobbin thread within the shuttle 37 to effect lockstitching of clothes.
An overedge stitching mechanism 44 will now be described. This overedge stitching mechanism 44 is also constructed similarly to a mechanism of a conventional overedge stitching machine. That is, the upright support 12 is interiorly provided with an overedge stitching spindle 45 which is laterally supported in a side wall 12a and a bearing member 46. A rotary plate 47 is mounted on one end of the spindle 45 and one end of a crank rod 48 is pivotally mounted at an eccentric position of the rotary plate 47. The crank rod 48 has the other end connected to a needle bar 49 which is supported movably up and down on supporting members 50 and 51. Thus, when the spindle 45 rotates, the needle bar 49 moves up and down in association therewith. It will be noted that a needle 52 is attached to the lower end of the needle bar 49.
An eccentric 55 is secured to the spindle 45 and an annular member 56 fits in an outer peripheral surface of the eccentric 55. A suspending rod 57 is integrally connected to the annular member 56. A transmission rod 58 connected to the lower end of the rod 57 extends externally of the upright support 12 passing through a slot 59 bored through a side wall 12c in the form of a concavity in the upright support 12 and is connected to a midportion of an oscillatory arm 60 having one end pivotally mounted on the side wall 12c. The oscillatory arm 60 has a cloth cutting edge 61 attached to the other end thereof.
With this construction, when the spindle 45 rotates, the oscillatory arm 60 is oscillated up and down through the rod 57 so that the cloth cutting edge 61 may cut an edge of an article of clothing to be overedge stitched.
Also, an eccentric 64 is secured to the spindle 45 and an annular member 65 fits in an outer peripheral surface of the eccentric 64. A suspending rod 66 is integrally connected to the annular member 65. The rod 66 has its lower end connected to a looper driving member 67 so that when the spindle 45 rotates to move the rod 66 up and down, the looper driving member 67 is actuated and a looper 68 is then operated in association therewith.
Further, a triangular cam 69 is secured to the spindle 45. An upper end of a bifurcated rod 70 is opposedly close to the triangular cam 69. A lower end of the bifurcated rod 70 is brought into association, in a known manner, with a feed dog 73 exposed at the upper surface of the bed 11, through a lever 71, a shaft 72 and the like. Accordingly, when the spindle 45 rotates to cause the needle bar 49, the cloth cutting edge 61 and the looper 68 to actuate, the feed dog is 73 is also associated therewith to effect the cloth feeding operation. It will be noted that a feed-amount setter 74 is connected to a midportion of the bifurcated rod 70 so that the amount of feeding of cloth the cloth feed dog 73 may be adjusted by operation of a lever 75.
Next, a selecting mechanism 77 is provided on the side wall 12a of the upright support 12. The aforementioned lockstitching arm shaft 28 and the overlock sewing spindle 45 are designed to be interlocked with a motor 88, which serves as a driving device, through the selecting mechanism 77. This selecting mechanism is principally shown in FIGS. 1 and 3. That is, pulleys 78 and 79 fit in the shaft 28 and spindle 45, respectively, so that the former may be freely rotated with respect to the shaft 28 and spindle 45, respectively, but may not be moved in an axial direction. Clutch members 80 and 81 are connected to the ends of shaft 28a and spindle 45a, respectively, in a splined manner so that the former may be rotated integral with the spindles, respectively, and may be moved in an axial direction. Mutually opposed surfaces in the pulleys 78 and 79 and the clutch members 80 and 81, respectively, are formed with a pair of concave portions 82 and 83 and raised portions 84 and 85 adapted to be fitted or disengaged from each other. Accordingly, when the raised portion 84 is fitted in the concave portion 82, the pulley 78 and shaft 28 integrally rotate, and when the raised portion 85 is fitted in the concave portion 83, the pulley 79 and spindle 45 integrally rotate. In order to be driven by the motor 88, the pulleys 78 and 79 are connected with a pulley 89 mounted on a rotary shaft of the motor 88 by belts 86 and 87. It will be noted that the motor 88 is mounted on the back of the upright support 12 through a bracket 90.
In the operation of lockstitching of clothes using the sewing machine as constructed above, the selecting mechanism 77 may be operated so that rotation of the motor 88 is transmitted only to the arm shaft 28 for lockstitching. The head 15 is placed to assume a position as shown in FIG. 1 with respect to the arm frame body 14 and secured by the fastening handle 21. When the motor 88 is rotated in a state as described above, the lockstitching for clothes may be accomplished by the lockstitch mechanism 24 entirely similarly to a conventional lockstitch sewing machine and in a state as indicated by full line in FIG. 6.
Next, in the operation of overedge stitching of clothes, the selecting mechanism 77 may be operated so that rotation of the motor 88 is transmitted only to the spindle 45 for overedge stitching. The head 15 is placed to assume a position as shown in FIG. 5 with respect to the arm frame body 14 and secured by the fastening handle 21. When the motor 88 is rotated in a state as described above, the overedge stitching for clothes may be accomplished by the overedge stitching mechanism 44 entirely similarly to a conventional overedge sewing machine and in a state as indicated by phantom line. In this case, even if the upper mechanism 25 in the lockstitch mechanism 24 is disposed at the foremost end of the arm frame 13, it is positioned greatly withdrawn from the upper surface of the bed 11 as shown in FIG. 5. Hence, the upper mechanism 25 will not stand in the way of clothes 91 to be overedge stitched as shown in FIG. 4. This facilitates the overedge stitched work.
It should be appreciated that in alternately carrying out the lockstitching work and overedge stitching as previously mentioned, the lockstitch mechanism 24 and the overedge stitching mechanism 44 are positioned with respect to the machine frame 10 as previously mentioned in the present sewing machine, so that either way of sewing may be initiated immediately only by slight movement of hand as shown in FIG. 6.
Also, in this case, either sewing mechanism 24 or 45 may merely be moved by means of the selecting mechanism 77. Accordingly, the driving force of the motor 88 required is not very much. Further, there prevention of accidents involved in a case, for example, where clothes to be lockstitched erroneously get entangled in the overedge stitching mechanism 44 during the operation of lockstitching sewing.
Moreover, since the upright support 12 is interposed between the lockstitch mechanism 24 and overstitch stitching mechanism 44, which are positioned to left of the upright support 12, and the selecting mechanism 77, which is positioned opposite thereof, clothes may be moved by the left hand and at the same time, the selecting mechanism 77 may be operated by the right hand, during the operation as mentioned above.
Next, FIGS. 7 and 8 illustrate a different form of embodiment. Those sewing machines shown in these figures are so designed that an upright support 12e is provided separately from an arm frame 13e, both being connected by a bolt 110 as a connecting member.
A bed 11e is designed in the form of an elongated structure and being raised from a base 111 so that the sleeves of a coat may be conveniently sewn.
In addition, in the selecting mechanism 77e, a belt 87e used to rotate a pulley 79e is passed over a pulley 112 secured to a pulley 78e.
In such sewing machines wherein the upright support 12e is separated from the arm frame 13e, it is possible to easily perform machining of a hole for supporting a needle bar 49e in an overedge stitching mechanism 44e, machining a hole for supporting a spindle 45e for overedge stitching, machining a hole for carrying a base of a looper 68e or work for affixing various parts to these holes.
Those parts in sewing machines shown in FIGS. 7 and 8 considered to have identical or equal constructions in terms of function to those sewing machines shown in FIGS. 1 through 6 are indicated by reference numerals with a suffix e added thereto to avoid the need for duplicate description.
Next, FIG. 9 shows a detailed construction of a presser foot in the overedge stitching mechanism 44e of the sewing machine shown in FIG. 8. A shaft 113 supported on an upright support 12ce is normally biased by a spring 114 shown in FIG. 8 in a direction as indicated by the arrow 116. The shaft 113 may be rotated in a direction as indicated by the arrow 117 by means of a handle 115 mounted on one end thereof. The shaft 113 has a bracket 118 secured to the other end thereof, and a holder member 119 for holding a presser foot 54e is pivotally mounted on the bracket 118 by a pin 120. The aforesaid pivotal position is displaced from a center line 122 of the presser 54e through a distance as indicated at W.
The abovementioned construction, in which the cloth holder 54e is supported, allows the presser foot 54e, when a thread is passed through a needle 52e shown in FIG. 8, to be moved in a direction as indicated by the arrow 123, thus facilitating work of passing a thread through a needle.
Further, where the presser foot 54e is then returned to a position as shown in FIG. 9 for sewing of clothes, when the clothes are fed in a direction as indicated by the arrow 124, the presser foot 54e is always maintained in a position as shown by the presence of the aforesaid distance W.
FIG. 10 shows a cover 125 for covering the overedge stitching mechanism. In the operation of the lockstitching, the cover 125 covers up the overedge stitching mechanism as shown in FIG. 11 to prevent clothes from being entangled in the needle or other parts in the overedge stitching mechanism. The cover 125 may be attached to the upright support by placing a magnet 126 affixed to the cover 125 on the upright support or other suitable stop means.
Finally, FIG. 12 shows a state where the upper mechanism in the overlock stitching mechanism is covered up by a cover 127. In the operation of overedge stitching, the upper mechanism may be covered up by the cover 127 as just mentioned to thereby prevent clothes from being entangled in the needle in the upper mechanism or other parts. It should be noted that the cover 127 may be mounted in a manner similar to that is accomplished when the cover 125 is mounted.
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A machine body of -shape as viewed in front is formed of a bed, an arm frame laterally disposed above the bed, and an upright support uprightly extended from the bed and supporting one end of the arm frame at an upper end thereof. An upper mechanism of a locking stitching sewing mechanism is disposed in the free end of the arm frame and a lower mechanism of the lockstitching sewing mechanism is disposed below the upper mechanism within the bed so that cloth may be subjected to lockstitching by these mechanisms. An overedge stitching mechanism is provided in a recess within the -shaped body in order to apply overedge to the edge of the cloth.
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BACKGROUND OF THE INVENTION
Polyethylene terephthalate (PET) resin is widely utilized in manufacturing industrial yarn. Industrial yarn made utilizing PET usually has much higher modulus and tenacity than textile yarn made utilizing PET. Industrial yarn usually also has a much higher denier than textile yarn. For example, industrial PET yarns commonly possess a tenacity of at least 6.2 cN/dtex (centinewtons/decitex) and have a dtex of about 833 to about 2220, while textile polyester yarns commonly have a tenacity of only about 3.0 to 4.0 cN/dtex and have a decitex of about 111 to about 556. It is important for industrial yarns to have higher levels of modulus and tenacity to be useful as reinforcements for manufactured articles, such as tires, hoses, belts, and the like. Such industrial yarns are of particular value as reinforcements for tires, conveyor belts, and power transmission belts.
In many applications it is also important for industrial yarns to exhibit dimensional stability as well as high modulus and high tenacity. It has been widely recognized that higher melt spinning speeds usually result in the production of yarns which exhibit lower shrinkage. Unfortunately, the utilization of increased melt spinning speeds results in yarns which have reduced tenacity. Increased melt spinning speeds have accordingly not proven to be an acceptable means for commercially producing industrial yarns which exhibit low levels of shrinkage in combination with high tenacity. In fact, heretofore, melt spun filaments have been formed through the utilization of relatively low stress spinning conditions to yield spun filaments having relatively low birefringence of less than about 0.03. Such melt spun filaments are particularly amenable to subsequent hot drawing procedures whereby the required tenacity values are ultimately developed. Such as-spun filaments are commonly subjected to subsequent hot drawing which may or may not be conducted in-line when forming textile as well as industrial fibers to develop the desired tensile properties. Drawing procedures which are carried out subsequent to the melt spinning process can have a significant effect on drawn yarn shrinkage. However, drawing procedures alone cannot typically be used to significantly improve yarn dimensional stability.
SUMMARY OF THE INVENTION
The subject invention relates to a process for manufacturing high strength industrial yarn which exhibits low shrinkage. High strength industrial cord produced from the yarn of this invention preferably has a shrinkage as measured after 2 minutes at 350° F. (177° C.) of less than about 2% and more preferably has a shrinkage of less than about 1.5%. In the process of this invention, spun filaments having a birefringence of at least about 0.075 and a crystallinity of at least about 10% are prepared. This is normally done by melt spinning at a spinning speed which is in excess of 2,500 meters per minute. The spun filaments made are subsequently drawn in a heated zone to a draw ratio of at least about 1.05:1. It is important for the spun filaments to be in the heated zone for a residence time of at least 0.3 seconds. This is typically accomplished by utilizing a relatively slow speed multiple-end drawing procedure. Thus, the process of this invention is typically carried out utilizing a high spinning speed in conjunction with a lower drawing speed.
The subject invention more specifically discloses a process for manufacturing industrial yarn having high tenacity, high modulus and dimensional stability which comprises melt spinning polyethylene terephthalate into spun filaments and subsequently drawing the spun filaments in a heated zone to a draw ratio of at least 1.05:1: wherein the spun filaments have a birefringence of at least about 0.075 and a crystallinity of at least about 10%; wherein the spun filaments are in the heated zone for a residence time of at least 0.3 seconds: and wherein the yarn in the heated zone is at a temperature which is between the glass transition temperature and the melting temperature of the polyethylene terephthalate.
The subject invention also discloses a process for manufacturing industrial yarn having high tenacity, high modulus and low shrinkage which comprises drawing polyethylene terephthalate spun filaments in a heated zone to a draw ratio of at least 1.05:1: wherein the spun filaments have a birefringence of at least about 0.075 and a crystallinity of at least about 10%; wherein the spun filaments are in the heated zone for a residence time of at least 0.3 seconds; and wherein the yarn in the heated zone is at temperature which is between the glass transition temperature and the melting temperature of the polyethylene terephthalate.
DETAILED DESCRIPTION OF THE INVENTION
The spun filaments utilized in accordance with this invention are made by melt spinning PET. The PET used will typically have an intrinsic viscosity of at least about 0.8 dl/g. It is normally preferred for the PET to have an intrinsic viscosity of at least about 0.9 dl/g. It is most preferred for the PET to have an intrinsic viscosity of at least about 1.0 dl/g. The intrinsic viscosities referred to herein are measured in a 60/40 phenol/tetrachloroethane mixed solvent system at 30° C. The PET can be made by utilizing a batch process or a continuous process. For example, the PET can be made by the process disclosed in U.S. Pat. No. 4,755,587.
It is to be understood that the PET used in making the spun filaments utilized in accordance with this invention can contain minor amounts of repeat units derived from monomers other than terephthalic acid or a diester thereof and ethylene glycol. For example, small amounts of isophthalic acid can be polymerized into the PET used in making the spun filaments. Minor amounts of other aromatic and/or aliphatic polybasic dicarboxylic acids, known to those skilled in the art, can also be polymerized into the PET. Minor amounts of glycols other than ethylene glycol and polyhydric alcohols can also be polymerized into the PET. In some cases, it is highly desirable to utilize internal lubricant modified PET for improved processability. Thus, the PET utilized in making the spun filaments of this invention contains predominantly repeat units which are derived from terephthalic acid or a diester thereof and ethylene glycol, but can also contain small amounts of repeat units derived from other polybasic carboxylic acids, glycols, and polyhydric alcohols. Persons skilled in the art generally know how much of these other monomers can be incorporated into the PET without greatly affecting its properties and, thus, its usefulness in making the spun filaments of this invention. As a rule, this minor amount will not exceed about 5%. However, in most cases this minor amount will be less than about 3%. In the case of polyhydric alcohols, not more than about 1% will be incorporated into the PET. It will generally be preferred for the PET to be a homopolymer of terephthalic acid or a diester thereof and ethylene glycol.
The spun filaments are made by extruding molten PET through one or more spinnerettes having a plurality of openings. The number of openings in the spinnerette can be varied widely. For example, a standard spinnerette containing from 1 to about 600 holes can be utilized. In most cases, it will be desirable for the spinnerette to contain from about 95 to about 380 holes. Typically the yarns will contain from 190 to 380 filaments which can be produced utilizing split threadlines. The holes in the spinnerette typically have a diameter which is within the range of about 5 mils (0.01 centimeter) to about 50 mils (0.13 centimeter). It is generally preferred for the holes in the spinnerette to have a diameter which is within the range of about 10 mils (0.03 centimeter) to about 30 mils (0.08 centimeter).
The PET is, of course, supplied to the spinnerette at a temperature above its melting point and below the temperature at which it thermally degrades substantially. The molten PET being melt spun is preferably at a temperature within the range of about 275° C. to about 325° C. It is most preferable for the PET being melt spun to be at a temperature of about 280° C. to about 310° C. when it is extruded through the spinnerette.
Following extrusion through the spinnerette, the molten PET filaments are passed through a solidification zone wherein the molten PET filaments are uniformly quenched to transform them to solid spun filaments. The quench employed is uniform in the sense that differential or asymmetrical cooling is not contemplated. However, it is desirable to control the quenching of PET after it exits the spinnerette. This is because it is necessary to provide the spun filaments with sufficient spinning orientation to provide a minimum birefringence of at least about 0.075 and a crystallinity of at least about.10%. To attain the requisite birefringence and crystallinity, a high speed spinning procedure will normally be employed. As a general rule, a minimum spinning speed of at least about 2,500 meters per minute will be utilized. It is generally preferred for the melt spinning procedure to be carried out at a minimum speed of about 3,500 meters per minute. In most cases the spinning speed will be within the range of about 3,500 meters per minute to about 6,500 meters per minute.
To attain the requisite degree of spinning orientation, it is generally necessary for the product of the intrinsic viscosity of the PET and the spinning speed to be at least about 2,500 (dl·m)/(g·minute). It is preferred for this product to be at least about 3,000 (dl·m)/(g·minute). It is most preferable for the product of the intrinsic viscosity and the spinning speed to be in excess of about 3,500 (dl·m)/(g·minute). As a general rule, spinning orientation increases with an increasing product of the intrinsic viscosity and spinning speed. It is normally advantageous for this product to be large to achieve a high level of birefringence and crystallinity. For instance, attaining a product of intrinsic viscosity and spinning speed as high as 6,500 (dl·m)/(g·minute) or even higher is sometimes desirable.
The design of the solidification zone is critical to the operation of the melt spinning process so that a substantially uniform quench is accomplished. It is preferable to impose quenching conditions which minimize the difference in birefringence values measured at the center and near the surface of a filament. When this difference is minimized, the radial birefringence profile is usually flattened. It is generally preferred for an inert gas atmosphere to provide the requisite cooling in the solidification zone. The inert gas atmosphere in the solidification zone will normally be at a temperature below about the glass transition temperature of the PET. It is normally preferred for the inert gas in the solidification zone to be at a temperature within the range of about 1° C. to about 60° C. below the glass transition temperature of the PET. It is most preferred for the inert gas in the solidification zone to be at a temperature within the range of about 35° C. to about 55° C. below the glass transition temperature of the PET. As a matter of convenience, the inert gas atmosphere will normally be air which is maintained at room temperature (from about 20° C. to about 30° C.). The chemical composition of the inert gas atmosphere is not critical to the operation of the melt spinning process provided that the gas is not unduly reactive with the hot PET filaments being solidified. Some representative examples of gases which can be utilized as the atmosphere include air, nitrogen, helium, argon, and the like. For purposes of cost reduction, air will normally be utilized.
Within the solidification zone, the molten PET passes from the melt to a semisolid consistency, and from the semisolid consistency to a solid consistency. While present in the solidification zone, the PET undergoes orientation which is sufficient to attain a birefringence of at least about 0.075 and a crystallinity of at least about 10%. It is desirable for the spun filaments produced to have a birefringence of greater than about 0.085 and preferred for the spun filaments to have a birefringence of at least about 0.095. It is typically more preferred for the spun filaments to have a birefringence of at least about 0.100. It is normally preferred for the spun filaments to have a crystallinity, as measured by wide-angle x-ray scattering (WAXS), of at least about 20% and more preferred for the spun filaments to have a crystallinity of at least about 25%. In a preferred embodiment of this invention, the spun filaments have a crystallinity which is within the range of about 30% to about 40%.
The solidification zone is preferably disposed below the spinnerette and the extruded PET is present while axially suspended therein for a residence time of about 0.0015 seconds to about 0.75 seconds and preferably for a residence time of about 0.065 seconds to 0.25 seconds. Commonly, the solidification zone possesses a length of about 0.25 feet (7.6 cm) to 20 feet (6 meters) and preferably a length of about 1 foot (30 cm) to about 7 feet (2 meters). The inert gas present in the solidification zone can be circulated to provide more efficient heat transfer. The quenching can be done utilizing a cross-flow or radial in-flow or out-flow technique whereby the gas is introduced along the length of the solidification zone or by any other technique capable of bringing about the desired quenching after the molten PET exits the spinnerette.
The PET spun filaments are withdrawn from the solidification zone while under a substantial stress of about 0.2 to about 0.7 cN/dtex and preferably under a stress of about 0.3 to about 0.6 cN/dtex. The stress is measured at a point immediately below the exit end of the solidification zone. For instance, the stress can be measured by placing a tension meter on the filamentary material as it exits from the solidification zone. As will be apparent to those skilled in the art, the exact stress upon the filamentary material is influenced by the molecular weight of the polyester, the temperature of the molten polyester when extruded, the size of the spinnerette openings, the polymer throughput rate during melt extrusion, the quench temperature and the rate at which the as-spun filamentary material is withdrawn from the solidification zone, as well as other factors.
After the spun filaments are prepared, they are drawn to a draw ratio of at least 1.05:1. The optimum draw ratio will vary with the spinning speed and intrinsic viscosity of the PET as well as other factors. Generally, the most favorable draw ratio decreases as the product of the intrinsic viscosity of the PET and the spinning speed increases. In cases where the product of the intrinsic viscosity of the PET and the spinning speed is within the range of 3500 to 4500 (dl·m)/(g·minute), the optimum draw ratio will normally be within the range of about 1.5:1 to about 2.0:1. The drawing procedure is carried out in a heated zone which is maintained at a temperature between the glass transition temperature of the PET and its melting point. The spun filaments are in the heated zone for a residence time of at least about 0.3 seconds. A relatively slow speed drawing procedure is typically utilized to attain the required residence time of at least about 0.3 seconds. However, the drawing speed can be increased while maintaining adequate residence time by increasing the length of the heated zone. In many cases, the spun filaments will have a residence time in the heated zone of at least about 0.5 seconds.
It is preferred to utilize a slow speed multiple-end drawing procedure in the practice of this invention. For instance, the spun filaments can be supplied from feed creels onto long godet rolls which are adequate to accommodate a large number of thread lines. The drawing procedure is then accomplished with the multiple thread lines being simultaneously drawn in the heated zone. For example, godet rolls which are approximately 1 meter in length can accommodate about 120 thread lines. By utilizing such a multiple end drawing procedure, slow speed drawing can be utilized without sacrificing throughput.
A single stage or multiple stage drawing procedure can be used to draw the spun filaments. In a representative example of a multiple stage drawing procedure, the yarns are sequentially passed through a tensioning device, a first septet, a second septet, a first heated zone, a third septet, a second heated zone and a trio to a winder. The rolls of the first septet are normally at a temperature ranging from ambient temperature (about 22° C.) to about 250° C. It is generally preferred for the first septet to be at a temperature from ambient temperature up to about 150° C. The first septet is normally operated at speeds of about 50 m/min. to about 500 m/min. The rolls of the second septet are generally at a temperature between the glass transition temperature of the PET up to about 250° C. In most cases the rolls of the second septet will be at a temperature between the glass transition temperature of the PET up to about 250° C. A draw ratio between about 1.0:1 and about 1.5:1 is normally utilized between the first septet and the second septet, with a draw ratio of about 1.0:1 being most common. The second septet is typically run at speeds of about 50 to about 600 m/min. After passing through the second septet, the yarn enters the first heated zone which is normally at a temperature of about 150° C. to about 300° C. The main draw is normally carried out in this zone at a draw ratio of about 1.2:1 to about 2.5:1. The length of the first heated zone is long enough for the yarn to achieve a minimum residence time of 0.3 second. For example, at a takeup speed of 200 m/min., the first heated zone will be at least about 1.0 m long. For a takeup speed of 400 m/min. the first heated zone will be at least about 2.0 m long and so forth. If a heated zone 5.0 m long is used in conjunction with a take up speed of 500 m/min., a residence time of 0.6 seconds is realized. In most cases the heated zone will be about 2.5 to about 10 meters in length.
After exiting the first heated zone, the yarn passes over the third septet which is run at a higher speed than the second septet to accomplish the desired draw ratio. The third septet is normally run at a speed of about 100 to about 900 m/min. and at a temperature of about 100° C. to 250° C. In many cases the third septet will be run at a speed of about 200 to about 600 m/min. The yarn then enters the second heated zone where several operations can be performed. In one embodiment, relaxation of the yarn can be accomplished by running the trio at a speed less than that of the third septet. The trio can be operated at a speed of about 1 to 10% lower than the third septet to achieve about a 1 to 10% relaxation. In a second embodiment, the trio can be operated at the same speed as the third septet in order to anneal the yarn under tension. In a third embodiment, the trio can be operated at a higher speed than the third septet to achieve further drawing of the yarn. Draw ratios of about 1.05 to 2.0 can be carried out in the second heated zone. The second heated zone is normally operated at a temperature of about 100° C. to about 300° C. The length of the second heated zone is dependent on takeup speed and should be sufficient to give at least 0.3 seconds residence time. The second heated zone is normally 2.5 to 5.0 m in length for typical takeup speeds. As mentioned, the yarn passes over the trio after exiting the second heated zone. The trio is typically operated at speeds of about 100 to about 900 m/min., depending on the length and specific operation performed in the second heated zone. The trio is usually operated at a temperature of about 10° C. to the glass transition temperature of the polyester. After leaving the trio, the drawn yarn is wound on packages for subsequent processing. Winding is normally done at about 100 to 900 m/min. In most cases the winding will be done at a speed of 200 to 600 m/min.
The drawn yarns of this invention can then be utilized in making cords. Such yarns typically are drawn to at least about 97% of the draw ratio that would fully draw the yarn. Such cords can be made by twisting together two or more drawn yarns. Most commonly, cords are made by twisting together two or three yarns. Standard techniques which are well known to persons skilled in the art can be used in twisting the drawn yarns into cords.
A plurality of cords which are made out of drawn yarns can then be woven into a greige fabric by utilizing standard weaving techniques. In cases where optimally drawn yarns are utilized, the greige woven fabric is stretched under conditions wherein further drawing is accomplished. This is generally done at an elevated temperature. For example, a temperature between 200° C. and 280° C. will commonly be utilized with a temperature of 230° C. to 250° C. being preferred. In many cases it will be convenient to provide this additional drawing while the greige fabric is being dipped. This is because the conditions commonly used in conventional dipping procedures can be easily modified so as to provide adequate tensions in order to accomplish the desired degree of additional drawing. In making high strength tire fabrics, the greige fabric can easily be stretched and relaxed in an appropriate treating dip, such as an RFL (resorcinol-formaldehyde-latex) dip. In other words, the woven fabric can be subjected to higher tensions in the RFL dip in order to provide it with further drawing which is necessary in order for the high strength fabric being made to have the requisite combination of mechanical properties. Such greige woven tire fabrics can be stretched and relaxed under tension before being dipped if so desired.
The tension required and process conditions utilized in stretching and relaxing greige fabric made utilizing optimally drawn yarns will normally be sufficient to reduce the denier of the cords in the greige woven fabric by 1% to 10% (based upon their denier prior to being stretched and relaxed in the greige woven fabric). It is generally preferred to reduce the denier of the cords by 2% to 5% during the process of stretching and relaxing the woven fabric. The tension and process conditions required to reduce denier will vary with the denier of the optimally drawn yarns utilized in making the fabric. However, persons skilled in the art will be able to ascertain the tension, temperature and other process conditions required to achieve these objectives. The optimally drawn yarns in such woven tire fabrics typically have a decitex of 1,130 to 1,180 prior to being stretched and relaxed, and accordingly, have an average decitex of from about 1,100 to 1,120 after being stretched and relaxed. Optimally drawn yarns having higher decitex prior to being stretched and relaxed can also be utilized in making woven tire fabrics containing yarns having other typical decitex values, such as 1444 or 1667, after stretching and relaxing the woven fabrics.
This invention is illustrated by the following examples which are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.
EXAMPLE 1
A continuous high speed spinning process was utilized in making spun filaments. High molecular weight polyethylene terephthalate having an initial intrinsic viscosity of 1.04 was spun into 380 filaments utilizing an extruder temperature of about 290° C. A spinning speed of 4800 m/min. and a throughput of about 120 lbs./hour (54 kg/hour) were maintained. This resulted in a spun yarn having a decitex of about 1,917, an optical birefringence of about 0.105, and a crystallinity of about 33%.
The spun yarns were then subsequently drawn using a slow speed multiple-end drawing procedure. The drawing line was arranged in the following order: an 8-position creel, 2 septets (seven roll draw stands), 1 hot air oven having a working length of 2.5 meters, 1 septet, a second hot air oven having a working length of 2.5 meters, 1 trio (three roll draw stand), and a winder module. The first septet had 7 polished chrome rolls that were all heated by hot oil. The second septet also had 7 polished chrome rolls, but only the last 4 were heated. The third septet had 4 polished chrome rolls followed by 3 matte chrome rolls. Only the matte chrome rolls were heated on the third septet. All of the rolls on the trio were polished chrome with the second roll cooled by chilled water. The first septet was operated at a speed of 114 meters per minute at a temperature of 95° C. The second septet was at a speed of 115 meters per minute at a temperature of 95° C. and the third septet was operated at a speed of 200 meters per minute at a temperature of 100° C. The trio was operated at a speed of 200 meters per minute at a temperature of 15° C. The first oven was maintained at a temperature of 280° C. and the second oven was also maintained at a temperature of 280° C. A draw ratio of 1.75:1 was applied between the second and third draw stands. This draw ratio was about 97% of the draw ratio that would have fully drawn the yarn. Accordingly, the yarn was optimally drawn in accordance with U.S. Pat. No. 4,654,253 to Brown et al. No relax was used between the third septet and the trio. The resulting drawn yarn had a decitex of about 1165, a tenacity of 7.78 cN/dtex with an average free shrinkage of 6.1% as determined in a Testrite oven at 177° C. using a pretension of 0.706 cN/dtex.
The optimally drawn yarns were then twisted into a two ply tire cord having 47 turns per decimeter in the ply and 47 turns per decimeter in the cable using standard techniques. The greige tire cords made were determined to have a decitex of 2660, a tensile strength of 160 N, a LASE (load required to elongate the fabric) at 5% of 52.4 N and an elongation at break of 12.5%.
The greige tire cords were then woven into a tire fabric containing 1710 cord ends. The process utilized in weaving the tire fabric was a standard procedure. The greige tire fabric was then processed in a multistage treating dip unit. After this dipping the cords had a break strength of 151 N, a LASE at 5% of 45.4 N, an elongation at break of 15.5%, and a shrinkage of 1.8% after 2 minutes at 350° F. (177° C.) in a Testrite oven. The dipped tire fabric was then used in making two ply high performance Eagle®VR 60 R15 radial passenger tires. The tires made exhibited reduced sidewall undulations and improved uniformity.
EXAMPLE 2
In this experiment, greige tire cords were produced utilizing the procedure specified in Example 1 except that 3 yarns were used in each cord. The spun filaments utilized in making the greige tire cords were determined to have a birefringence of 0.105 and a crystallinity of 33%. The greige tire cords made in this experiment were then dipped at 465° F. (241° C.). After this dipping, the cords had a break strength of 213 N, a LASE at 5% of 61 N, an elongation at break of 17% and a shrinkage of 1.2% after 2 minutes at 350° F. (177° C.).
EXAMPLE 3
In this experiment, greige tire cords were produced utilizing the procedure specified in Example 2 except that the spinning speed used in making the spun filaments was 4500 m/min. The spun filaments made were determined to have a birefringence of 0.105 and a crystallinity of 27%. After the greige tire cords were dipped, they were determined to have a break strength of 218 N, a LASE at 5% of 65 N, an elongation at break of 15.4%, and a shrinkage of 1.4% after 2 minutes at 350° F. (177° C.).
COMPARATIVE EXAMPLE 4
In this experiment, greige tire cords were produced utilizing the procedure specified in Example 2 except that the spinning speed used in making the spun filaments was 2500 m/min. The spun filaments made were determined to have a birefringence of 0.040 and a crystallinity of 0%. After the greige tire cords were dipped, they were determined to have a break strength of 207 N, a LASE at 5% of 61.2 N, an elongation at break of 17.2%, and a shrinkage of 2.4% after 2 minutes at 350° F. (177° C.).
COMPARATIVE EXAMPLE 5
In this experiment, spun filaments were made utilizing the procedure specified in Comparative Example 4. The spun filaments were then continuously drawn in one step utilizing a drawing speed of 5600 m/min. to a total draw of 2.3:1. After the greige tire cords were dipped, they were determined to have a shrinkage of 3.1% after 2 minutes at 350° F. (177° C.). In Comparative Example 4 wherein the spun filaments were drawn utilizing a drawing speed of 200 m/min., the greige tire cords were determined to have a shrinkage of only 2.4% after 2 minutes at 350° F. (177° C.). This experiment shows that lower shrinkage can be attained by utilizing a slow speed draw.
COMPARATIVE EXAMPLE 6
Greige tire cords were made utilizing the procedure specified in Example 2 except that the spinning speed used in making the spun filaments was 956 m/min. The spun filaments made were determined to have a birefringence of 0.0050 and a crystallinity of 0%. The greige tire cords made were then dipped and were determined to have a break strength of 198 N, a LASE at 5% of 61.4 N, an elongation at break of 16.0%, and a shrinkage of 2.7% after 2 minutes at 350° F. (177° C.).
While certain representative embodiments and details have been shown for the purpose of illustrating the present invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the invention.
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Industrial yarn is used as a reinforcement in a wide variety of manufactured articles, such as conveyor belts, drive belts, V-belts, seat belts, hoses, tires, and the like. It is often important for the industrial yarn to have high tenacity, high modulus and dimensional stability. The present invention discloses an improved process for manufacturing highly uniform industrial yarn which exhibits high tenacity, high modulus and very low shrinkage. The present invention more specifically discloses a process for manufacturing industrial yarn having high tenacity, high modulus and low shrinkage which comprises melt spinning polyethylene terephthalate into spun filaments and subsequently drawing the spun filaments in a heated zone to a draw ratio of at least about 1.05:1; wherein the spun filaments have a birefringence of at least about 0.075 and a crystallinity of at least about 10%; wherein the spun filaments are in the heated zone for a residence time of at least 0.3 seconds; and wherein the yarn in the heated zone is at a temperature which is between the glass transition temperature and the melting temperature of the polyethylene terephthalate.
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FIELD OF THE INVENTION
[0001] The present invention relates to isoxazoline derivatives, which can be used as selective inhibitors of phosphodiesterase (PDE) type IV. In particular, compounds disclosed herein can be useful in the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases in a patient, particularly in humans. The present invention also relates to processes for the preparation of disclosed compounds, as well as pharmaceutical compositions thereof, and their use as phosphodiesterase (PDE) type IV inhibitors.
BACKGROUND OF THE INVENTION
[0002] It is known that cyclic adenosine-3′,5′-monophosphate (cAMP) exhibits an important role of acting as an intracellular secondary messenger. The intracellular hydrolysis of cAMP to adenosine 5′-monophosphate (AMP) causes a number of inflammatory conditions, which include, but are not limited to, psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, and ulcerative colitis. Cyclic nucleotide phosphodiesterases (PDE), a biochemically and functionally, highly variable superfamily of the enzyme, is the most important factor in the control of cAMP (as well as of cGMP) levels. Eleven distinct families with more than 25 gene products are currently recognized. Although PDE I, PDE II, PDE III, PDE IV, and PDE VII all use cAMP as a substrate, only the PDE IV and PDE VII types are highly selective for hydrolysis of cAMP. Accordingly, inhibitors of PDE, particularly the PDE IV inhibitors, such as rolipram or Ro-1724, are known as cAMP-enhancers. Immune cells contain PDE IV and PDE III, of which PDE IV is prevalent in human mononuclear cells. Thus, the inhibition of phosphodiesterase type IV has been a target for modulation and, accordingly, for therapeutic intervention in a range of disease processes.
[0003] The initial observation that xanthine derivatives, theophylline and caffeine inhibit the hydrolysis of cAMP led to the discovery of the required hydrolytic activity in the cyclic nucleotide phosphodiesterase (PDE) enzymes. More recently, distinct classes of PDE have been recognized, and their selective inhibition has led to improved drug therapy. Thus, it was recognized that inhibition of PDE IV could lead to inhibition of inflammatory mediator release and airway smooth muscle relaxation.
[0004] 3-Aryl-2-isoxazoline derivatives are known as anti-inflammatory agents and isoxazoline compounds are known as inhibitors of TNF release. However, there remains a need for new selective inhibitors of phosphodiesterase (PDE) type IV.
SUMMARY OF THE INVENTION
[0005] The present invention provides isoxazoline derivatives, which can be used for the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases, and the processes for the synthesis of these compounds.
[0006] Pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides of these compounds having the same type of activity are also provided.
[0007] Pharmaceutical compositions containing the compounds, which may also contain pharmaceutically acceptable carriers or diluents, can be used for the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases.
[0008] The present invention encompasses a compound having the structure of Formula I,
[0000]
[0000] and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides, wherein
[0009] R 1 and R 2 together forms an optionally substituted cycloalkyl or heterocyclyl ring wherein one or more optional substituent are oxo, alkyl, alkaryl, alkenyl, alkynyl, heterocyclylalkyl, cycloalkylalkyl, —SO 2 NR x R y , halogen, —NH 2 , —(CH 2 ) g C(═O)NR x R y , —NHC(═O)OR 6 , —NHC(═O)NR x R y , —C(═O)OR 3 , —NHC(═O)R x , —SO 2 R 3 , cyano, hydroxy, alkoxy, substituted amino, —C(═O)R 3 ;
[0010] R 4 can be hydrogen; alkyl; hydroxy; halogen; carboxy;
[0011] R 7 can be hydrogen; alkyl;
[0012] R 1 is independently hydrogen or alkyl and R 2 and R 4 forms an optionally substituted 4-12 membered saturated or unsaturated monocyclic or bicyclic ring system fused to ring B having 0-4 heteroatom(s) selected from the group consisting of N, O and S, wherein the substituents is one or more of oxo, alkyl, —C(═O)OR 3 , —SO 2 R 3 , halogen, hydroxy, alkoxy, —NH 2 or substituted amino, with the proviso that R 2 and R 4 together does not form —CH 2 —O—CH 2 —O—CH 2 —;
[0013] X 1 and X 2 can be hydrogen, alkyl, cycloalkyl, alkaryl, alkenyl, cycloalkylalkyl, heteroaryl, heterocyclyl, heteroarylalkyl, heterocyclylalkyl, —(CH 2 ) g C(═O)NR x R y or —(CH 2 ) g1 C(═O)OR 3 (wherein g can be an integer from 0-3 and g 1 can be an integer from 1-3);
[0014] X 1 and X 2 together can optionally form a cyclic ring fused with the ring A shown in Formula I, the ring containing 3-5 carbon atoms within the ring and having 2-3 heteroatoms selected from the group consisting of N, O and S;
[0015] wherein R 3 can be alkyl, cycloalkyl or heterocyclyl;
[0016] wherein the halogen can be F, Cl, Br, or I; R x , and R y each independently can be hydrogen, alkyl, C 3 -C 6 alkenyl, C 3 -C 6 alkynyl, carboxy, cycloalkyl, —S(O) m R 5 , aryl, alkaryl, heteroaryl, heterocyclyl, heteroarylalkyl, and heterocyclylalkyl; m can be an integer between 0-2; R 6 can be alkyl, alkenyl, alkynyl, cycloalkyl, alkaryl, heteroarylalkyl or heterocyclylalkyl;
[0017] wherein R 5 can be hydrogen, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, alkaryl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl;
[0018] The following definitions apply to terms as used herein:
[0019] The term “alkyl,” unless otherwise specified, refers to a monoradical branched or unbranched saturated hydrocarbon having from 1 to about 20 carbon atoms. This term is exemplified by groups, such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, t-butyl, n-hexyl, n-decyl, tetradecyl, and the like. The alkyl groups may be further substituted with one or more substituents such as alkenyl, alkynyl, alkoxy, cycloalkyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, —S(O) n R 5 (wherein n can be 0, 1 or 2 and R 5 can be hydrogen, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, alkaryl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl), heterocyclyl or heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, aminocarbonyl, hydroxy, alkoxy, halogen, —CF 3 , amino, substituted amino, cyano, and —S(O) n R 5 (wherein n and R 5 are the same as defined earlier) or an alkyl group as defined above that is interrupted by 1-5 atoms or groups independently chosen from oxygen, sulfur and —NR a — (where R a can be hydrogen, alkyl, cycloalkyl, alkenyl, alkynyl, or aryl). Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) n R 5 (wherein n and R 5 are the same as defined earlier); or an alkyl group as defined above that has both substituents as defined above and is also interrupted by 1-5 atoms or groups as defined above.
[0020] The term “alkenyl,” unless otherwise specified, refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group preferably having from 2 to 20 carbon atoms with cis or trans geometry. Preferred alkenyl groups include ethenyl or vinyl (CH═CH 2 ), 1-propylene or allyl (—CH 2 CH═CH 2 ), or iso-propylene (—C(CH 3 )═CH 2 ), bicyclo[2.2.1]heptene, and the like. In the event that the alkenyl is attached to a heteroatom, the double bond cannot be alpha to the heteroatom. The alkenyl group may be further substituted with one or more substituents, such as alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, —S(O) n R 5 (wherein n and R 5 are the same as defined earlier), heterocyclyl or heteroaryl. Unless otherwise constrained by the definition, all substituents may be optionally further substituted by 1-3 substituents, which can be alkyl, carboxy, aminocarbonyl, hydroxy, alkoxy, halogen, —CF 3 , amino, substituted amino, cyano, or —S(O) n R 5 (wherein R 5 and n are the same as defined earlier).
[0021] The term “alkynyl,” unless otherwise specified, refers to a monoradical of an unsaturated hydrocarbon, preferably having from 2 to 20 carbon atoms. Preferred alkynyl groups include ethynyl, (—C═CH), or propargyl (or propynyl, —CH 2 C═CH), and the like. In the event that the alkynyl is attached to a heteroatom, the triple bond cannot be alpha to the heteroatom. The alkynyl group may be further substituted with one or more substituents, such as alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, or —S(O) n R 5 (wherein R 5 is the same as defined earlier). Unless otherwise constrained by the definition, all substituents may be optionally further substituted by 1-3 substituents, which can be alkyl, carboxy, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano or —S(O) n R 5 (wherein R 5 and n are the same as defined earlier).
[0022] The term “cycloalkyl,” unless otherwise specified, refers to saturated or unsaturated cyclic alkyl groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings, which contains an optional olefinic bond. Such cycloalkyl groups include, by way of example, single ring structures, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclooctyl, cyclopropylene, cyclobutylene and the like, or multiple ring structures, such as adamantanyl, and bicyclo [2.2.1]heptane, or cyclic alkyl groups to which is fused an aryl group, for example, indane and the like. The cycloalkyl may be further substituted with one or more substituents such as alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aryloxy, alkaryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, —S(O) n R 5 (wherein R 5 is the same as defined earlier), heteroaryl or heterocyclyl. Unless otherwise constrained by the definition, all substituents may be optionally further substituted by 1-3 substituents, which can be alkyl, carboxy, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , —NH 2 , substituted amino, cyano, or —S(O) n R 5 (wherein R 5 and n are the same as defined earlier).
[0023] The term “alkoxy” denotes the group O-alkyl, wherein alkyl is the same as defined above.
[0024] The term “alkaryl” refers to alkyl-aryl linked through alkyl portion (wherein alkyl is the same as defined earlier) and the alkyl portion contains carbon atoms from 1-6 and aryl is same as defined below.
[0025] The term “aryl,” unless otherwise specified, refers to phenyl or naphthyl ring, and the like, optionally substituted with 1 to 3 substituents selected from the group consisting of halogen (such as F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, aryloxy, —S(O) n R 5 (wherein R 5 is the same as defined earlier), cyano, nitro, carboxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, acyl and (CH 2 ) 0-3 C(═O)NR x R y (wherein R x and R y are same as defined earlier).
[0026] The term “carboxy,” unless otherwise specified, refers to —C(═O)O—R 6 , wherein R 6 can be, for example, hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, alkaryl, heteroarylalkyl or heterocyclylalkyl.
[0027] The term “heteroaryl,” unless otherwise specified, refers to an aromatic ring structure containing 5 or 6 carbon atoms, or a bicyclic aromatic group having 8 to 10 carbon atoms, with one or more heteroatom(s) independently selected from the group consisting of N, O and S, optionally substituted with 1 to 3 substituent(s), such as halogen (F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, —S(O) n R 5 (wherein n and R 5 are the same as defined earlier), alkoxy, alkaryl, cyano, nitro, acyl or C(═O)NR x R y (wherein R x and R y are the same as defined earlier). Examples of heteroaryl groups include, but are not limited to, pyridinyl, pyridazinyl, pyrimidinyl, pyrrolyl, oxazolyl, thiazolyl, thienyl, isoxazolyl, triazinyl, furanyl, benzofuranyl, indolyl, benzothiazolyl, benzoxazolyl, and the like, including analogous oxygen, sulphur, and mixed hetero atom containing groups.
[0028] The term ‘heterocyclyl,” unless otherwise specified, refers to a saturated or unsaturated monocyclic or polycyclic ring having 5 to 10 atoms, in which 1 to 3 carbon atoms in a ring are replaced by heteroatoms selected from the group consisting of O, S and N, and optionally are benzofused or fused heteroaryl of 5-6 ring members and/or optionally are substituted, wherein the substituents can be halogen (F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, hydroxyalkyl, cycloalkyl, carboxy, aryl, alkoxy, alkaryl, heteroaryl, heterocyclyl, heteroarylalkyl, heterocyclylalkyl, oxo, alkoxyalkyl or —S(O) n R 5 (wherein n and R 5 are the same as defined earlier), cyano, nitro, —NH 2 substituted amino, acyl or —C(═O)NR x R y (wherein R x and R y are the same as defined earlier). Examples of heterocyclyl groups include, but are not limited to, tetrahydrofuranyl, dihydrofuranyl, azabicyclohexane dihydropyridinyl, piperidinyl, isoxazoline, piperazinyl, dihydrobenzofuryl, isoindole-dione, dihydroindolyl,
[0000]
[0000] and the like.
[0029] “Heteroarylalkyl,” unless otherwise specified, refers to an alkyl-heteroaryl group, wherein the alkyl and heteroaryl portions are the same as defined earlier.
[0030] “Heterocyclylalkyl,” unless otherwise specified, refers to an alkyl-heterocyclyl group, wherein the alkyl and heterocyclyl portions of the group are the same as defined earlier.
[0031] The term “acyl” as defined herein refers to —C(═O)R″, wherein R″ is the same as defined earlier.
[0032] The term “substituted amino,” unless otherwise specified, refers to a group —N(R k ) 2 wherein each R k can be hydrogen [provided that both R k groups are not hydrogen (defined as “—NH 2 ”)], alkyl, alkenyl, alkynyl, alkaryl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl, heteroarylalkyl, acyl, S(O) m R 5 (wherein m and R 5 is the same as defined above), —C(═O)NR x R y , —C(═O)OR x (wherein R x and R y are the same as defined earlier) or —NHC(═O)NR y R x (wherein R y and R x are the same as defined earlier).
[0033] Unless otherwise constrained by the definition, all substituents optionally may be further substituted by 1-3 substituents, which can be alkyl, alkaryl, cycloalkyl, aryl, heteroaryl, heterocyclyl, carboxy, hydroxy, alkoxy, halogen, —CF 3 , cyano, —C(═O)NR x R y , —O(C═O)NR x R y (wherein R x and R y are the same as defined earlier) and —OC(═O)NR x R y or —S(O) m R 5 (where R 5 is the same as defined above and m is 0, 1 or 2).
[0034] The compounds of the present invention can be used for treating AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease, psoriasis, allergic rhinitis, shock, atopic dermatitis, crohn's disease, adult respiratory distress syndrome, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases. Accordingly, the present invention encompasses a method of treating AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease, psoriasis, allergic rhinitis, shock, atopic dermatitis, crohn's disease, adult respiratory distress syndrome, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis or other inflammatory diseases, which comprises administering to a patient in need thereof a therapeutically effective amount of an isoxazoline derivative compound of the present invention, and particularly an isoxazoline derivative compound of the present invention together a pharmaceutically acceptable carrier, excipient or diluent.
[0035] In accordance with yet another aspect, there are provided processes for the preparation of the compounds as described herein.
[0036] The compounds of the present invention may be prepared by techniques well known in the art. In addition, the compounds of the present invention may be prepared following a reaction sequence as depicted below.
[0037] The compounds of this invention contain one or more asymmetric carbon atoms and thus occur as racemic mixtures, enantiomers and diastereomers. These compounds also exist as conformers/rotamers. All such isomeric forms of these compounds are expressly included in the present invention. Each stereogenic carbon may be of the R or S configuration. Although the specific compounds exemplified in this application may be depicted in a particular stereochemical configuration, compounds having either the opposite stereochemistry at any given chiral center or mixtures thereof are envisioned as part of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The compounds of the present invention may be prepared by techniques well known in the organic synthesis and familiar to a practitioner skilled in art of this invention. In addition, the process described herein may prepare the compounds of the present invention, however that may not be the only means by which the compounds described may be synthesised. Further, the various synthetic steps described herein may be performed in an alternate sequence in order to give the desired compounds.
[0000]
[0039] The compounds of Formulae VII, IX, XI, XIII and XV can be prepared by following the reaction sequence as depicted for example in Scheme I. Thus, a compound of Formula I (wherein n can be 1, 2 or 3) can be N-protected to give a compound of Formula II (wherein P 1 can be —C(═O)OC(CH 3 ) 3 , —C(═O)OC(CH 3 ) 2 CHBr 2 or —C(═O)OC(CH 3 ) 2 CCl 3 ), which can be oxidized to give a compound of Formula III, which can undergo methylenation to give a compound of Formula IV, which can be reacted with a compound of Formula V (which was prepared following the procedure as described in U.S. patent application Ser. No. 10/930,569 wherein R z is alkyl optionally substituted with halogen (for example, trifluoromethyl) or alkaryl (for example, benzyl) and R z1 can be cycloalkylalkyl, alkaryl, cycloalkyl or alkyl optionally substituted with halogen) to give a compound of Formula VI, which can be deprotected to give a compound of Formula VII, which can be reacted with
[0000] Path a: a compound of Formula VIII (wherein Y is oxygen or sulphur and R x is the same as defined earlier) to give a compound of Formula IX;
Path b: a compound of Formula X (wherein A′ is —NR x R y or alkyl where R x and R y are the same as defined earlier) to give a compound of Formula XI;
Path c: a compound of Formula XII (wherein A″ is cycloalkyl, heterocyclyl or alkyl) to give a compound of Formula XIII; or
Path d: a compound of Formula XIV (wherein hal is Br, Cl or I and A′″ is heterocyclylalkyl, cycloalkylalkyl, alkaryl or alkyl optionally substituted with —CONR x R y wherein R x and R y are the same as defined earlier).
[0040] The N-protection of a compound of Formula I to give a compound of Formula II [wherein P can be —C(═O)OC(CH 3 ) 3 ] can be carried out in an organic solvent, such as, for example, dichloromethane, dichloroethane, chloroform or carbon tetrachloride, in the presence of a base, such as, for example triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0041] The N-protection of a compound of Formula I to give a compound of Formula II [when P can be —C(═O)OC(CH 3 ) 2 CHBr 2 or —C(═O)OC(CH 3 ) 2 CCl 3 ] can be carried out following procedures described in Theodora W. Greene and Peter G. M. Wuts, “Protecting Groups In Organic Synthesis,” 3 rd edition, John Wiley and Sons, New York 1999.
[0042] The oxidation of a compound of Formula II to give a compound of Formula III can be carried out using an oxidizing agent, such as, for example, pyridinium chlorochromate, manganese dioxide, potassium permanganate or Jones reagent (CrO 3 /H 2 SO 4 ).
[0043] The methylenation of a compound of Formula III to give a compound of Formula IV can be carried out in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, dioxane or diethylether, in the presence of a Wittig salt for example, triphenylmethylphosphonium iodide or triphenylmethylphosphonium bromide.
[0044] Alternatively, the methylenation of a compound of Formula III to give a compound of Formula IV can be carried out using Zn/CH 2 Br 2 /TiCl 4 in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, dioxane or diethylether.
[0045] The reaction of a compound of Formula IV with a compound of Formula V to give a compound of Formula VI can be carried out in an organic solvent, such as, for example, dichloromethane, chloroform, carbon tetrachloride or dichloroethane, tetrahydrofuran with oxidants such as, for example, sodium hypochlorite, N-chlorosuccinimide or tert-butoxychloride in the presence of an optional base, such as, for example, pyridine, butyl lithium, N-methylmorpholine, diisopropylethylamine or triethylamine.
[0046] The deprotection of a compound of Formula VI (wherein P can be —C(═O)OC(CH 3 ) 3 ) to give a compound of Formula VII can be carried out in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol, in the presence of an alcoholic acid solution, such as, for example, ethanolic hydrochloric acid or methanolic hydrochloric acid.
[0047] The deprotection of a compound of Formula VI (wherein P can be —C(═O)OC(CH 3 ) 2 CHBr 2 ) can be carried out in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropylalcohol in the presence of hydrobromic acid or hydrochloric acid).
[0048] The deprotection of a compound of Formula VI (wherein P can be —C(═O)OC(CH 3 ) 2 CCl 3 ) can be carried out by a supernucleophile, such as, for example, lithium cobalt (I) phthalocyanine, zinc and acetic acid or cobalt phthalocyanine.
[0049] The compound of Formula VII can be reacted with a compound of Formula VIII (path a) to give a compound of Formula IX in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0050] The compound of Formula VII can be reacted with a compound of Formula X (path b) to give a compound of Formula XI in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0051] The compound of Formula VII can be reacted with a compound of Formula XII (path c) to give a compound of Formula XIII in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base such as, for example, N-methylmorpholine, triethylamine, diisopropylethylamine or pyridine.
[0052] The compound of Formula VII can be reacted with a compound of Formula XIV (path d) to give a compound of Formula XV in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which can be prepared following Scheme I include:
Tert-butyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene-7-carboxylate (Compound No. 21), Hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 25),
Some representative compounds which can be prepared following Scheme I, path a include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-N-(4-fluorophenyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 2), N-butyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 5), N-butyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 9), N-benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 19), N-Benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 32), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 143), N-Butyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene-7-carboxamide (Compound No. 144).
Some representative compounds which can be prepared following Scheme I, path b include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-N,N-dimethyl-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-sulfonamide (Compound No. 4), 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-8-(methylsulfonyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 10), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-(methylsulfonyl)-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 145).
Some representative compounds which can be prepared following Scheme I, path c include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-(tetrahydrofuran-3-ylcarbonyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 3), Hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-8-prolyl-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 7), 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-7-(cyclopropylcarbonyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 18), 7-acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 20), 8-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 48), 8-(Cyclopentylcarbonyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 49), 7-(Cyclopentylcarbonyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 141), 7-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 155).
Some representative compounds which can be prepared following Scheme I, path d include:
2-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-7-yl}acetamide (Compound No. 6), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(2-morpholin-4-yl-ethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 8), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-isopropyl-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 17), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(cyclopropylmethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 31), 8-Benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 38), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(2-piperidin-1-ylethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 50), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-ethyl-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 54).
[0000]
[0079] Compounds of Formulae XXIV, XXV, XXVI and XXVII can be prepared, for example, by following a reaction sequence of Scheme II. Thus, the compound of Formula XVI can be reacted with a compound of Formula XVII (wherein B′ can be alkaryl) to give a compound of Formula XVIII, which can be reacted with hydroxylamine hydrochloride to give a compound of Formula XIX, which can be reacted with a compound of Formula XX (wherein P can be alkyl or alkaryl) to give a compound of Formula XXI, which can undergo hydrolysis to give a compound of Formula XXII, which can undergo reduction to give a compound of Formula XXIII, which can undergo ring cyclisation to give a compound of Formula XXIV which can undergo deprotection to give a compound of Formula XXV, which can be reacted with
[0080] Path a: a compound of Formula hal(CH 2 ) v hal [wherein hal is (Br, Cl or I) and v is an integer from 1-4] to give a compound of Formula XXVI; or
[0081] Path b: a compound of Formula B″ hal (wherein B″ is alkyl) and hal is the same as defined above) to give a compound of Formula XXVII.
[0082] The reaction of compound of Formula XVI with a compound of Formula XVII to give a compound of Formula XVIII can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane, in the presence of base, such as, for example, potassium carbonate, sodium carbonate or sodium bicarbonate.
[0083] The reaction of a compound of Formula XVIII with hydroxylamine hydrochloride to give a compound of Formula XIX can be carried out in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropylalcohol.
[0084] The compound of Formula XIX can be reacted with a compound of Formula XX to give a compound of Formula XXI in an organic solvent, such as, for example, dichloromethane, chloroform, carbon tetrachloride or dichloroethane with oxidants such as, for example, sodium hypochlorite, N-chlorosuccinimide or tert-butoxychloride in the presence of an optional base, such as, for example, pyridine, butyl lithium, N-methylmorpholine, diisopropylethylamine or triethylamine
[0085] The hydrolysis of a compound of Formula XXI to give a compound of Formula XXII can be carried out in a solvent system, such as, for example, tetrahydrofuran, methanol, dioxane or ethanol, in water in the presence of base, such as, for example, lithium hydroxide, sodium hydroxide or potassium hydroxide.
[0086] The compound of Formula XXII can undergo reduction to give a compound of Formula XXIII in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, dioxane or diethyl ether, with reducing agent, such as, for example, sodium borohydride or lithium borohydride or lithium aluminium hydride.
[0087] The compound of Formula XXIII can undergo ring cyclisation to give a compound of Formula XXIV in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, dioxane or diethyl ether in the presence of a redox couple. The oxidizing part of the redox couple is selected from the group diisopropylazodicarboxylate (DIAD), diethylazodicarboxylate (DEAD), N,N,N′,N′-tetramethylazodicarboxylate (TMAD), 1,1′-(azodicarbonyl) dipiperidine (ADDP), cyanomethylenetributylphosphorane (CMBP), 4,7-dimethyl-3,5,7-hexahydro-1,2,4,7-tetrazocin-3,8-dione (DHTD) or N,N,N′,N,′-tetraisopropylazodicarboxamide (TIPA). The reduction part of the redox couple is phosphine such as, for example, trialkylphosphine (such as tributylphosphine), triarylphosphine (such as triphenylphosphine), tricycloalkylphosphine (such as triscyclohexylphosphine) or tetraheteroarylphosphine. The phosphine reagents with a combination of aryl, alkyl or heteroaryl substituents may also be used (such as diphenylpyridylphosphine).
[0088] The compound of Formula XXIV can be deprotected to give a compound of Formula XXV in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol with a deprotecting agent, such as, for example, palladium on carbon or palladium on carbon with ammonium formate.
[0089] The compound of Formula XXV (path a) can be reacted with a compound of Formula hal(CH 2 ) v hal to give a compound of Formula XXVI in an organic solvent such as, for example, dimethylformamide, tetrahydrofuran, diethyl ether or dioxane in the presence of a base such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0090] The compound of Formula XXV (path b) can be reacted with a compound of Formula B″ hal to give a compound of Formula XXVII in an organic solvent such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which may be prepared following Scheme II include:
3-[3,4-Bis(benzyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 33), 4-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)benzene-1,2-diol (Compound No. 34).
Some representative compounds which may be prepared following Scheme II, path a include:
3-(2,3-Dihydro-1,4-benzodioxin-6-yl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 51).
Some representative compounds prepared following Scheme II, path b include:
3-[3,4-bis(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 12), 3-(3,4-diisopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 13), 3-[3,4-bis(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 27), 3-[3,4-Bis(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 28),
[0000]
[0097] The compounds of Formula XXX can be prepared by following the procedure as depicted in scheme III. Thus a compound of Formula XXVIII (wherein Rz 1 is the same as defined earlier) undergoes demethylation to give a compound of Formula XXIX, which was reacted, with a compound of Formula C′-hal (wherein C′ is heterocyclylalkyl, cycloalkylalkyl, cycloalkyl or C 2-10 alkyl optionally substituted with halogen) to give a compound of Formula XXX.
[0098] The demethylation of a compound of Formula XXVIII to give a compound of Formula XXIX can be carried out with reducing agent such as, for example, sodium ethane thiolate, sodium decane thiolate, sodium dodecane thiolate, sodium thiocresolate in the presence of solvent for example N,N-dimethylacetamide, hexamethyl phosphoramide or dimethylformamide.
[0099] The reaction of a compound of Formula XXIX with a compound of Formula C′-hal can be carried out in an organic solvent such as, for example, dimethylformamide, tetrahydrofuran, diethyl ether or dioxane in the presence of a base such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which may be prepared following Scheme III include:
2-(Cyclopentyloxy)-4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol (Compound No. 62), 3-(4-Butoxy-3-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 63), 3-(3-Isobutoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 64), 3-[3-Butoxy-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 65), 3-(3-Butoxy-4-ethoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 66), 3-[3-Butoxy-4-(cyclohexyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 67), 3-[3-(Cyclohexylmethoxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 68), 3-[3-(Cyclohexylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 69), 3-[4-Butoxy-3-(cyclohexylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 70), 3-(4-Isobutoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 71), 3-(4-Butoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 72), 3-[4-(Cyclohexylmethoxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 73), 3-[3-Isopropoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 74), 3-[3-(Cyclopropylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 75), 3-[3-(Cyclopropylmethoxy)-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 76), 3-[4-Butoxy-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 77), 3-[3-(Cyclopropylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 78), 3-(3-Isobutoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 79), 3-[4-(Cyclopropylmethoxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 80), 3-[4-(cyclohexyloxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 81) 3-[4-(Cyclohexylmethoxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 82), 3-[4-(Cyclopropylmethoxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 83), 3-[3-(Cyclopentyloxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 84), 3-[3-(Cyclopentyloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 85), 3-[3-(Cyclopropylmethoxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 86), 3-[4-(Cyclopentyloxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 87), 3-[3-Isopropoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 88), 3-(4-Ethoxy-3-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 89) 3-[3-(Cyclopentyloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 90), 3-[4-Butoxy-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 91), 3-[3-(Cyclopentyloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 92), 3-[3-(Cyclopentyloxy)-4-(cycloheptyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 93), 3-[3-(Cyclopentyloxy)-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 94), 3-[4-(Cyclohexylmethoxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 95), 3-[4-(Cyclohexylmethoxy)-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 96), 3-[3-(Cyclopropylmethoxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 97), 3-[4-(Cyclopentyloxy)-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 98), 3-[4-(Cyclopropylmethoxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 99), 3-[4-(Cyclopentyloxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 100), 3-(3-Isopropoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 101), 3-(4-Ethoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 102), 3-[3-Butoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 103), 3-[3-Butoxy-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 104), 3-(3-Butoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 105), 3-(3-Butoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 106), 3-[3-(Cyclohexylmethoxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 107), 3-[3-(Cyclohexylmethoxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 108), 3-[3-(Cyclohexylmethoxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 109), 3-[3-(Cyclohexylmethoxy)-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 110), 3-[4-(Cyclohexylmethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 111), 3-[4-(Cyclopropylmethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 112), 3-[4-(Cyclopentyloxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 113), 3-[4-(3-Isobutoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 114), 3-[3-(Cycloheptyloxy)-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 115), 3-[3-(Cycloheptyloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 116), 3-[4-Butoxy-3-(cycloheptyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 117), 3-[3-(Cycloheptyloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 118), 3-[3-(Cycloheptyloxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 119), 3-(3-Ethoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 120), 3-[4-(Cycloheptyloxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 121), 3-[4-(Cyclopropylmethoxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 122), 3-[4-(Cyclohexylmethoxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 123), 3-(3-Butoxy-4-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 125), 3-(3-Ethoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 126), 3-[4-(Cyclopentyloxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 127), 3-(4-Butoxy-3-ethoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 128), 3-(3-Ethoxy-4-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 129), 3-[3-(Cycloheptyloxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 130), 3-[3-(Cycloheptyloxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 131), 3-[3-(Cycloheptyloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 132), 3-(4-Butoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 133), 3-(4-Ethoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 134), 3-[4-(Morpholin-4-ylethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 135), 3-(4-Isopropoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 136), 3-[4-(Difluoromethoxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 151), 3-[4-(Cyclopentyloxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 152), 3-[4-Butoxy-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 153), 3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 157), 3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 158), 3-[4-(Cyclopropylmethoxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 159), 3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 160), 2-(2,3-Dihydro-1H-inden-2-yloxy)-4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol (Compound No. 161),
[0000]
[0182] Compounds of Formulae XXXIII and XXXV can be prepared, for example, by following the reaction sequence as depicted, for example, in Scheme IV. Thus, the compound of Formula XXXI (prepared following the procedure reported in U.S. patent application Ser. No. 10/930,569 wherein Rz is the same as defined above) can be reacted with a compound of Formula XXXII [wherein R w can be heteroarylalkyl, alkenyl or alkyl optionally substituted with cyano, carboxy or halogen and hal can be Br, Cl or I) to give a compound of Formula XXXIII, which can be reacted with a compound of formula XXXIV (wherein D′ is cycloalkyl or hydrogen) to give a compound of Formula XXXV.
[0183] The reaction of a compound of Formula XXXI with a compound of Formula XXXII to give a compound of Formula XXXIII can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane, in the presence of base, such as, for example, potassium carbonate, sodium carbonate or sodium bicarbonate.
[0184] The compound of Formula XXXIII can be reacted with a compound of Formula XXXIV to give a compound of Formula XXXV.
[0185] Particular compounds which can be formed following the procedure shown in Scheme VII include:
3-[3-(Difluoromethoxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 40), 3-[3-(Allyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 60), 3-[3-(2-Chloroethoxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 61), 3-[4-Methoxy-3-(pyridin-3-ylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 146), 3-[4-Methoxy-3-(pyridin-2-ylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 156), N-cyclopropyl-2-[5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetamide (Compound No. 162), 2-[5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetamide (Compound No. 164), Ethyl [5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetate (Compound No. 165), [5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetonitrile (Compound No. 166),
[0000]
[0195] The compounds of Formulae XXXVII, XXXVIII and XXXIX can be prepared by following the procedure as depicted in Scheme V. Thus a compound of Formula XXXVI (prepared following the procedure disclosed in U.S. patent application Ser. No. 10/930,569 wherein Rz and Rz1 are the same as defined earlier) can be reacted with
[0000] Path a: a compound of Formula VIII (wherein Y and R x are the same as defined earlier) to give a compound of Formula XXXVII;
Path b: a compound of Formula XII (wherein A″ is the same as defined earlier) to give a compound of Formula XXXVIII; or
Path c: a compound of Formula X (wherein A′ is the same as defined earlier) to give a compound of Formula XXXIX.
[0196] The compound of Formula XXXVI can be reacted with a compound of Formula VIII (path a) to give a compound of Formula XXXVII in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0197] The compound of Formula XXXVI can be reacted with a compound of Formula XII (path b) to give a compound of Formula XXXVIII in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base such as, for example, N-methylmorpholine, triethylamine, diisopropylethylamine or pyridine.
[0198] The compound of Formula XXXVI can be reacted with a compound of Formula X (path c) to give a compound of Formula XXXIX in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0000] Some representative compounds which may be prepared following Scheme V, path a include:
N-butyl-N′-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}urea (Compound No. 22), N-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}-N′-(2-methoxyphenyl)urea (Compound No. 23), Tert-butyl [({3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}amino)carbonyl]carbamate (Compound No. 46),
Some representative compounds which may be prepared following Scheme V, path b include:
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}cyclopentanecarboxamide (Compound No. 47), N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}-2-fluorobenzamide (Compound No. 138), N-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}benzamide (Compound No. 139).
Some representative compounds which may be prepared following Scheme V, path c include:
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}methanesulfonamide (Compound No. 58),
[0000]
[0206] The compounds of Formulae XLIII, XLIV, XLV, XLVI, XLVII, XLVIII, XLIX, L, LI and LIV can be prepared, for example, by following the procedure as described, for example, in Scheme VI. Thus a compound of Formula XL (wherein X 1 and X 2 are the same as defined earlier) can be reacted with a compound of Formula XLI, wherein
[0000] a. R h and R i may together join to form a cycloalkyl or heterocyclyl ring optionally substituted with alkaryl or oxo; R j is hydrogen or —COOalkyl and R k is hydrogen,
b. R h is hydrogen or —CH 2 OH; R i is —(CH 2 ) 1-2 OH; R j is hydrogen or —(CH 2 ) 1-2 OH and R k is hydrogen,
c. R i and R j together joins to form cycloalkyl or heterocyclyl ring; R h and R k are hydrogen;
to give a compound of Formula XLII, which can undergo hydrolysis (when R j is —COOalkyl) to give a compound of Formula XLIII,
path a: the compound of Formula XLII undergoes dehydration (when R i =R j =—(CH 2 ) 1-2 OH) to give a compound of Formula XLIV;
Path b: the compound of Formula XLII undergoes oxidation (when R h is —CH 2 OH and R i is —(CH 2 ) 1-2 OH) to give a compound of Formula XLV, which undergoes reduction to give a compound of Formula XLVI;
Path c: the compound of Formula XLII undergoes deprotection (R i and R j together joins to form
[0000]
[0000] wherein represents a point of attachment and P 1 represents —C(═O)OC(CH 3 ) 3 , —C(═O)OC(CH 3 ) 2 CHBr 2 or —C(═O)OC(CH 3 ) 2 CCl 3 ) to give a compound of Formula XLVII,
[Path c1: which can be reacted with a compound of Formula XII (wherein A″ is the same as defined earlier) to give a compound of Formula XLVIII]; or
[Path c2: which can be reacted with a compound of Formula X (wherein A′ is the same as defined earlier) to give a compound of Formula XLIX];
Path d: the compound of Formula XLII undergoes reduction (when R h and R i together joins to form
[0000]
[0000] wherein represents a point of attachment) to give a compound of Formula L;
Path e: the compound of Formula XLII can be reacted with a compound of Formula LI (wherein R x is the same as defined earlier) to give a compound of Formula LII, which can be reacted with a compound of Formula X to give a compound of formula LIII, which undergoes cyclisation to give a compound of Formula LIV; or
Path f: the compound of Formula XLII can be reacted with hydrazine hydrochloride to give a compound of Formula LIVa.
[0207] The reaction of a compound of Formula XL with a compound of Formula XLI to give a compound of Formula XLII can be carried out in an organic solvent, such as, for example, dichloromethane, chloroform, carbon tetrachloride, dichloromethane or tetrahydrofuran, with oxidants such as, for example, sodium hypochlorite, N-chlorosuccinimide or tert-butoxychloride, in the presence of an optional base, such as, for example, pyridine, butyl lithium, N-methylmorpholine, diisopropylethylamine or triethylamine.
[0208] The compound of Formula XLII can undergo hydrolysis (when R j is —COOalkyl) to give a compound of Formula XLIII in the presence of a basic hydrolyzing agent, such as, for example, sodium hydroxide, lithium hydroxide, potassium hydroxide, and a mixture thereof.
[0209] The compound of Formula XLII can undergo dehydration (when R i =R j =—(CH 2 ) 1-2 OH) at temperature ranging from about 100-150° C. to give a compound of Formula XLIV with dehydrating agents, such as, for example, acetic anhydride, glacial acetic acid, calcium oxide or sulphuric acid.
[0210] The compound of Formula XLII can undergo oxidation (path b, when R h is —CH 2 OH and R i is —(CH 2 ) 1-2 OH) to give a compound of Formula XLV in an organic solvent, such as, for example, dichloromethane, dichloroethane, chloroform or carbon tetrachloride, in the presence of a base for example, pyridine, triethylamine, N-methylmorpholine or diisopropylethylamine with oxidizing agents, such as, for example, chromic anhydride, sodium dichromate, potassium permanganate or potassium dichromate, pyridium chlorochromate or pyridinium dichromate
[0211] The compound of Formula XLV can undergo reduction to give a compound of Formula LXVI in an organic solvent, such as, for example, toluene, benzene or xylene, with reducing agent diisobutylaluminium hydride, sodiumborohydride, lithium aluminium hydride or sodium (bisethoxymethoxy) aluminium hydride
[0212] The compound of Formula XLII can undergo deprotection (path c, when R i and R j together joins to form
[0000]
[0000] where P 1 is —C(═O)OC(CH 3 ) 3 ) to give a compound of Formula XLVII, which can be carried out in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol, in the presence of an alcoholic acid solution, such as, for example, methanolic hydrochloric acid or ethanolic hydrochloric acid.
[0213] The compound of Formula XLII can undergo deprotection (when R i and R j together joins to form
[0000]
[0000] where P 1 is —C(═O)OC(CH 3 ) 2 CHBr 2 ) to give a compound of Formula XLVII, which can be carried out in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropylalcohol, or by hydrobromide in acetic acid.
[0214] The compound of Formula XLII can undergo deprotection (when R i and R j together joins to form
[0000]
[0000] where P 1 is —C(═O)OC(CH 3 ) 2 CCl 3 ) to give a compound of Formula XLVII, which can be carried out by a supernucleophile, such as, for example, lithium cobalt (I) phthalocyanine, zinc and acetic acid or cobalt phthalocyanine.
[0215] The reaction of a compound of Formula XLVII with a compound of Formula XII (path c1) to give a compound of Formula XLVIII can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base such as, for example, N-methylmorpholine, triethylamine, diisopropylethylamine or pyridine.
[0216] The reaction of a compound of Formula XLVII with a compound of Formula X (path c2) to give a compound of Formula XLIX can be carried out in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0217] The compound of formula XLII (path d, when R h and R i together joins to form
[0000]
[0000] ) can undergo reduction to give a compound of Formula L, in an organic solvent for example, toluene, benzene or xylene with reducing agent, such as, for example, diisobutylaluminium hydride, sodiumborohydride or lithium aluminium hydride.
[0218] The reaction of a compound of formula XLII (path e, when R h and R i together joins to form
[0000]
[0000] ) with a compound of Formula LI to give a compound of Formula LII can be carried out in an organic solvent for example methanol, ethanol, propanol or isopropylalcohol.
[0219] The reaction of a compound of Formula LII with a compound of Formula X to give a compound of Formula LIII can be carried out in an organic solvent, such as, for example, dichloroethane, dichloromethane, chloroform or carbon tetrachloride in the presence of a base, such as, for example, triethylamine, diisopropylethylamine, N-methylmorpholine or pyridine.
[0220] The compound of Formula LIII can undergo cyclisation to give a compound of Formula LIV in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane, in the presence of a base, such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0221] The reaction of a compound of Formula XLII (path f) can be reacted with hydrazine hydrochloride to give a compound of Formula LIVa in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropylalcohol.
[0000] Some representative compounds which can be prepared following Scheme VI include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.4]non-2-ene (Compound No. 11), Ethyl 8-benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-4-carboxylate (Compound No. 36), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-ene-4-carboxylic acid (Compound no. 37), Ethyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-ene-4-carboxylate (Compound No. 39), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,6a-dimethyl-3aH-cyclopenta[d]isoxazole-4,6(5H,6aH)-dione (Compound No. 43), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-6,6a-dihydrofuro[3,4-d]isoxazol-4(3aH)-one (Compound No. 45), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1,8-dioxa-2-azaspiro[4.5]dec-2-ene (Compound No. 52), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3aH-cyclopenta[d]isoxazole-4,6(5H,6aH)-dione (Compound No. 53), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,4,5,6,7,7a-hexahydro-1,2-benzisoxazole (Compound No. 56), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-cyclopenta[d]isoxazole (Compound No. 57), Tert-butyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-3a,4,6,6a-tetrahydro-5H-pyrrolo[3,4-d]isoxazole-5-carboxylate (Compound No. 142), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,5,6,7a-tetrahydro-1,2-benzisoxazol-7(4H)-one (Compound No. 150).
Some representative compounds which can be prepared following Scheme VI, path a include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,4,6,6a-tetrahydrofuro[3,4-d]isoxazole (Compound No. 44).
Some representative compounds which can be prepared following Scheme VI, path b include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-8-one (Compound no. 15), 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-8-ol (Compound No. 16).
Some representative compounds which can be prepared following scheme VI, path c include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole (Compound No. 140)
Some representative compounds prepared following scheme VI, path c1 include:
5-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole (Compound No. 147).
Some representative compounds which can be prepared following scheme VI, path c2 include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-5-(methylsulfonyl)-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole (Compound No. 148).
Some representative compounds which can be prepared following scheme VI, path d include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-6-ol (Compound No. 1).
Some representative compounds which can be prepared following scheme VI, path e include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-6-one (Compound No. 42).
Some representative compounds which can be prepared following scheme VI, path f include:
7-Amino-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-6-one (Compound No. 35).
[0000]
[0243] The compounds of Formulae LVIII, LIX and LX can be prepared, for example, by following the procedure as depicted in scheme VII. Thus a compound of Formula LV (wherein X 1 is the same as defined earlier and X 3 is hydrogen, alkyl, cycloalkyl, alkaryl, alkenyl, cycloalkylalkyl, heteroaryl, heterocyclyl, heteroarylalkyl, heterocyclylalkyl) can be reacted with a compound of Formula LVI to give a compound of Formula LVII, which can undergo deprotection to give a compound of Formula LVIII, which
Path a: undergoes reduction to give a compound of Formula LIX; or Path b: can be reacted with a compound of Formula E′Mghal (wherein E′ is alkyl, alkenyl or alkynyl and hal is the same as defined earlier) to give a compound of Formula LX.
[0246] The reaction of a compound of Formula LV with a compound of Formula LVI to give a compound of Formula LVII can be carried out in an organic solvent, such as, for example, dichloromethane, chloroform, carbon tetrachloride or dichloromethane, with oxidants such as, for example, sodium hypochlorite, N-chlorosuccinimide or tert-butoxychloride, in the presence of an optional base, such as, for example, pyridine, butyl lithium, N-methylmorpholine, diisopropylethylamine or triethylamine.
[0247] The deprotection of a compound of Formula LVII to give a compound of Formula LVIII can be carried out in an organic solvent for such as, for example, dichloromethane, dichloroethane, carbon tetrachloride or chloroform, with deprotecting agent, such as, for example, trifluoroacetic acid, hydrochloric acid or sulphuric acid.
[0248] Alternatively the deprotection of a compound of Formula LVII to give a compound of Formula LVIII can also be carried out with benzyltriphenylphosphonium peroxymonosulphate or benzyltriphenylphosphonium in the presence of aluminium trichloride.
[0249] The reduction of a compound of Formula LVIII (path a) to give a compound of Formula LIX can be carried out in an organic solvent, such as, for example, methanol, ethanol or isopropylalcohol with reducing agents, such as, for example, sodium borohydride, lithium aluminium hydride or diisobutylaluminium hydride.
[0250] The reaction of a compound of Formula LVIII with a compound of Formula E′Mghal (path b) to give a compound of Formula LX can be carried out in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, diethyl ether or dioxane.
[0000] Some representative compounds which can be prepared following Scheme VII include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 26),
Some representative compounds which can be prepared following Scheme VII, path a include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 24),
Some representative compounds which can be prepared following Scheme VII, path b include:
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-vinyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 55), 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-methyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 59).
[0000]
[0255] The compounds of Formulae LXIII can be prepared, for example, by the procedure as depicted, for example, in Scheme VIII. Thus, a compound of Formula LXI (wherein Rz is the same as defined earlier) can be reacted with a compound of Formula LXII (wherein c is an integer from 1-3) to give a compound of Formula LXIII.
[0256] The reaction of a compound of Formula LXI with a compound of Formula LXII to give a compound of Formula LXIII can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethylether or dioxane in the presence of a base, such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which may be prepared following Scheme VIII include:
2-[5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]cyclopentanol (Compound No. 137).
[0000]
[0258] Compounds of Formulae LXVI and LXVII can be prepared, for example, by following a procedure as depicted, for example, in Scheme IX. Thus, a compound of Formula LXIV (wherein Rz is the same as defined earlier) can be reacted with a compound of Formula LXV [wherein P 2 is —O-tosyl, —O-mesyl, —O-4-bromophenylsulphonate, —O-4-nitrophenylsulfonate or —O-triflate and F′ is
[0000]
[0000] (where hal and n are the same as defined earlier and P 1 is —C(═O)OC(CH 3 ) 3 , —C(═O)OC(CH 3 ) 2 CHBr 2 or —C(═O)OC(CH 3 ) 2 CCl 3 )] to give a compound of Formula LXVI, which can undergo deprotection (when F′ is
[0000]
[0000] ) to give a compound of Formula LXVII.
[0259] The reaction of a compound of Formula LXIV with a compound of Formula LXV to give a compound of Formula LXVI can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethyl ether or dioxane, in the presence of a base, such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0260] The deprotection of a compound of Formula LXVI (wherein P 1 can be —C(═O)OC(CH 3 ) 3 ) to give a compound of Formula LXVII can be carried out in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol, in the presence of an alcoholic acid solution, such as, for example, ethanolic hydrochloric acid or methanolic hydrochloric acid.
[0261] The deprotection of a compound of Formula LXVI (wherein P 1 can be —C(═O)OC(CH 3 ) 2 CHBr 2 ) to give a compound of Formula LXVII can be carried out in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropylalcohol or by hydrobromide in acetic acid.
[0262] The deprotection of a compound of Formula LXVI (wherein P 1 can be —C(═O)OC(CH 3 ) 2 CCl 3 ) to give a compound of Formula LXVII can be carried out by a supernucleophile, such as, for example, lithium cobalt (I) phthalocyanine, zinc and acetic acid or cobalt phthalocyanine.
[0000] Some representative compounds which can be prepared following Scheme IX include:
3-(3-{[3-(Benzyloxy)cyclopentyl]oxy}-4-methoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 154), Hydrochloride salt of 3-[4-methoxy-3-(piperidin-3-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 163), 3-{3-[(2,6-Dichloropyridin-4-yl)methoxy]-4-methoxyphenyl}-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 167).
[0000]
[0266] Compounds of Formulae LXXIII and LXXIV can be prepared, for example, by following the reaction sequence of Scheme X. Thus, the compound of Formula LXVIII (wherein B′ can be alkaryl) and Rz is the same as defined earlier) can be reacted with hydroxylamine hydrochloride to give a compound of Formula LXIX, which can be reacted with a compound of Formula XX to give a compound of Formula LXX, which can undergo hydrolysis to give a compound of Formula LXXI, which can undergo reduction to give a compound of Formula LXXII, which can undergo ring cyclisation to give a compound of Formula LXXIII, which can undergo deprotection to give a compound of Formula LXXIV.
[0267] The reaction of a compound of Formula LXVIII with hydroxylamine hydrochloride to give a compound of Formula LXIX can be carried out in an organic solvent, such as, for example, ethanol, methanol, propanol or isopropyl alcohol.
[0268] The compound of Formula LXIX can be reacted with a compound of Formula XX to give a compound of Formula LXX in an organic solvent, such as, for example, dichloromethane, chloroform, carbon tetrachloride or dichloromethane with oxidants such as, for example, sodium hypochlorite, N-chlorosuccinimide or tert-butoxychloride, in the presence of an optional base, such as, for example, pyridine, butyl lithium, N-methylmorpholine, diisopropylethylamine or triethylamine
[0269] The hydrolysis of a compound of Formula LXX to give a compound of Formula LXXI can be carried out in a solvent system, such as, for example, tetrahydrofuran, methanol, dioxane or ethanol, in water in the presence of base, such as, for example, lithium hydroxide, sodium hydroxide or potassium hydroxide.
[0270] The compound of Formula LXXI can undergo reduction to give a compound of Formula LXXII in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, dioxane or diethyl ether, with reducing agent, such as, for example, sodium borohydride or sodium cyanoborohydride.
[0271] The compound of Formula LXXII can undergo ring cyclisation to give a compound of Formula LXXIII in an organic solvent, such as, for example in an organic solvent for example, tetrahydrofuran, dimethylformamide, dioxane or diethyl ether in the presence of a redox couple. The oxidizing part of the redox couple can be selected from, for example, diisopropylazodicarboxylate (DIAD), diethylazodicarboxylate (DEAD), N,N,N′,N′-tetramethylazodicarboxylate (TMAD), 1,1′-(azodicarbonyl) dipiperidine (ADDP), cyanomethylenetributylphosphorane (CMBP), 4,7-dimethyl-3,5,7-hexahydro-1,2,4,7-tetrazocin-3,8-dione (DHTD) or N,N,N′,N,′-tetraisopropylazodicarboxamide (TIPA). The reduction part of the redox couple can be phosphine, for example, trialkylphosphine (such as tributylphosphine), triarylphosphine (such as triphenylphosphine), tricycloalkylphosphine (such as triscyclohexylphosphine) or tetraheteroarylphosphine. The phosphine reagents with a combination of aryl, alkyl or heteroaryl substituents may also be used (such as diphenylpyridylphosphine).
[0272] The compound of Formula LXXIII can be deprotected to give a compound of Formula LXXIV in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol, with a deprotecting agent, such as, for example, palladium on carbon.
[0000] Some representative compounds which can be prepared following the procedure as described in Scheme X include:
2-(Difluoromethoxy)-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol (Compound No. 41)
[0000]
[0274] Compounds of Formula LXXX can be prepared by, for example, following a procedure as depicted in Scheme XI. Thus a compound of Formula LXXV (wherein X 1 and X 2 are the same as defined earlier) can be reacted with a compound of Formula LXXVI (wherein Q is a chiral resolving agent, for example, L-Ephederine, D-Ephederine, Brucine, (1S,2R) (−)-cis-1-amino-2-indanol, (1R2S) (+)-cis-1-amino-2-indanol, (1R,2R)-(−)-1,2-diamino cyclohexane or (1S,2S)-(+)-1,2-diamino cyclohexane or α-methylbenzylamine) to give a compound of Formula LXXVII, which can undergo protection with a compound of Formula P′-OH to give a compound of Formula LXXVIII (wherein P′ is alkyl), which can undergo reduction to give a compound of Formula LXXIX, which undergoes cyclisation to give a compound of Formula LXXX (wherein LXXX represents S-isomer when L-Ephidrine is used or R-isomer when D-Ephidrine is used).
[0275] The compound of Formula LXXV can be reacted with a compound of Formula LXXVI to give a compound of Formula LXXVII in an organic solvent such as, for example, acetone, dichloromethane or chloroform.
[0276] The protection of a compound of Formula LXXVII with a compound of Formula P′-OH to give a compound of Formula LXXVIII can be carried out with halogenating agents such as, for example, thionyl chloride, phosphorous pentachloride or phosphorous trichloride.
[0277] The compound of Formula LXXVIII undergoes reduction to give a compound of Formula LXXIX in an organic solvent, such as, for example, tetrahydrofuran, dimethylformamide, diethyl ether or dioxane, with reducing agent, such as, for example, sodiumboro hydride, lithium aluminium hydride or lithiumboro hydride.
[0278] Alternatively, the compound of Formula LXXIX can also be prepared by reducing free acid form of compound of Formula LXXVII.
[0279] The compound of Formula LXXIX can undergo cyclisation to give a compound of Formula LXXX in an organic solvent, such as, for example in an organic solvent for example, tetrahydrofuran, dimethylformamide, dioxane or diethyl ether, in the presence of a redox couple. The oxidizing part of the redox couple can be, for example, diisopropylazodicarboxylate (DIAD), diethylazodicarboxylate (DEAD), N,N,N′,N′-tetramethylazodicarboxylate (TMAD), 1,1′-(azodicarbonyl) dipiperidine (ADDP), cyanomethylenetributylphosphorane (CMBP), 4,7-dimethyl-3,5,7-hexahydro-1,2,4,7-tetrazocin-3,8-dione (DHTD) or N,N,N′,N,′-tetraisopropylazodicarboxamide (TIPA). The reduction part of the redox couple can be phosphine, for example, trialkylphosphine (such as tributylphosphine), triarylphosphine (such as triphenylphosphine), tricycloalkylphosphine (such as triscyclohexylphosphine) or tetraheteroarylphosphine. The phosphine reagents with a combination of aryl, alkyl or heteroaryl substituents may also be used (such as diphenylpyridylphosphine).
[0000] Some representative compounds which may be prepared following Scheme XI include:
(R)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 30), (S)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 124).
[0000]
[0282] The compounds of Formulae LXXXIV and LXXXV can be prepared by, for example, following a procedure as depicted, for example, in Scheme XII. Thus a compound of Formula LXXXI (wherein Rz and Rz1 are the same as defined earlier) can undergo halogenation to give compounds of Formula LXXXII and LXXXIII. The compound of Formula LXXXIII can be reacted with a compound of Formula E′COONa (wherein E′ is the same as defined earlier) to give a compound of Formula LXXXIV, which can be hydrolysed to give a compound of Formula XXXV.
[0283] The halogenation of a compound of Formula LXXXI to give a compound of Formula LXXXII and LXXXIII can be carried out in an organic solvent, such as, for example, chloroform, carbon tetrachloride, dichloromethane or dichloroethane, in the presence of radical initiator, such as, for example, azoisobutyronitrile (AIBN) or di-tert-butyl peroxide (BOOB), with halogenating agent, such as, for example, N-bromosuccinimide, N-chlorosuccinimide or N-iodosuccinimide.
[0284] The reaction of a compound of Formula LXXXIII with a compound of Formula E′COONa to give a compound of Formula LXXXIV can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethyl ether or dioxane.
[0285] The hydrolysis of a compound of Formula LXXXIV to give a compound of Formula LXXXV can be carried out in an organic solvent, such as, for example, methanol, ethanol or isopropylalcohol, in the presence of a base, such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which may be prepared following Scheme XII include:
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-4-ol (Compound No. 29), 4-Bromo-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 149)
[0000]
[0288] The compound of Formula LXXXVIII can be prepared, for example, by reaction sequence as depicted, for example, in Scheme XIII. Thus, a compound of Formula LXXXVI can be debenzylated (wherein Z 3 can be alkaryl) to give a compound of Formula LXXXVII, which can be reacted with a compound of Formula C′-hal to give a compound of Formula LXXXVIII.
[0289] The debenzylation of a compound of Formula LXXXVI to give a compound of formula LXXXVII can be carried out in an organic solvent, such as, for example, methanol, ethanol, propanol or isopropylalcohol, with a deprotecting agent, such as, for example, using hydrogen and palladium on carbon, or under catalytic hydrogenation transfer conditions of ammonium formate and palladium on carbon.
[0290] The reaction of a compound of Formula LXXXVII with a compound of Formula C′-hal to hive a compound of Formula LXXXVIII can be carried out in an organic solvent, such as, for example, dimethylformamide, tetrahydrofuran, diethyl ether or dioxane, in the presence of a base such as, for example, potassium carbonate, sodium carbonate or lithium carbonate.
[0000] Some representative compounds which can be prepared following Scheme XIII include:
3-[3-methoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 14),
EXAMPLES
Synthesis of Ethyl Cyclohexylideneacetate
[0292] To slurry of triethyl phosphonoacetate (5.05, 22.3 mmole) in tetrahydrofuran (5 ml) at 20° C. was added sodium hydride (0.892 g, 22.3 mmole) portionwise with constant stirring followed by the addition of cyclohexanone (1.87 ml, 22.3 mmole) in tetrahydrofuran (2 ml) dropwise. The reaction mixture was stirred for 1 hour. The mixture was diluted with water and extracted with ethyl acetate, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 2.5 gm
Synthesis of tert-Butyl 2,5-dihydro-1H-pyrrole-1-carboxylate
[0293] To a solution of the compound 2,5-dihydro-1H-pyrrole (commercially available) (400 mg, 0.0078 mol) in dichloromethane (50 ml) was added triethyl amine (1.75 g, 0.0173 mol) and cooled the mixture to 0° C. followed by the addition of di-tert-butoxy carbonyl anhydride (1.89 g, 0.00868 mol) dropwise. The reaction mixture was stirred for overnight. The mixture was extracted with dichloromethane. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 1 g.
Synthesis of 4-(Difluoromethoxy)3-benzyloxybenzaldehyde
[0294] To a solution of 3-hydroxy-4-difluoromethoxymethoxy-benzaldehyde (1 eq) was taken in dimethylformamide (10 mL), was added potassium iodide (0.1 eq) and potassium carbonate (2 eq). The reaction mixture was stirred at 70° C. and cyclopentyl bromide (2 eq) was added dropwise. The resulting reaction mixture was stirred at 70-80° C. for 16 hours. The reaction mixture was cooled and diluted with water, extracted with ethyl acetate and washed with saturated solution of sodium chloride. The organic solvent was removed under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound.
Synthesis of 3-(Benzyloxy)cyclopentanol
[0295] To a stirred solution of cyclopentane-1,3-diol (1.0 g, 9.80 mmol) and silver oxide (3.41 g, 14.7 mmol) in dichloromethane (300 ml) was added benzyl bromide (1.05 ml, 8.82 mmol) under dark conditions at room temperature and stirred the reaction mixture for 44 hours. The reaction mixture was filtered through celite pad and washed with dichloromethane. The combined organic layer was washed with water, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.38 g.
Synthesis of tert-Butyl 3-hydroxypiperidine-1-carboxylate
[0296] To a mixture of 3-hydroxy piperidine (4.0 gm, 39.6 mmole) and triethyl amine (11.0 ml, 79.0 mmole) in dichloromethane (70 ml) at 0° C. was added tert-butoxy carbonyl anhydride (10.4 gm, 47.4 mmole) and stirred the reaction mixture at room temperature for 12 hrs. The reaction mixture was washed with water and saturated sodium chloride solution, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Mass (m/z): 128 (MH + −tert. butanol).
Synthesis of 2,6-dichloropyridin-3-yl)methanol
[0297] To a solution of the compound 2,6-dichloronicotinic acid (0.5 g, 2.6 mmol) in tetrahydrofuran (10 ml) at 0° C. was added sodium borohydride (0.29 g, 7.8 mmol) portion wise and stirred the reaction mixture at room temperature for 30 minutes. The resulting reaction mixture was again cooled to 0° C. followed by the addition of etheral solution of boron trifluoride (1.1 ml, 7.8 mmole) dropwise and stirred the mixture at room temperature for overnight. The reaction mixture was quenched with aqueous sodium hydroxide (1N) and the solvent was evaporated under reduced pressure to furnish the title compound. The residue thus obtained was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 0.44 g.
Synthesis of 2,6-dichloropyridin-3-yl)methyl toluenesulphonate
[0298] To a stirred solution of the compound 2,6-dichloropyridin-3-yl)methanol (0.4 g, 2.25 mmol), 4-dimethylaminopyridine (0.028 g, 0.225 mmol) and triethylamine (0.62 ml, 4.5 mmol) in dichloromethane (20 ml) was added p-toluene sulphonyl chloride (0.64 g, 3.75 mmol) portion wise at 0-5° C. and stirred the reaction mixture at room temperature for overnight. The mixture was diluted with dichloromethane, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 0.725 g.
[0000] The following compounds can be prepared analogously,
[0299] 3-(Benzyloxy)cyclopentyl methanesulfonate: Mass (m/z): 347.0 (M + +1).
[0300] Tert-butyl 3-[(methylsulfonyl)oxy]piperidine-1-carboxylate: Mass (m/z): 280.0 (M + +1).
Example 1
Tert-butyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene-7-carboxylate
Compound No. 21
Step a: Synthesis of 3-oxo-piperidine-1-carboxylic acid tert-butyl ester
[0301] To a solution of the compound 3-hydroxy-piperidinyl-1-carboxylic acid tert-butyl ester (7.5 gm, 37.3 mmole) in dichloromethane (100 mL) was added celite (5.0 gm) and stirred at room temperature for 10 minutes. Pyridinium chlorochromate (9.57 gm, 44.4 mmole) was added portionwise over a period of 5 minutes. The reaction mixture was stirred at room temperature for 3 hours. Dichloromethane was removed under reduced pressure followed by the addition of ethyl acetate. The resulting reaction mixture was again stirred for 10 minutes and filtered through celite pad. The organic layer was removed under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 1.4 gm, 19%
Step b: Synthesis of 3-methylene-piperidine-1-carboxylic acid tert-butyl ester
[0302] The solution of a compound triphenylmethylphosphonium iodide (7.12 gm, 17.6 mmole), potassium tert-butoxide (1.58 gm, 14.1 mmole) in tetrahydrofuran (100 mL) was stirred at −78° C. for 20 minutes and then at room temperature for 1 hour. To the resulting reaction mixture was added a solution of the compound obtained from step a above (1.4 gm, 7.04 mmole) in tetrahydrofuran (50 mL) at 0° C. The resulting reaction mixture was stirred at room temperature for 10 min. followed by diluting it with water. Tetrahydrofuran was evaporated under reduced pressure, extracted with ethyl acetate, washed with anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.6 gm.
Step c: Synthesis of tert-butyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene-7-carboxylate (Compound No. 21)
[0303] The compound obtained from step b above (0.4 gm, 2.04 mmole) and 3-cyclopentyloxy-4-methoxy-benzaldehyde oxime (0.53 gm, 2.25 mmole) was taken in dichloromethane (20%) in chloroform followed by the addition of pyridine (2 drops). The reaction mixture was stirred at room temperature for 10 minutes followed by the addition of sodium hypochlorite (2 mL) dropwise. The resulting reaction mixture was stirred at room temperature for 4 hours. Tetrahydrofuran was evaporated under reduced pressure followed by diluting it with water. The compound was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and evaporated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.26 gm. Mass (m/z): 431 (M + +1).
Example 2
Hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene
Compound No. 25
[0304] To a solution of Compound No. 21 (0.18 gm, 0.42 mmole) in dichloromethane (50 mL), was added methanolic hydrochloric acid (4.2 ml, 8.37 mmole) at 0° C. and the reaction mixture was stirred at room temperature for 7 hours. The resulting reaction mixture was concentrated under reduced pressure, washed with saturated sodium bicarbonate solution and extracted with ether. Organic layer was concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.19 g. Mass (m/z): 331 (M + +1).
Example 3
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-N-(butyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide
Compound No. 5
[0305] To a solution of the compound hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.2840 mmol) in dichloroethane (2 mL) was added triethylamine (0.061 ml, 0.568 mmol) at room temperature followed by the addition of 1-isocyanatobutane dropwise (42.1 mg, 0.420 mmol). The reaction mixture was stirred at room temperature for 8 hours. The resulting mixture was quenched with aqueous sodium bicarbonate solution and dichloroethane was removed under reduced pressure. The mixture was extracted with ethyl acetate. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were then filtered and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 80% ethyl acetate in hexane solvent mixture as eluent to furnish the title compound. Yield: 50 mg. Mass (m/z): 416.17 (M + +1).
[0000] Analogues of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-N-(butyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 5) described below, can be prepared analogously,
N-4-Fluoro phenyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 2),
[0307] Mass (m/z): 454.25 (M + +1).
N-Butyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 9),
[0309] Mass (m/z): 430.25 (M + +1).
N-Benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-carboxamide (Compound No. 19),
[0311] Mass (m/z): 450.25 (M + +1).
N-Benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 32),
[0313] Mass (m/z): 464.0 (M + +1).
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 143),
[0315] Mass (m/z): 388.19 (M + +1).
N-Butyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene-7-carboxamide (Compound No. 144).
Example 4
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-N,N-dimethyl-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-sulfonamide
Compound No. 4
[0317] To a solution of the compound hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.2840 mmol) in dichloromethane (1 mL) was added triethylamine (71.7 mg, 0.7102 mmol) at room temperature followed by the addition of dimethylsulfamoylchloride (61 mg, 0.054 ml, 0.426 mmol). The reaction mixture was stirred at room temperature for 10 hours. The resulting mixture was quenched with aqueous sodium bicarbonate solution and extracted with dichloromethane followed by the removal of dichloromethane under reduced pressure. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were then filtered and concentrated under reduced pressure to furnish the title compound. Yield: 70 mg. Mass (m/z): 424.19 (M + +1).
[0000] Analogues of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-N,N-dimethyl-1-oxa-2,7-diazaspiro[4.4]non-2-ene-7-sulfonamide (Compound No. 4) described below, can be prepared analogously,
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(methylsulfonyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 10),
[0319] Mass (m/z): 409.08 (M + +1).
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-(methylsulfonyl)-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 145)
[0321] Mass (m/z): 409.22 (M + +1).
Example 5
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-7-(tetrahydrofuran-3-ylcarbonyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene
Compound No. 3
[0322] To a solution of the compound hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.2840 mmol) in dimethylformamide (1 mL) was added tetrahydrofuran-3-carboxylic acid (36.24 mg, 0.31249 mmol). The reaction mixture was cooled to 0° C. stirred followed by the addition of N-methylmorpholine (0.187 ml, 1.704 mmol) and hydroxybenzotriazole (38.38 mg, 0.284 mmol). The resulting mixture was stirred for 30 minutes at the same temperature followed by the addition of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (60 mg, 0.3124 mmol). The mixture was again stirred for 10 hours. The resulting mixture was diluted with water and extracted with ethyl acetate. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were then filtered and concentrated under reduced pressure and the residue thus obtained was purified by column chromatography using 5% methanol in ethyl acetate solvent mixture as eluent to furnish the title compound. Yield: 80 mg. Mass (m/z): 415.22 (M + +1).
[0000] Analogues of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-7-(tetrahydrofuran-3-ylcarbonyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 3) described below, can be prepared analogously,
Hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-8-prolyl-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 7)
[0324] Mass (m/z): 428.24 (M + +1).
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-(cyclopropylcarbonyl)-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 18)
[0326] Mass (m/z): 385.23 (M + +1).
7-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 20)
[0328] Mass (m/z): 359.25 (M + +1).
8-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 48)
[0330] Mass (m/z): 373.22 (M + +1).
8-(Cyclopentylcarbonyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 49)
[0332] Mass (m/z): 427.21 (M + +1).
7-(Cyclopentylcarbonyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 141)
[0334] Mass (m/z): 427.30 (M + +1).
7-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.5]dec-2-ene (Compound No. 155)
[0336] Mass (m/z): 373.07 (M + +1).
Example 6
2-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-7-yl}acetamide
Compound No. 6
[0337] To a solution of the compound hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (99 mg, 0.2553 mmol) in dimethylformamide (2 ml), was added potassium carbonate (70 mg, 0.5106 mmol) and heated the reaction mixture to 60° C. To the resulting mixture was added bromoacetamide (42.5 mg, 0.306 mmol) dropwise and stirred the reaction mixture at 60° C. for 10 hours. The reaction mixture was diluted with water and extracted with ethyl acetate. The organic extracts were collected, washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in ethyl acetate solvent mixture as eluent to furnish the title compound. Yield: 80 mg. Mass (m/z): 374.20 (M + +1).
[0000] Analogues of 2-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-7-yl}acetamide (Compound No. 6) described below, can be prepared analogously,
3-[3-Cyclopentyloxy)-4-methoxyphenyl]-8-(2-morpholin-4-ylethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 8)
[0339] Mass (m/z): 444.25 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-7-isopropyl-1-oxa-2,7-diazaspiro[4.4]non-2-ene (Compound No. 17)
[0341] Mass (m/z): 359.25 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(cyclopropylmethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 31)
[0343] Mass (m/z): 385.16 (M + +1),
8-Benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 38)
[0345] Mass (m/z): 421.22 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-(2-piperidin-1-ylethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 50)
[0347] Mass (m/z): 442.24 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-ethyl-1-oxa-2,8-diazaspiro[4.5]dec-2-ene (Compound No. 54)
[0349] Mass (m/z): 359.21 (M + +1).
Example 7
4-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)benzene-1,2-diol
Compound No. 34
Step a: Synthesis of 3,4-bis(benzyloxy)benzaldehyde
[0350] To a solution of the compound 3,4-dihydroxybenzaldehyde (25 g, 181.1 mmol) in dimethylformamide (150 ml) was added benzyl chloride (114.6 g, 905.7 mmol) and potassium carbonate (124.9 g, 905.7 mmol). The reaction mixture was stirred for 20 hours at 65-70° C. which subsequently cooled and diluted with toluene (50 ml) and filtered. The solid thus obtained was washed with toluene. The organic extracts were collected and washed with sodium hydroxide, water and dried over anhydrous sodium sulphate. The organic layer was concentrated under reduced pressure and the solid thus formed was added in hexane with vigorous stirring. Filtered and dried under reduced pressure. Yield: 49.732 g.
Step b: Synthesis of 3,4-bis(benzyloxy)benzaldehyde oxime
[0351] Hydroxylamine hydrochloride (42.8 g, 616.3 mmole) and sodium acetate (50.5 g, 616.3 mmole) was added to a stirred solution of compound obtained from step a above (49.0 g, 154.0 mmole) in ethanol (200 ml). The reaction mixture was stirred at room temperature for 50 minutes. Ethanol was evaporated under reduced pressure, which was diluted with water (100 ml) and the organic compound was extracted with ethyl acetate (3×100 ml). The ethyl acetate layer was dried over anhydrous sodium sulphate, filtered and concentrated under reduced pressure to afford the title compound.
Step c: Synthesis of methyl 3-[3,4-bis(benzyloxy)phenyl]-5-(2-methoxy-2-oxoethyl)-4,5-dihydroisoxazole-5-carboxylate
[0352] Dimethyl 2-methylenesuccinate (38.5 g, 122.0 mmole) was added to the solution of compound obtained from step b above (40.6 h, 122.0 mmole) in tetrahydrofuran (240 mL), and the resulting reaction mixture was stirred at room temperature. Sodium hypochlorite (250 mL) was added slowly to the mixture thus obtained over the period of 20 minutes and the reaction mixture was allowed to stir at room temperature overnight. A second lot of sodium hypochlorite (100 mL) was again added to it and stirred for 2 hours at room temperature. Tetrahydrofuran was evaporated off and the organic compound was extracted with ethyl acetate twice. The organic layer was concentrated to furnish the title compound. Yield: 56.3 g.
Step d: Synthesis of 3-[3,4-bis(benzyloxy)phenyl]-5-(carboxymethyl)-4,5-dihydroisoxazole-5-carboxylic acid
[0353] The compound obtained from step c above (0.70 gm, 2.102 mmole, 1 eq.) was dissolved in tetrahydrofuran (15 mL) and lithium hydroxide in water solution (4.8 mL of 0.5 M aqueous solution, 2.4 mmoles, 1.2 eq) was added. The mixture was stirred for 1 hour at room temperature and an additional amount of lithium hydroxide in water solution (1.9 mL, 0.5 M) was added. The mixture was stirred for 2 hour 35 minutes. Solvent was removed under reduced pressure and the residue thus obtained was diluted with water and acidified with drop of concentrated hydrochloric acid. The organic compound was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and finally concentrated under reduced pressure to afford the title organic compound with a yield of 0.500 g.
Step e: Synthesis of 2-[3-[3,4-bis(benzyloxy)phenyl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl]ethanol
[0354] To a solution of sodium borohydride (3 eq) in tetrahydrofuran, was added a solution of the compound obtained from step d above (1 eq) in tetrahydrofuran. To the resulting reaction mixture was added ethereal solution of trifluoroborane (3 eq) at 0° C. and stirred for 14-16 hours at ambient temperature. To it was added sodium hydroxide (1N) solution at 0° C. and stirred for 1 hour. The reaction mixture was diluted with ethylacetate and water. The combined extract was washed with saturated solution of sodium chloride and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.340 g
Step f: Synthesis of 3-[3,4-bis(benzyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
[0355] To a solution of the compound obtained from step e above (1 eq) in tetrahydrofuran, triphenylphosphine (1.12 eq) and succinimide (1 eq) was added diisopropyldiazadicarboxylate (1.14 eq). The reaction mixture was stirred at room temperature for overnight. The organic solvent was removed under reduced pressure and the residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 250 mg.
Step g: Synthesis of 4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)benzene-1,2-diol
Compound No. 34
[0356] To a solution of the compound obtained from step f above (00.250 g, 0.6 mmole) in methanol (10 ml), was added palladium on carbon (0.500 g, 10%). The reaction mixture was evacuated with hydrogen gas and the resulting reaction mixture was allowed to stir under hydrogen atmosphere at room temperature for 1 hour. The reaction mixture was filtered through celite pad. The filtrate was concentrated under reduced pressure to furnish the title compound. Yield: 110 mg. Mass (m/z): 236.19 (M + +1).
Example 8
Synthesis of 3-(2,3-Dihydro-1,4-benzodioxin-6-yl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 51
[0357] To a solution of Compound No. 34 (0.200 g, 0.85 mmol) above in dimethylformamide (60 ml), was added 1,2-dibromoethane (0.160 g, 0.85 mmol) and potassium carbonate (0.176 g, 1.27 mmol). The reaction mixture was stirred for 20 hours at 60-65° C. The mixture was extracted with ethyl acetate, washed with brine and water and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 20% ethyl acetate in hexane solvent mixture as eluent to furnish the title compound. Yield: 0.079 gm. Mass (m/z): 262.17 (M + +1).
Example 9
3-[3,4-bis(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 27
[0358] To a solution of Compound No. 34 (0.070 g, 0.29 mmol) in dimethylformamide (2 ml), was added potassium carbonate (0.164 g, 1.1 mmol) and cyclopentyl bromide (0.132 g, 0.891 mmol). The reaction mixture was stirred for 20 hours at 50-60° C. The mixture was extracted with ethyl acetate, washed with water, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography by using 20% ethyl acetate in hexane solvent mixture as eluent to furnish the title compound. Yield: 0.040 gm. Mass (m/z): 372.14 (M + +1).
[0000] Analogues of 3-[3,4-bis(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 27) described below, can be prepared analogously,
3-[3,4-bis(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 12)
[0360] Mass (m/z): 349.19 (M + +1),
3-(3,4-diisopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 13)
[0362] Mass (m/z): 320.21 (M + +1),
3-[3,4-Bis(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 28)
[0364] Mass (m/z): 344.12 (M + +1),
3-[3,4-Bis(benzyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 33)
[0366] Mass (m/z): 416.06 (M + +1).
Example 10
2-(Cyclopentyloxy)-4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol
Compound No. 62
[0367] To a solution of the compound 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.315 mmol) in dimethylacetamide (2 ml), sodium ethane thiolate (79.6 mg, 0.94637 mmol) and stirred the reaction mixture at 110° C. for 7-9 hours under nitrogen atmosphere. The mixture was quenched with aqueous ammonium chloride and extracted with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 90 mg. Mass (m/z): 304.23 (M + +1).
[0000] Analogues of 2-(cyclopentyloxy)-4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol (Compound No. 62) described below can be prepared analogously,
2-(2,3-Dihydro-1H-inden-2-yloxy)-4-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol (Compound No. 161)
[0369] Mass (m/z): 352.0 (M + +1).
Example 11
3-[3-(Cyclopentyloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 85
[0370] To a solution of the Compound No. 62 (50 mg, 0.16 mmole) in dimethylformamide (2 ml), was added potassium carbonate (46 mg, 0.33 mmole) and heated the reaction mixture to 60° C. To the resulting mixture was added ethyl bromide (36 mg, 0.33 mmole) dropwise and stirred the reaction mixture at 60° C. for 10 hours. The reaction mixture was diluted with water and extracted with ethyl acetate. The organic extracts were collected, washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 46 mg. Mass (m/z): 332.18 (M + +1).
[0000] Analogues of 3-[3-(Cyclopentyloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound no. 85) described below can be prepared similarily,
3-[3-methoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 14)
[0372] Mass (m/z): 363.24 (M + +1),
3-(4-Butoxy-3-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 63)
[0374] Mass (m/z): 348.33 (M + +1),
3-(3-Isobutoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 64)
[0376] Mass (m/z): 334.21 (M + +1),
3-[3-Butoxy-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 65)
[0378] Mass (m/z): 346.23 (M + +1),
3-(3-Butoxy-4-ethoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 66)
[0380] Mass (m/z): 320.23 (M + +1),
3-[3-Butoxy-4-(cyclohexyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 67)
[0382] Mass (m/z): 388.26 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 68)
[0384] Mass (m/z): 360.22 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 69)
[0386] Mass (m/z): 374.27 (M + +1),
3-[4-Butoxy-3-(cyclohexylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 70)
[0388] Mass (m/z): 388.26 (M + +1),
3-(4-Isobutoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 71)
[0390] Mass (m/z): 334.28 (M + +1),
3-(4-Butoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 72)
[0392] Mass (m/z): 334.21 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 73)
[0394] Mass (m/z): 374.27 (M + +1),
3-[3-Isopropoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 74)
[0396] Mass (m/z): 391.19 (M + +1),
3-[3-(Cyclopropylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 75)
[0398] Mass (m/z): 346.20 (M + +1),
3-[3-(Cyclopropylmethoxy)-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 76)
[0400] Mass (m/z): 403.22 (M + +1),
3-[4-Butoxy-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 77)
[0402] Mass (m/z): 346.19 (M + +1),
3-[3-(Cyclopropylmethoxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 78)
[0404] Mass (m/z): 332.18 (M + +1),
3-(3-Isobutoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 79)
[0406] Mass (m/z): 334.21 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 80)
[0408] Mass (m/z): 346.29 (M + +1),
3-[4-(cyclohexyloxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 81)
[0410] Mass (m/z): 386.23 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 82)
[0412] Mass (m/z): 400.21 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 83)
[0414] Mass (m/z): 358.19 (M + +1),
3-[3-(Cyclopentyloxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 84)
[0416] Mass (m/z): 360.22 (M + +1),
3-[3-(cyclopropylmethoxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 86)
[0418] Mass (m/z): 318.20 (M + +1),
3-[4-(Cyclopentyloxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 87)
[0420] Mass (m/z): 360.21 (M + +1),
3-[3-Isopropoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 88)
[0422] Mass (m/z): 405.18 (M + +1),
3-(4-Ethoxy-3-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 89)
[0424] Mass (m/z): 320.16 (M + +1),
3-[3-(Cyclopentyloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 90)
[0426] Mass (m/z): 346.16 (M + +1),
3-[4-Butoxy-3-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 91)
[0428] Mass (m/z): 360.21 (M + +1),
3-[3-(Cyclopentyloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 92)
[0430] Mass (m/z): 346.16 (M + +1),
3-[3-(Cyclopentyloxy)-4-(cycloheptyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 93)
[0432] Mass (m/z): 400.21 (M + +1),
3-[3-(Cyclopentyloxy)-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 94)
[0434] Mass (m/z): 417.21 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 95)
[0436] Mass (m/z): 388.19 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 96)
[0438] Mass (m/z): 386.23 (M + +1),
3-[3-(Cyclopropylmethoxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 97)
[0440] Mass (m/z): 332.25 (M + +1),
3-[4-(Cyclopentyloxy)-3-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 98)
[0442] Mass (m/z): 358.19 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 99)
[0444] Mass (m/z): 332.25 (M + +1),
3-[4-(Cyclopentyloxy)-3-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 100)
[0446] Mass (m/z): 346.23 (M + +1),
3-(3-Isopropoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 101)
[0448] Mass (m/z): 320.23 (M + +1),
3-(4-Ethoxy-3-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 102)
[0450] Mass (m/z): 306.25 (M + +1),
3-[3-Butoxy-4-(2-morpholin-4-ylethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 103)
[0452] Mass (m/z): 405.18 (M + +1),
3-[3-Butoxy-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 104)
[0454] Mass (m/z): 360.24 (M + +1),
3-(3-Butoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 105)
[0456] Mass (m/z): 334.21 (M + +1),
3-(3-Butoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 106)
[0458] Mass (m/z): 334.21 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 107)
[0460] Mass (m/z): 374.27 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 108)
[0462] Mass (m/z): 388.19 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 109)
[0464] Mass (m/z): 400.21 (M + +1),
3-[3-(Cyclohexylmethoxy)-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 110)
[0466] Mass (m/z): 386.23 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 111)
[0468] Mass (m/z): 374.27 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 112)
[0470] Mass (m/z): 332.18 (M + +1),
3-[4-(Cyclopentyloxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 113)
[0472] Mass (m/z): 346.23 (M + +1),
3-[4-Isobutoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 114)
[0474] Mass (m/z): (M + +1),
3-[3-(Cycloheptyloxy)-4-(cyclopropylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 115)
[0476] Mass (m/z): 386.23 (M + +1),
3-[3-(Cycloheptyloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 116)
[0478] Mass (m/z): 374.27 (M + +1),
3-[4-Butoxy-3-(cycloheptyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 117)
[0480] Mass (m/z): 388.26 (M + +1),
3-[3-(Cycloheptyloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 118)
[0482] Mass (m/z): 374.08 (M + +1),
3-[3-(Cycloheptyloxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 119)
[0484] Mass (m/z): 428.26 (M + +1),
3-(3-Ethoxy-4-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 120)
[0486] Mass (m/z): 306.18 (M + +1),
3-[4-(Cycloheptyloxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 121)
[0488] Mass (m/z): 360.29 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 122)
[0490] Mass (m/z): 318.20 (M + +1),
3-[4-(Cyclohexylmethoxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 123)
[0492] Mass (m/z): 360.22 (M + +1),
3-(3-Butoxy-4-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 125)
[0494] Mass (m/z): 348.18 (M + +1),
3-(3-Ethoxy-4-isopropoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 126)
[0496] Mass (m/z): 306.16 (M + +1),
3-[4-(Cyclopentyloxy)-3-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 127)
[0498] Mass (m/z): 332.20 (M + +1),
3-(4-Butoxy-3-ethoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 128)
[0500] Mass (m/z): 320.18 (M + +1),
3-(3-Ethoxy-4-isobutoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 129)
[0502] Mass (m/z): 320.18 (M + +1),
3-[3-(Cycloheptyloxy)-4-isobutoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 130)
[0504] Mass (m/z): 388.20 (M + +1),
3-[3-(Cycloheptyloxy)-4-(cyclopentyloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 131)
[0506] Mass (m/z): 400.22 (M + +1),
3-[3-(Cycloheptyloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 132)
[0508] Mass (m/z): 360.20 (M + +1),
3-(4-Butoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 133)
[0510] Mass (m/z): 334.21 (M + +1),
3-(4-Ethoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 134)
[0512] Mass (m/z): 306.22 (M + +1),
3-[4-(Morpholin-4-ylmethoxy)-3-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 135)
[0514] Mass (m/z): 391.16 (M + +1),
3-(4-Isopropoxy-3-propoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 136)
[0516] Mass (m/z): 320.18 (M + +1),
3-[4-(Difluoromethoxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 151)
[0518] Mass (m/z): 402.0 (M + +1),
3-[4-(Cyclopentyloxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 152)
[0520] Mass (m/z): 420.10 (M + +1),
3-[4-Butoxy-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 153)
[0522] Mass (m/z): 408.2 (M + +1),
3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-ethoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 157)
[0524] Mass (m/z): 380.04 (M + +1),
3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-propoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 158)
[0526] Mass (m/z): 394.08 (M + +1),
3-[4-(Cyclopropylmethoxy)-3-(2,3-dihydro-1H-inden-2-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 159)
[0528] Mass (m/z): 406.05 (M + +1),
3-[3-(2,3-Dihydro-1H-inden-2-yloxy)-4-isopropoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 160)
[0530] Mass (m/z): 394.2 (M + +1),
Example 12
3-[3-(Difluoromethoxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 40
[0531] To a solution of the compound 5-(1,7-Dioxa-2-aza-spiro[4.4]non-2-en-3-yl)-2-methoxy-phenol (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (90 mg) 90 mg) in dimethylformamide (10 ml), benzyltriethyl ammonium chloride (0.036 mole) was added. To the resulting reaction mixture was added sodium hydroxide solution (0.0018 mole of 30% solution) dropwise for about 3 minutes with a continuous flow of chloro-difluoro methane. The reaction mixture was acidified with dilute hydrochloric acid and diluted with water. The reaction mixture was extracted with ethyl acetate, washed with saturated solution of sodium chloride and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compounds. Yield: 25 mg. Mass (m/z): 300.1. (M + +1).
[0000] Analogues of 3-[3-(Difluoromethoxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 40), described below can prepared analogously,
3-[3-(Allyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 60)
[0533] Mass (m/z): 290.11 (M + +1),
3-[3-(2-Chloroethoxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 61)
[0535] Mass (m/z): 312.12 (M + +1),
3-[4-Methoxy-3-(pyridin-3-ylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 146)
[0537] Mass (m/z): 341.06 (M + +1),
3-[4-Methoxy-3-(pyridin-2-ylmethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 156)
[0539] Mass (m/z): 341.0 (M + +1),
Ethyl [5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetate (Compound No. 165)
[0541] Mass (m/z): 336.0 (M + +1),
[5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetonitrile (Compound No. 166)
[0543] Mass (m/z): 289.0 (M + +1).
Example 13
2-[5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetamide
Compound No. 164
[0544] A solution of the Compound No. 165 (50 mg) in methanolic ammonia (2 ml, 4.5 N) was stirred at room temperature for 6 hrs followed by the removal of methanol under reduced pressure. Solid thus separated out was washed with hexane and dried under vacuum to furnish the title compound. Yield 30 mg. Mass (m/z): 307.0 (M + +1).
[0000] The following compound can be prepared analogously,
N-cyclopropyl-2-[5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]acetamide (Compound No. 162)
[0546] Mass (m/z): 347.0 (M + +1).
Example 14
N-butyl-N′-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}urea
Compound No. 22
[0547] To a solution of the compound hydrochloride salt of 3-(3-cyclopentyloxy-4-methoxy-phenyl)-1-oxa-2-aza-spiro[4.5]dec-2-en-8-ylamine (disclosed in U.S. patent application Ser. No. 10/930,569) (100 mg, 0.262 mmol) in dichloroethane (10 mL) was added triethylamine (0.0.04 ml, 0.0262 mmol) at room temperature followed by the addition of 1-isocyanatobutane dropwise (28 mg, 0.288 mmol). The reaction mixture was stirred at room temperature for 12 hours. The resulting mixture was quenched with aqueous sodium bicarbonate solution and dichloroethane was removed under reduced pressure. The mixture was extracted with ethyl acetate. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were also filtered and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 60 mg. Mass (m/z): 444.23 (M + +1).
[0000] The following compounds can be prepared analogously,
N-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}-N-(2-methoxyphenyl)urea (Compound No. 23)
[0549] Mass (m/z): 494.19 (M + +1),
Tert-butyl [({3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}amino)carbonyl]carbamate (Compound No. 46)
[0551] Mass (m/z): 502.22 (M + +1),
Example 15
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}cyclopentanecarboxamide
Compound No. 47
[0552] To a solution of the compound hydrochloride salt of 3-(3-cyclopentyloxy-4-methoxy-phenyl)-1-oxa-2-aza-spiro[4.5]dec-2-en-8-ylamine (disclosed in U.S. patent application Ser. No. 10/930,569) (100 mg, 0.260 mmol) in dimethylformamide (1 mL) was added cyclopentylcarboxylic acid (0.025 ml, 0.236 mmole). The reaction mixture was cooled to 0° C. stirred followed by the addition of N-methylmorpholine (0.0318 ml, 0.289 mmol) and hydroxybenzotriazole 39 mg, 0.289 mmole). The resulting mixture was stirred for 30 minutes at the same temperature followed by the addition of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (55 mg, 0.289 mmol). The mixture was again stirred for 10 hours. The resulting mixture was diluted with water and extracted with ethyl acetate. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were then filtered and concentrated under reduced pressure and the residue thus obtained was purified by column chromatography using 5% methanol in ethyl acetate solvent mixture as eluent to furnish the title compound. Yield: 80 mg. Mass (m/z): 441.34 (M + +1).
[0000] The following compounds can be prepared analogously,
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}-2-fluorobenzamide (Compound No. 138)
[0554] Mass (m/z): 467.0 (M + +1),
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}benzamide (Compound No. 139)
[0556] Mass (m/z): 449.0 (M + +1).
Example 16
N-{3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl}methanesulfonamide
Compound No. 58
[0557] To a solution of the compound hydrochloride salt of 3-(3-cyclopentyloxy-4-methoxy-phenyl)-1-oxa-2-aza-spiro[4.5]dec-2-en-8-ylamine (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (0.17 gm, 0.45 mmole) in dichloromethane (50 mL) was added triethylamine (0.13 ml, 0.090 mmole) at room temperature followed by the addition of methane sulphonylchloride (0.05 ml, 0.58 mmole). The reaction mixture was stirred at room temperature for 2 hours. The resulting mixture was quenched with aqueous sodium bicarbonate solution and extracted with ethyl acetate followed by the removal of dichloromethane under reduced pressure. The organic extracts were separated, washed with water and brine and dried over anhydrous sodium sulphate. They were then filtered and concentrated under reduced pressure to furnish the title compound. Yield: 70 mg.
Example 17
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,4,5,6,7,7a-hexahydro-1,2-benzisoxazole
Compound No. 56
[0558] To a solution of the compound 3-(cyclopentyloxy)-4-methoxybenzaldehyde oxime (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (0.26 g, 1.11 mmol), cyclohexene (0.091 g, 1.11 mmol), 3 to 4 drops of pyridine in 20% chloroform in dichloromethane (50 ml) was added sodium hypochlorite (4%, 2.5 ml, 1.33 mmol) under nitrogen atmosphere. The resulting reaction mixture was stirred at room temperature for 18 hours followed by the addition of aqueous sodium hypochlorite (4%, 2.5 ml, 1.33 mmol) dropwise again. The reaction mixture was again stirred for 36 hours, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.100 g. Mass (m/z): 317 (M + +1).
[0000] The following compounds can be prepared analogously,
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.4]non-2-ene (Compound No. 11)
[0560] Mass (m/z): 316.25 (M + +1),
Ethyl 8-benzyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-4-carboxylate (Compound No. 36)
[0562] Mass (m/z): 493.33 (M + +1),
Ethyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-ene-4-carboxylate (Compound No. 39)
[0564] Mass (m/z): 402.17 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,6a-dimethyl-3aH-cyclopenta[d]isoxazole-4,6(5H,6aH)-dione (Compound No. 43)
[0566] Mass (m/z): 406.25 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-6,6a-dihydro furo[3,4-d]isoxazol-4(3aH)-one (Compound No. 45)
[0568] Mass (m/z): 318.34. (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1,8-dioxa-2-azaspiro[4.5]dec-2-ene (Compound No. 52)
[0570] Mass (m/z): 332.18 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3aH-cyclopenta[d]isoxazole-4,6(5H,6aH)-dione (Compound No. 53)
[0572] Mass (m/z): 332.30 (M + +1),
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-cyclopenta[d]isoxazole (Compound No. 57)
[0574] Mass (m/z): 302.0 (M + +1),
Tert-butyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-3a,4,6,6a-tetrahydro-5H-pyrrolo[3,4-d]isoxazole-5-carboxylate (Compound No. 142)
[0576] Mass (m/z): 303.16 (M + +BOC)
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,5,6,7a-tetrahydro-1,2-benzisoxazol-7(4H)-one (Compound No. 150)
[0578] Mass (m/z): 330.10 (M + +1).
Example 18
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-ene-4-carboxylic acid
Compound No. 37
[0579] Compound No. 39 (50 mg, 0.12 mmole) was dissolved in ethanol (1.5 mL) and lithium hydroxide in water solution (16 mg, 0.37 mmole) was added. The mixture was stirred for 4 hour at refluxing temperature. Solvent was removed under reduced pressure and the residue thus obtained was diluted with water and acidified with drop of concentrated hydrochloric acid. The organic compound was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and finally concentrated under reduced pressure to afford title organic compound with a yield of 32 mg. Mass (m/z): 374.20 (M + +1).
Example 19
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,4,6,6a-tetrahydrofuro[3,4-d]isoxazole
Compound No. 44
Step a: Synthesis of {3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5-dihydroisoxazole-4,5-diyl}dimethanol
[0580] But-2-ene-1,4-diol (29 mg, 0.328 mmole) was added to the solution of the compound 3-(cyclopentyloxy)-4-methoxybenzaldehyde oxime (70 mg, 0.298 mmole) in tetrahydrofuran (10 mL), and the resulting reaction mixture was stirred at room temperature. Sodium hypochlorite (1 mL) was added slowly to the mixture thus obtained over the period of 20 minutes and the reaction mixture was allowed to stir at room temperature overnight. A second lot of sodium hypochlorite (1 mL) was again added to it and stirred for 2 hours at room temperature. Tetrahydrofuran was evaporated off and the organic compound was extracted with ethyl acetate twice. The organic layer was concentrated to yield the title compound with a yield of 25 mg.
Step b: Synthesis of 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-3a,4,6,6a-tetrahydrofuro[3,4-d]isoxazole
[0581] A solution of the compound obtained from step a above (100 mg, 0.00031 mole) in acetic anhydride (10 ml) was refluxed for 100-110 C for 12 hours. The reaction mixture was diluted with water and extracted with ethyl acetate, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 10% ethyl acetate in hexane solvent mixture as eluent to furnish the title compound. Yield: 65 mg. Mass (m/z): 304.38 (M + +1).
Example 20
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-8-one
Compound No. 15
[0582] To a suspension of chromic anhydride (3.6 g, 35.82 mmol) in dichloromethane (20 ml) was added pyridine (5.66 g, 71.64 mmol) and stirred the reaction mixture for 15 minutes at room temperature. To it was added a solution of the compound 2-[3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl]ethanol (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (1.0 g, 2.99 mmol) in dichloromethane (5 ml) and stirred the reaction mixture for 1 hour. The solvent was evaporated under reduced pressure and the mixture was filtered through celite pad. The filterate was concentrated under reduced pressure and the residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 230 mg. Mass (m/z): 332.17 (M + +1).
Example 21
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-8-ol
Compound No. 16
[0583] A solution of the Compound No. 15 (30 mg, 0.09 mmol) in dry toluene (5 ml) was cooled to −78° C. followed by the addition of diisobutylaluminium hydride (19.3 mg, 0.14 mmol) dropwise and stirred the reaction mixture at same temperature for 2 hours under argon atmosphere. To it was added sodium potassium tartarate solution followed by ethyl acetate and water. The organic layer was separated, washed with brine and water, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 18 mg. Mass (m/z): 334 (M + +1).
Example 22
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole
Compound No. 140
[0584] To a solution of the Compound No. 142 (120 mg) in dichloromethane (5 ml) at 0° C. was added methanolic hydrochloric acid (1 ml) dropwise and stirred the reaction mixture for overnight. The solvent was evaporated under reduced pressure and the residue thus obtained was recrystallised with dichloromethane in hexane (20:80) solvent mixture as eluent to furnish the title compound. Yield: 100 mg. Mass (m/z): 303.99 (M + +1).
Example 23
5-Acetyl-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole
Compound No. 147
[0585] The compound No. 140 (45 mg, 0.149 mmole) and acetic anhydride (18.25 mg, 0.1788 mmole) were taken in dichloromethane (6 ml) followed by the addition of catalytic amount of dimethylamino pyridine was added and stirred for overnight. The resulting reaction mixture was diluted with water (15 ml) and extracted with dichloromethane. The organic layer was separated, washed with brine and water, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield 36 mg. Mass (m/z): 345.0 (M + +1).
Example 24
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-5-(methylsulfonyl)-4,5,6,6a-tetrahydro-3aH-pyrrolo[3,4-d]isoxazole
Compound No. 148
[0586] The title compound was prepared following the procedure as described for the synthesis in Example 4, by using Compound No. 140 in place of hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene. Yield: 35 mg.
[0587] Mass (m/z): 381.37 (M + +1).
Example 25
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-6-ol
Compound No. 1
[0588] The title compound was prepared by following the procedure as described for the synthesis of Compound No. 16, by using compound 3-[3-cyclopentyloxy-4-methoxy-phenyl)-1,7-dioxa-2-aza-spiro[4.4]non-2-ene-6-one (disclosed in our copending patent application U.S. Ser. No. 60/498,947) in place of using Compound No. 15. Yield: 28 mg.
[0589] Mass (m/z): 334.0 (M + +1).
Example 26
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-6-one
Compound No. 42
Step a: Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-(2-hydroxyethyl)-4,5-dihydroisoxazole-5-carboxamide
[0590] To a compound 3-[3-cyclopentyloxy-4-methoxy-phenyl)-1,7-dioxa-2-aza-spiro[4.4]non-2-ene-6-one (described in copending U.S. patent application Ser. No. 10/930,569) (0.20 g) was added methanolic ammonia (3 mL) and stirred the reaction mixture for 2.5 hours at room temperature. The reaction mixture was concentrated under vacuum to yield white solid compound. Yield 0.16 gm.
Step b: Synthesis of 2-{5-(aminocarbonyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5-dihydroisoxazol-5-yl}ethyl methanesulfonate
[0591] The title compound was prepared following the procedure as described for the synthesis of Compound No. 4, by using the compound obtained from step a above in place of hydrochloride salt of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-ene.
Step c: Synthesis of 3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-6-one
Compound No. 42
[0592] The compound obtained from step b above (0.16 gm, 0.375 mmole) was taken in dimethylformamide (1.4 ml) followed by the addition of anhydrous potassium carbonate (0.518 gm, 3.75 mmole) stirred for 24 hrs. The resulting reaction mixture was diluted with water and extracted with ethylacetate. Organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to give 20 mg of final product. Mass (m/z): 331.24 (M + +1).
Example 27
7-Amino-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2,7-diazaspiro[4.4]non-2-en-6-one
Compound No. 35
[0593] To a solution of the compound 3-[3-cyclopentyloxy-4-methoxy-phenyl)-1,7-dioxa-2-aza-spiro[4.4]non-2-ene-6-one (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.0003 mmole) in ethanol (5 ml) was added hydrazine hydrate (0.061 ml, 0.0012 mmole) was added and refluxed for 10 hrs. Solvent was removed under reduced pressure, water was added and extracted with ethyl acetate. Organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield (20 mg). Mass (m/z): 346.24 (M + +1).
Example 28
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one
Compound No. 26
Step a: Synthesis of 8-methylene-1,4-dioxaspiro[4.5]decane
[0594] A solution of the compound methyltriphenylphosphine iodide (19.5 g, 48.0 mmol) and potassium tert-butoxide (4.32 g, 38.4 mmol) in tetrahydrofuran (100 ml) was stirred for 3 hours at room temperature. To the resulting reaction mixture was added to a solution of 1,4-dioxaspiro[4.5]decan-8-one (3.0 g, 19.2 mmol) in tetrahydrofuran (50 ml) and stirred the mixture for 6 hours. The reaction mixture was quenched with aqueous ammonium chloride solution (10 ml) and concentrated under reduced pressure followed by diluting it with dichloromethane. The organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 1.52 g.
Step b: Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-ene
[0595] The title compound was prepared following the procedure as described for the synthesis of Compound No. 21 by using the compound obtained from step a above in place of 3-methylene-piperidine-1-carboxylic acid tert-butyl ester. Yield: 0.76 g.
Step c: Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one
Compound No. 26
[0596] To a solution of the compound obtained from step b above (0.6 g, 1.55 mmol) in dichloromethane (30 ml) was added trifluoroacetic acid (0.72 ml) in three lots over a time interval of 1 hour followed by the addition of water (1 ml) and stirred the reaction mixture for 6 hours at room temperature. The reaction mixture was diluted with water and extracted with dichloromethane. The organic layer was washed with aqueous sodium bicarbonate, water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained as purified by column chromatography to furnish the title compound. Yield: 0.44 g. Mass (m/z): 344 (M + +1).
Example 29
Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol
Compound No. 24
[0597] To a solution of the Compound No. 26 (290 mg, 0.85 mmol) in methanol (50 ml) at 0° C. was added sodium borohydride (45 mg, 1.18 mmol) and stirred the reaction mixture for 2 hours. The mixture was quenched with saturated ammonium chloride and evaporated under reduced pressure. The residue thus obtained was diluted with dichloromethane, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.18 g. Mass (m/z): 346 (M + +1).
Example 30
Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-8-methyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol
Compound No. 59
[0598] To a solution of the Compound No. 26 (0.3 g, 0.88 mmol) in dry tetrahydrofuran (50 ml) at 0° C. was added methyl magnesium chloride (0.5 ml, 1.14 mmol) and stirred the reaction mixture for 2 hours. The mixture was quenched with aqueous ammonium hydroxide (5 ml) and concentrated under reduced pressure. The residue thus obtained was dissolved in dichloromethane, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.22 g. Mass (m/z): 361 (M + +1).
[0000] The following compound can be prepared analogously,
3-[3-(Cyclopentyloxy)-4-methoxyphenyl]-8-vinyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 55)
[0600] Mass (m/z): 372 (M + +1).
Scheme VIII, Procedure:
Example 31
2-[5-(1,7-Dioxa-2-azaspiro[4.4]non-2-en-3-yl)-2-methoxyphenoxy]cyclopentanol
Compound No. 137
[0601] To a solution of the compound 5-(1,7-dioxa-2-aza-spiro[4.4]non-2-en-3-yl)-2-methoxy-phenol (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (0.11 g, 0.44 mmol) in dry dimethylformamide (20 ml) was added potassium carbonate (0.18 g, 1.33 mmol) at room temperature under nitrogen atmosphere followed by the addition of cyclopentene oxide (0.77 ml, 8.84 mmol) and stirred the reaction mixture at 80-90° C. for 24-48 hours. The reaction mixture was then diluted with ice-cold water and extracted with ethyl acetate. The combined organic extracts were washed with ice-cold water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.03 g. Mass (m/z): 334.24 (M + +1).
Example 32
3-(3-{[3-(Benzyloxy)cyclopentyl]oxy}-4-methoxyphenyl)-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 154
[0602] The title compound was synthesised by following the procedure as described for the synthesis of (Compound No. 137) by using the compound 3-(benzyloxy)cyclopentyl methanesulfonate in place of cyclopentene oxide. Mass (m/z): 424.07 (M + +1).
[0000] The following compound was prepared analogously,
Hydrochloride salt of 3-[4-methoxy-3-(piperidin-3-yloxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 163)
[0604] Mass (m/z): 331.1 (M + −HCl).
3-{3-[(2,6-Dichloropyridin-4-yl)methoxy]-4-methoxyphenyl}-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 167)
[0606] Mass (m/z): 408.8 (M + +1).
Example 33
2-(Difluoromethoxy)-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol
Compound No. 41
Step a: Synthesis of 3-(benzyloxy)-4-(difluoromethoxy)benzaldehyde oxime
[0607] Hydroxylamine hydrochloride (1.50 g, 21.58 mmole) and sodium acetate (1.769 g, 21.573 mmole) was added to a stirred solution of compound 4-(difluoromethoxy)-3-phenoxybenzaldehyde (1.50 g, 5.395 mmole) in ethanol (10 mL). The reaction mixture was stirred at room temperature for 3-4 hrs. Ethanol was evaporated under reduced pressure, which was diluted with water (20 mL) and the organic compound was extracted with ethyl acetate (2×15 mL). The ethyl acetate layer was dried over anhydrous sodium sulphate, filtered and concentrated under reduced pressure to afford the title compound.
Step b: Synthesis of methyl 3-[3-(benzyloxy)-4-(difluoromethoxy)phenyl]-5-(2-methoxy-2-oxoethyl)-4,5-dihydroisoxazole-5-carboxylate
[0608] Dimethyl 2-methylenesuccinate (1.078 g, 6.824 mmole) was added to the solution of compound obtained from step a above (1.00 g, 3.412 mmole) in tetrahydrofuran (5 mL), and the resulting reaction mixture was stirred at room temperature. Sodium hypochlorite (10 mL) was added slowly to the mixture thus obtained over the period of 20 minutes and the reaction mixture was allowed to stir at room temperature overnight. Tetrahydrofuran was evaporated off and the organic compound was extracted with ethyl acetate twice. The organic layer was concentrated to yield the title compound with a yield of 1.50 g.
Step c: Synthesis of 2-[3-[3-(benzyloxy)-4-(difluoromethoxy)phenyl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl]ethanol
[0609] The compound obtained from step b above (1.5 g, 3.340 mmole) was dissolved in tetrahydrofuran (10 mL) and lithium hydroxide in water solution (0.68 mL of 0.5 M aqueous solution, 16.682 mmoles, 5 eq) was added. The mixture was stirred for 1 hour at room temperature. The mixture was stirred for 5 hrs at 55-60° C. Solvent was removed under reduced pressure and the residue thus obtained was diluted with water and acidified with drops of concentrated hydrochloric acid. The organic compound was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and finally concentrated under reduced pressure to afford title organic compound with a yield of 1.103 g.
Step d: Synthesis of 2-[3-[3-(benzyloxy)-4-(difluoromethoxy)phenyl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl]ethanol
[0610] The compound obtained from step c (1.1 g, 2.428 mmole) was taken in tetrahydrofuran (7 ml) followed by the addition of sodium borohydride (0.276 g, 7.26 mmole) at 0-5° C. and boron trifluoride etherate (1.02 g, 7.28 mmole) was added dropwise and stirred for 14 hrs at room temperature. Solvent was removed under reduced pressure, water was added and extracted with ethylacetate. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish final product with the yield 0.732 g.
Step e: Synthesis of 3-[3-(benzyloxy)-4-(difluoromethoxy)phenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
[0611] To a solution of the compound obtained from step d above (1 eq) in tetrahydrofuran, triphenylphosphine (1.12 eq) and succinimide (1 eq), was added diisopropyldiazadicarboxylate (1.14 eq). The reaction mixture was stirred at room temperature for overnight. The organic solvent was removed under reduced pressure and the residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 40%.
Step f: Synthesis of 2-(difluoromethoxy)-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)phenol
Compound No. 41
[0612] To a solution of the compound obtained from step e above (0.200 g, 0.53 mmole) in methanol (10 mL), was added palladium on carbon (300 mg, 10%). The reaction mixture was evacuated with hydrogen gas and the resulting reaction mixture was allowed to stir at room temperature for 1 hour under hydrogen atmosphere. The reaction mixture was filtered through celite pad. The filtrate was concentrated under reduced pressure to furnish the title compound. Yield=60 mg. Mass (m/z): 286.03 (M + +1).
Example 34
(S)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 124
Step a: Synthesis of L-Ephedrine salt of 5-(carboxymethyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5-dihydroisoxazole-5-carboxylic acid
[0613] 5-(carboxymethyl)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-4,5-dihydroisoxazole-5-carboxylic acid (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (1.0 g, 2.87 mmol) and L-Ephedrine (0.95 g, 5.73 mmol) were dissolved in acetone (50 ml) and the mixture was refluxed for 4 h. The reaction mixture was slowly brought to room temperature (35° C.) and kept as it is for 24-36 hours to furnish the S-isomer. Yield: 0.3 g.
Step b: Preparation of (S)-methyl 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-(2-methoxy-2-oxoethyl)-4,5-dihydroisoxazole-5-carboxylate
[0614] Thionyl chloride (0.80 ml, 11.1 mmol) was added slowly to a dry-methanol (50 mL) at 0° C. under nitrogen atmosphere and stirred for 1 hour followed by the addition of solution of the compound obtained from step a above (1.88 g, 2.77 mmol) in dry-methanol (50 mL) at 0° C. The reaction mixture was slowly brought to room temperature and stirred at that temperature for 12 hours. The reaction mixture was concentrated and diluted with dichloromethane. The organic portion was washed with water, brine and dried over sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.92 g. m.p.: 92-93° C.; [α] D =−113.9° (C, 1.17, CH 3 OH).
[0615] 1 H NMR (CDCl 3 ) δ 7.35 (s, 1H), 7.05 (d, J=0.02 Hz, 1H), 6.85 (d, J=0.02 Hz, 1H), 4.81 (m, 1H), 4.00 (d, J=0.04 Hz, 1H), 3.88 (s, 3H), 3.82 (s, 3H), 3.72 (s, 3H), 3.48 (d, J=0.04 Hz, 1H), 3.27 (d, J=0.04 Hz, 1H), 3.00 (d, J=0.04 Hz, 1H), 1.95 (m, 2H), 1.88 (m, 4H), 1.63 (m, 2H). Mass (m/z): 393 (M + +1).
Step c: Synthesis of (S)-2-[3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl]ethanol
[0616] The compound obtained from step b above (0.85 g, 2.17 mmol) was dissolved in tetrahydrofuran (100 mL) and cooled to 0° C. and sodium borohydride (0.41 g, 10.9 mmol) was added portion wise. The reaction mixture was stirred for 1 hour followed by the addition of methanol (10 mL). The reaction mixture was stirred for 10 hour at room temperature. Reaction mixture was filtered and the solid thus obtained was washed with tetrahydrofuran. The organic solution was cooled to 0° C. and saturated ammonium chloride solution was added slowly over a period of 30 minutes. The reaction mixture was concentrated and diluted with ethyl acetate (100 mL). The organic portion was washed with saturated ammonium chloride solution, water and brine, dried over sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.5 g. m.p.: 108-109° C. [α] D =−5.32° (c, 1.17, CH 3 OH).
[0617] 1 H NMR (CDCl 3 ) δ 7.33 (s, 1H), 7.04 (d, J=0.02 Hz, 1H), 6.84 (d, J=0.02 Hz, 1H), 4.81 (m, 1H), 3.92-3.83 (m, 2H), 3.85 (s, 3H), 3.72 (m, 2H), 3.41 (d, J=0.04 Hz, 1H), 3.20 (d, J=0.04 Hz, 1H), 2.40 (bs, 2H, —OH), 2.07 (m, 2H), 2.05-1.83 (m, 6H), 1.63-1.61 (m, 2H). Mass (m/z): 336 (M + +1).
Step d: Synthesis of (S)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 124)
[0618] To a solution of the compound obtained from step c above (0.43 g, 1.28 mmol), triphenyl phosphine (0.37 g, 1.41 mmol) and succinimide (0.14 g, 1.41 mmol) was added dry tetrahydrofuran (20 mL) and stirred the reaction mixture for 20 minutes at room temperature which was subsequently cooled to 0° C. Diisopropylazodicarboxylate (0.30 mL, 1.54 mmol) was added slowly over a period of 10 minutes at 0° C. and further stirred the reaction mixture at room temperature for overnight. The reaction mixture was concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 0.28 g. m.p.: 110.5° C. [α] D =+1.76° (c, 1.19, CH 3 OH).
[0619] 1 H NMR (CDCl 3 ) δ 7.37 (s, 1H), 7.00 (d, J=0.02 Hz, 1H), 6.85 (d, J=0.02 Hz, 1H), 4.82 (m, 1H), 4.10 (d, J=0.03 Hz, 1H), 4.03 (m, 2H), 3.88 (s, 3H), 3.82 (d, J=0.03 Hz, 1H), 3.37 (s, 2H), 2.06 (m, 1H), 1.97-1.62 (m, 7H), 1.61 (m, 2H); Mass (m/z): 319 (M + +1).
[0620] The following compound can be prepared analogously by using D-Ephidrine in place of L-Ephidrine,
(R)-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (Compound No. 30)
[0622] Mass (m/z): 319 (M + +1).
Example 35
4-Bromo-3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene
Compound No. 149
[0623] To a solution of the compound 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene (disclosed in our copending patent application U.S. Ser. No. 60/498,947) (100 mg, 0.32 mmol) in chloroform (5 ml) was added N-bromosuccinimide (84 mg, 0.47 mmol) and azobutyronitrile (10 mg, 0.06 mmol). The reaction mixture was stirred for 2 hours and subsequently diluted with water. The mixture was extracted with dichloromethane, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified with column chromatography to furnish the title compounds. Yield: 40 mg. Mass (m/z): 395.97 (M + +1, Compound No. 149).
Example 36
3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4,4]non-2-en-4-ol
Compound No. 29
Step a: Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-4-yl acetate
[0624] To a solution of the 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-ene which is disclosed in our copending patent application U.S. Ser. No. 60/498,947 (100 mg, 0.26 mmol) in dimethylformamide (5 ml), was added sodium acetate (104 mg, 1.26 mmol) and stirred the mixture at 110° C. for 14 hours. The resulting reaction mixture was diluted with water and extracted with ethyl acetate. The organic layer was separated, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 110 mg.
Step b: Synthesis of 3-[3-(cyclopentyloxy)-4-methoxyphenyl]-1,7-dioxa-2-azaspiro[4.4]non-2-en-4-ol
[0625] To a solution of the compound obtained from step a above (42 mg, 0.11 mmol) in methanol (2 ml) was added potassium carbonate (46 mg, 0.34 mmol) under argon atmosphere and stirred the reaction mixture for 30 minutes at room temperature. The mixture was diluted with water and extracted with ethyl acetate. The organic layer was separated, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 28 mg. Mass (m/z): 334.13 (M + +1).
PDE-IV Enzyme Assay
[0626] The efficacy of compounds as PDE-4 inhibitor was determined by an enzyme assay (Burnouf et al.; J. Med. Chem., 2000, 43:4850-4867). The PDE-4 enzyme source used was U937 cell cytosolic fraction prepared by sonication. The enzyme reaction was carried out, with the cytosolic fraction as the enzyme source, in the presence of cAMP (1 μM) at 30° C. in the presence or absence of NCE for 45-60 min. An aliquot of this reaction mixture was taken further for the ELISA assay to determine level of cAMP in the sample. The concentration of the cAMP in the sample directly correlates with the degree of PDE-4 enzyme inhibition. Results were expressed as percent control and the IC 50 values of test compounds were reported to be in the range of about μM to low fM. For example, the IC 50 for PDE-IV inhibition ranged from about 1 μM to about 100 fM, or from about 600 nM to about 100 fM, or from about 400 nM to about 100 fM, or from about 200 nM to about 100 fM, or from about 100 nM to about 100 fM, or from about 75 nM to about 100 fM, or from about 1 nM to about 100 fM, as compared to rolipram (about 480 nM 5 repetitions). Compound No. 119 was not tested as it was insoluble under the experimental conditions.
Cell Based Assay for TNF-α Release
Method of Isolation of Human Peripheral Blood Mononuclear Cells:
[0627] Human whole blood was collected in vacutainer tubes containing heparin or EDTA as an anti coagulant. The blood was diluted (1:1) in sterile phosphate buffered saline and 10 ml. was carefully layered over 5 ml Ficoll Hypaque gradient (density 1.077 g/ml) in a 15 ml conical centrifuge tube. The sample was centrifuged at 3000 rpm for 25 minutes in a swing-out rotor at room temperature. After centrifugation, interface of cells were collected, diluted at least 1:5 with PBS and washed three times by centrifugation at 2500 rpm for 10 minutes at room temperature. The cells were resuspended in serum free RPMI 1640 medium at a concentration of 2 million cells/ml. Alternatively whole blood was used.
[0000] LPS stimulation of Human PBMNC's:
[0628] PBMN cells (0.1 ml; 2 million/ml) were co-incubated with 20 μl of compound (final DMSO concentration of 0.2%) for 10 min in a flat bottom 96 well microtiter plate. Compounds were dissolved in DMSO initially and diluted in medium for a final concentration of 0.2% DMSO. LPS (1 μg/ml, final concentration) was then added at a volume of 10 μl per well. After 30 min, 20 μl of fetal calf serum (final concentration of 10%) was added to each well. Cultures were incubated overnight at 37° C. in an atmosphere of 5% CO 2 and 95% air. Supernatant were then removed and tested by ELISA for TNF-α release using a commercial kit (e.g. BD Biosciences). For whole blood, the plasma samples were diluted 1:20 for ELISA. The level of TNFα in treated wells was compared with the vehicle treated controls and inhibitory potency of compound was expressed as IC 50 values calculated by using Graph pad prism.
[0629] Compounds 29, 33, 39, 52, 56, 57, 60, 61, 140, 148, 151, 154, 157 and 164 exhibited IC 50 in the TNF assay of from about 10 μM to about 0.27 nM, or from about 200 nM to about 0.24 nM, or from about 130 nM to about 0.24 nM, or from about 12 nM to about 0.24 nM, as compared to rolipram (about 240 nM, 4 repetitions).
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The present invention relates to isoxazoline derivatives, which can be used as selective inhibitors of phosphodiesterase (PDE) type IV. In particular, compounds disclosed herein can be useful in the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases in a patient, particularly in humans. The present invention also relates to processes for the preparation of disclosed compounds, as well as pharmaceutical compositions thereof, and their use as phosphodiesterase (PDE) type IV inhibitors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of co-pending application Ser. No. 223,203 filed Jan. 7, 1981 now U.S. Pat. No. 4,362,189.
FIELD OF THE INVENTION
This invention relates to an improved yarn clamp for controlling the movement of a strand of yarn, particularly in conjunction with the insertion of such strand within the shed of a weaving loom by means of a fluid insertion or projection system, and is concerned more particularly with a solenoid activated double acting yarn clamp providing positive clamping action.
BACKGROUND OF THE INVENTION
It is now well known in the textile art that weaving can be carried out at unusually high speeds and enhanced efficiency by means of so-called fluid weft insertion looms in which the weft strand is projected within the warp shed of the loom across the width of the loom by means of a burst of a fluid, such as air or even water, emitted under pressure from a propulsion nozzle disposed at one side of the loom and aimed towards the opposite side. The operation of looms of this type requires careful control of the movement of the yarn being inserted therein since during the insertion stage of the weaving cycle, the yarn must be able to be delivered freely to the insertion nozzle and thence across the loom shed while during other stages, it becomes necessary to positively restrain or clamp the yarn, during for example the accumulation of the supply of yarn for the next insertion cycle. These looms operate at levels of several hundred cycles or picks per minute or even higher and must be designed for a minimum of several million operating cycles at the very least with a minimum requirement for maintenance, and yarn clamps of the type previously known in this art are poorly suited for trouble-free operation during so large a number of cycles and, moreover, tend to lack the rapidity of operating response that is ideally needed for controlling the movement of the yarn under these conditions.
The object of the present invention is consequently to provide an improved yarn clamp characterized by an extraordinary durability and length of trouble-free operation and which, moreover, is capable of extremely rapid response under the control of an applied electrical signal.
A further object of the present invention is a yarn clamp which is movable between operative and inoperative positions in two steps or stages, thereby achieving an enhanced acceleration of its operating response.
A further object of the invention is a yarn clamp of the type described which is controlled by means of an electronic circuit designed following initiation by the application of a control signal to control the actuation of the clamp automatically through one complete cycle, with the possibility of readily adjusting the respective durations of the clamped and unclamped portions of that cycle.
These and other objects will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, somewhat idealistic, of the several individual event sensing units operative in the monitoring system of the invention arranged in sequence generally in operative relation as in a loom, all of the working parts of the loom, however, including supporting members for the units, etc., being omitted for sake of clarity, except as needed for an adequate understanding of such relation, e.g. of the yarn storage means.
FIGS. 2 and 3 are detailed views of the solenoid operated yarn clamp in which:
FIG. 2 is a top view, taken in section generally along line 2--2 of FIG. 3, to reveal the interior of the unit;
FIG. 3 is a vertical cross-section view taken substantially along lines 3--3 of FIGS. 2 and 4, while
FIG. 4 is a transverse cross-section view taken substantially along line 4--4 of FIG. 3;
FIG. 5 is an enlarged detailed view in perspective of the working end of the clamp of the invention, showing the relation in operative clamped position of the clamping bale, the fixed cylindrical clamping drum and the yarn clamped therebetween;
FIG. 6 is a diagram of the electrical circuit for operating the solenoid actuated yarn clamp; and
FIG. 7 is a collection of wave forms illustrating the operation of the components of the circuit of FIG. 6; and
DETAILED DESCRIPTION OF THE INVENTION
While the improved clamp of the present invention can be employed in association with a variety of different weft insertion systems and indeed for yarn clamping purposes generally, it is preferably associated with a weft insertion system as described and claimed in application Ser. No. 223,203, filed Jan. 7, 1981 and for a complete understanding of the details of the system found there, reference may be had to the complete contents of that application. In order to convey here a broad understanding of the type of context in which the improved clamp of this invention is preferably utilized, the following is a general description of the principal components of the arrangement employed for manipulating the yarn during its insertion as a weft in the shed of a loom, not shown.
A. Overall System
An overall view of the arrangement of the sensing units employed in the monitoring system of the present invention appears in FIG. 1 wherein the components of the loom which have no material relation to the present invention have been omitted for sake of clarity. Thus, all of the interior loom components which form and define the shed, etc., do not appear in FIG. 1, which is broken away to suggest this absence. FIG. 1 does show the end of the yarn metering and storage unit which functions to meter out the appropriate length of yarn according to the width of the loom in question, and store the same in readiness for delivery to the insertion nozzle when needed. The yarn metering and storage unit is the same as disclosed in the above identified related application, Ser. No. 64,180, and for further details of its structure and operation, reference may be had to the disclosure of that application.
As shown in FIG. 1, the yarn Y is delivered from a supply source not shown through a fixed yarn stop in the form, for example, of a guide aperture onto the surface of a storage drum D where it is collected into coils or windings W. From the coils W, the yarn passes through a yarn withdrawal or delivery monitoring unit generally designated T capable of sending a sudden rise in yarn operating tension incidental to complete withdrawal of the stored yarn supply from storage drum D, a solenoid-actuated yarn clamp generally designated C, which positively grips and holds the yarn during its accumulation on the storage drum and then releases the yarn preparatory to the weft insertion phase of the cycle, the weft insertion nozzle generally designated N which when actuated emits a blast of pressurized air through the throat thereof, and a yarn reception unit generally designated R which includes a suction tube for aspirating the leading yarn end therein with an associated sensing unit for sensing the actual arrival of the yarn end therein.
B. Improved Solenoid-Actuated Yarn Clamp
While it is within the scope of the broad concept of the present invention to utilize any type of solenoid-actuated yarn clamp and to derive a control signal from the actuation of that clamp in any of the ways available to do so in the art, there has been developed a special high speed solenoid-actuated clamp assembly that possesses operating characteristics peculiarly suitable for purposes of the overall monitoring system of the invention. This specially designed preferred clamping unit C is illustrated in FIGS. 2 through 5.
The solenoid is enclosed within the housing generally designated 71 the structure of which obviously can be subject to broad variation, but in the illustrative embodiment is constituted of a housing body 73 having bottom, top, opposed end walls and one side wall, and a removable side wall cover 75 forming the other side wall. The interior of the body is open and is divided into a shallow top compartment 77 together with a larger lower compartment 79 separated by a partition 82 which is interrupted as at 83 for a purpose to be explained later. The interior floor of the bottom wall of housing body 73 has two sections 85a, 85b the planes of which are relatively slightly inclined, say about 5°-10°, with an intermediate recess 87. Each of the floor sections 85a, 85b carries one of the coils or windings 89a, 89b of the solenoid and the area of these coils therefore diverge slightly, as indicated by the angle α between the cotted lines at the right of FIG. 9, and being about 5°-10° as explained.
Each of the solenoid windings 89a and 89b includes a center core 91a, 91c formed of soft iron with good magnetic properties and the mutually facing inner ends of these cores project somewhat beyond the corresponding limits of the windings with their end faces spaced apart a short distance and diverging at the same small angle α. The opposite end of each of the center cores 91a, 91b is formed as an L-shaped pole piece 93a, 93b also constituted of strongly magnetic soft iron, having the upstanding leg 95a,b thereof abutting the outward end of the core and its base leg passing beneath the windings to terminate in line with the plane of the end face of the associated core, thus, in effect, both poles of the magnetic core of each winding are located at the same end of the winding with their ends in alignment but in vertically spaced apart relation. The aligned end faces of the poles are separated by a space 99 and planes passing therethrough intersect at the same small angle α.
Within the space 99 separating the poles of the solenoid windings is a two-piece or duplex armature of which the premier body 101 has a generally rectangular yoke-like configuration, with its central area open as at 103. The lower end of body 101 extends into recess 87 in the housing body floor and is pivoted there for rocking movement around a transverse axis 105. Within the open central area 103 of the primary body 101 swings a secondary armature element 107, pivoted at its upper end of a pin 109 anchored in the upper ends of the primary body. As best seen in FIG. 10, the axes of the opposed solenoid windings 89a, b intersect at approximately the midpoint in the vertical dimension or height of the duplex armature assembly just described and well below the support axis for the swinging secondary element 107. It will be seen that the armature assembly as a whole is free to pivot bodily in the space 99 between the end faces of the opposed poles of the windings while the secondary armature element can swing independently.
The operation of the solenoid so far described is as follows: Assuming the duplex armature to be in a starting position abutting core 91a, as shown in FIG. 3, as the opposite winding 89b is energized (the electrical leads to the windings being omitted as unnecessary), the duplex armature responds in two-step fashion. Maximum magnetic field flux will exist across the end of pole piece 97b and the lower end of secondary element 107. The secondary element being freely swingable swings under the attracting force of this magnetic flux into contact with the adjacent end of the L-shaped pole piece 93a, b. due to this contact, the total air gap in the flux field is reduced and the flux field across the gap between the core 91b and the swingable secondary element 107 is thereby intensified which increases the magnetic attractive force of the coil for the upper end of secondary element 107 therefore bodily moves into contact with the core and, in so doing, carries along the primary yoke-shaped armature element 101. It has been found that this two-step action of the duplex armature actually achieves a significantly accelerated virtually instantaneous response of the armature which is highly desirable for high speed operation as is required in the operating loom.
The upper end of the primary yoke-like armature element is extended in tongue-like fashion as at 111 and privotally connected by a pin 113 to an elongated tubular slide or plunger 115 mounted for sliding movement within the upper compartment 77 of the housing 71. Preferably, the upper compartment is made oversize and a guide sleeve 117, which can be made of low friction material, such as "Teflon" plastic, is inserted therein, the interior of the guide sleeve being accurately dimensioned to receive tubular plunger 115 and to support the same for free reciprocating movement with a minimum of friction and wear. Tubular plunger 115 projects at one end externally of the housing as at 119 and from end 119 projects a C-shaped bail 121 which functions as the movable part of the yarn clamp. The fixed part or anvil of the clamp takes the form of cylinder 123 preferably mounted for free rotation about a vertical post 125. The bail moves as the plunger reciprocates in a vertical plane which is offset slightly to one side of the axis 125 of the cylinder 123 so that it makes contact with the periphery of the cylinder to one side of dead center. The throw of the bail 121 and sliding plunger 115 is adjusted to ensure the bail impacts firmly against the cylinder periphery and preferably must flex slightly out of a normal planar condition when in its ultimately projected position (as seen in exaggerated fashion in FIG. 2). As a consequence of this arrangement, the impact of the bail against the cylinder causes the cylinder 123 to rotate gradually about post 125 and thereby distribute the wear over its entire periphery and greatly prolong its useful life.
The supporting post 125 for cylinder 123 projects upwardly from a platform 127 attached to a flange-like extension 129 of the front end by means of a bolt 131, the opening for which is horizontally elongated as at 133 to allow the position of cylinder 123 to be adjusted relative to the path of the bail 121. As seen in FIGS. 2 and 3, the back edge of the platform carries an upstanding flange or ear 135 which has a horizontal yarn guiding slot 137 cut therein for stabilizing the path of the yarn Y passing between the bail and cylinder. Preferably, guiding means are provided for the yarn on the front side of the cylinder but such means need not be associated with the housing and are consequently omitted.
As explained, the top, back side, and interior partition 81 of the housing define a three sided channel 77 for receiving the clamp plunger and its guiding sleeve and the open side of this channel is closed by means of an elongated cover block 141 held in position by set screws 143. In accordance with the invention, the actuation of the yarn clamp serves to generate a control signal and while this could be achieved in any number of ways within the skill of the art, a preferred approach is to mount a Hall effect switch 145 is an insulating plug 147 fitted in a recess 149 on the interior side of the cover block for cooperation with a small magnetic plus 151 embedded in the clamp plunger 114. The relative positioning of Hall effect switch 145 and magnetic plug 141 are such that the two coincide with the switch when the clamp carrier is projected full outwardly to pinch the yarn between the bail and the cylinder and, in effect, close the clamp. In this position, the Hall effect switch is closed by the magnetic plug generating a positive control signal which is then utilized for purposes to be described later.
It will be obvious that the front side cover 75 of the housing 71 can be removed for easy access to its interior compartments to permit servicing and/or replacement of any of the parts of the unit. The angle of separation between the poles of the respective cores 91a, b is obviously selected to match the pivotal angle of the primary armature body 101. Adjustment of the winding assemblies of the solenoid can be facilitated by anchoring the assemblies on the housing with bolts (not seen) passing through oversize apertures.
The electrical circuit for energizing the solenoid windings of the clamp can naturally take many forms but a preferred circuit which has been found to be particularly suitable to the goals of the invention is illustrated in FIG. 6. This circuit utilizes a dual voltage concept in which the solenoid windings are subjected to an excess voltage, above their normal rated voltage, for a brief period at the beginning of each stage of operation of the solenoid and hence receive added energy to achieve positive and rapid response of the armature movement. For example, the windings of the unit in question are designed, say, for normal operation at 12 volts, but for a few milliseconds at the beginning of each transition of the armature, a significantly higher voltage, for example, about 30 volts, is applied across each winding to increase the magnetic flux field set up between their poles and the armature.
Further, it is preferred that this dual voltage concept be applied in a predetermined automatic stepwise sequence whereby when the operative cycle of the solenoid clamp has been once initiated, the unit proceeds automatically through its entire cgcle without further control intervention. The circuit illustrated in FIG. 6 is effective to accomplish this automatic stepwise sequential energization. A timing pulse or signal T 0 , generated in a manner to be explained more fully later, is applied to the input of a first or #1 one-shot 161. As known, a one-shot is an available electronic device which is capable upon the application thereto of either a rising or falling pulse of emitting an output pulse for a predetermined duration, according to its characteristics. In this case, the #1 one-shot 161 is activated by the rising pulse of the T 0 signal and is adapted to be adjusted in the length of its duration, an exemplary duration being 100 ms. The output from #1 one-shot 161 is delivered to the input of a second (#2) one-shot 163 which responds to a falling pulse and emits an output pulse for a period of e.g. 10 ms, and this output pulse in turn passes to a third (#3) one-shot 165 which again responds to a falling pulse and is adjustable in its duration, for example 35 ms. The output next passes to a fourth (#4) one-shot 167 responsive to a falling pulse with a duration of 10 ms, for example, which passes its output signal to the S input of an S-R flip-flop 169 which upon receipt of a positive pulse latches the pulse in the positive mode until it is reset by a signal at its R input. Resetting is accomplished with the output of the #1 one-shot 161, after inversion at the inverter 171 of its polarity so that the flip-flop is reset at the end of the output signal of #1 one-shot 161.
The opposed windings 89a, b of the solenois unit are for convenience designated right and left, according to their relationship in FIG. 3 and each winding is connected in parallel to each of a 30 volt and a 12 volt source through corresponding control relays. Relay CR 1 controls the 30 volt line 173 and the coil 163 of this relay is connected to the output of #2 one-shot 163 while relay CR 2 is in the 12 volt line 175 for the right winding and its coil is connected to the output of #3 one-shot 165. Relay CR 3 connects the left solenoid winding to the 10 volt source via line 177 and its coil is connected to the output of #4 one-shot 167, while relay CR 4 connects the left coil to the 12 volt source by line 179 and its coil is connected to the output of the flip-flop 169.
The circuit of FIG. 6 in effect constitutes a cascading series of four one-shots plus a terminal flip-flop which series responds automatically to carry out a complete operative cycle upon the receipt of an initiating pulse T 0 and then resets itself for the next cycle upon arrival of the next timing pulse. The operation of the circuit is illustrated by wave forms a-g in FIG. 19, and while such operation is undoubtedly self-explanatory, it will be summarized briefly as follows. A brief timint pulse T 0 (wave form g) is initially applied to the input of the #1 one-shot (wave form a) which holds the pulse for the adjustable period, in this instance 100 ms. When the output pulse of the #1 one-shot falls, the #2 one-shot is activated in the positive mode (wave form b) and emits a positive pulse for the set period of 10 ms which closes relay CR 1 for 10 ms applying 30 volts across the right solenoid coil for that period, opening the clamp (waveform f). When the #2 one-shot output ceases, the #3 one-shot is activated for the set time, in this case 35 ms, and the right coil thereby receives 12 volts over this period via relay CR 2 and the clamp remains open. With the expiration of the output of the #3 one-shot, the #4 one-shot is activated for its interval of 10 ms (waveform c) and the 30 volt source is thereby connected via relay CR 3 to the left winding of the clamping unit so as to return the solenoid armature and clamp to closed position and upon the expiration of #4 one-shot output, the flip-flop goes positive and latches its output in the positive mode, which connects the left winding to the 12 volt source through relay CR 4 and thus holds the 12 volts on the left coil so that the clamp remains in closed position and continues so (to hold the clamp closed) until the flip-flop is reset by the falling pulse of the #1 one-shot simultaneously with the activation of the #2 one-shot to open the clamp when the next timing pulse T 0 is received.
The timing of the opening of the clamp obviously has to be correlated with the working cycle of the loom so that the clamp is open to release the yarn for insertion into the loom shed when the loom is at the proper point in its operative cycle, i.e., approaching back dead center, for such insertion to take place. T 0 is fixed relative to the loom cycle and will normally correspond to front dead center and the purpose of the adjustable duration of the #1 one-shot is to allow the timing of the clamp actuating sequence to be varied to suit the requirements of the particular weaving cycle.
From these few possible variations in the practice of the invention, one will immediately perceive that the invention is not intended to be restricted to the specific embodiments selected for purposes of illustration and explanation but should be interpreted to encompass other modifications and variations possible in its construction and utilization within the skill of this art, and the invention should not, therefore, be limited in its scope except as required by the limitations of the appended claims.
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An improved solenoid actuated yarn clamp for controlling the flow of a moving strand of yarn particularly in conjunction with a fluid weft insertion loom. The improved clamp is double acting, being displaced positively between an operative yarn clamping position and an inoperative position releasing the yarn for further movement. The actuation of the clamp in both directions preferably occurs in two stages in which a relatively movable portion of the armature is first attracted into engagement with the energized solenoid, resulting in enhancement of the flux path of the solenoid, causing movement of the remainder of the armature. A preferred electronic circuit for regulating the actuation of the improved clamp is also disclosed which permits the adjustment of the clamping and nonclamping portions of the operative cycle of the clamp.
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FIELD OF THE INVENTION
The present invention relates to a device which reduces the risk of injury or damage occurring when a weapon impacts against a human being or an object.
BACKGROUND
In both military and civilian handling of firearms a large number of accidents occur every year in which injury is caused to people or damage to objects. In the handling of handguns it also happens that, for example, personal injury occurs when teeth are damaged or knocked out, because someone strikes the barrel of the weapon. Such accidents occur on many different occasions, for example in troop transport. In such transport, it is common that the soldiers sit with the weapon in front of them and support the butt of the weapon against the floor. In such instance, the barrel of the weapon is at face height. When the vehicle bumps and shakes while moving, there is a risk that the barrel of the weapon strike some part of the body. On such occasions, facial injuries and injuries to other parts of the body are unfortunately not uncommon.
Also on other occasions, for example on manoeuvres, on embarking or disembarking from means of transport etc., a soldier may be injured by his own weapon or his comrade's weapon. Material, which, for example, accompanies such transport may be damaged when the barrel of a weapon strikes the material.
It is obvious that there is a need for a device which reduces the risk of damage and injury of the above-type.
As regards military weapons, there is a need that the device can be employed regardless of whether the weapon is used for shooting with live or blank ammunition.
SUMMARY OF THE INVENTION
An object of the invention is to provide a device which satisfies the above needs. Hereafter the designation impact protection device will generally be employed for the device according to the invention.
The impact protection device according to the present invention is of a design and includes parts which consist of material which is deformed when the weapon strikes against something. As a rule, the impact protection device is designed such that the portions which are deformed consist of a material which reassumes its original form once the deforming forces aimed at the impact protection device have ceased.
As a result of the capability of the impact protection device to absorb impact and jolts, the risk is reduced that a person be injured or an object be damaged when a weapon with a mounted impact protection device strikes with its muzzle against the person or the object. Naturally, the risk that the weapon itself be damaged is also reduced.
Further objects and features of the present invention will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described further with the aid of embodiments shown in the accompanying drawings. In the accompanying drawing:
FIG. 1 is a cross-section through an impact protection device according to the present invention mounted on the flashguard of a weapon;
FIG. 2 is a cross-section through the impact protection device according to FIG. 1 in another configuration;
FIG. 3 is a perspective view of a bracket which is included in the impact protection device according to FIG. 1;
FIG. 4 shows an impact protector which forms part of an impact protection device according to FIG. 1 seen from the rear;
FIG. 5 shows a brace which is included in the impact protection device according to FIG. 1;
FIG. 6 is a longitudinal section through one embodiment of the impact protection device and a blank fire arrangement on which the impact protection device is placed;
FIG. 7 is a longitudinal section corresponding to that of FIG. 6 turned through 90° in relation to the longitudinal section in FIG. 6;
FIG. 8 is an end elevation of a part which is included in the impact protection device according to FIGS. 6 and 7;
FIG. 9 is a perspective view of an alternative version of a bracket according to the present invention; and
FIG. 10 is a side elevation, partly in section, of an alternative version of a combination of impact protector and brace included in the device.
DETAILED DESCRIPTION
FIGS. 1-5 show one embodiment of an impact protection device 1 . In the illustrated embodiment, the device includes an impact protector 1 a which is manufactured from an elastic material, for example a thermoplastic, a rubber material etc. By the intermediary of a brace 3 of elastic material, for example, rubber, the impact protector is connected to a bracket 2 . In FIGS. 1-5, the impact protection device is shown as applied on a flash protector 14 , hereinafter generally designated flashguard 14 . The flashguard is shown in the Figs. in one embodiment intended to be employed together with a weapon designated Ak 5 (automatic carbine). In use, the flashguard, which is designed to surround the barrel of the weapon when firing, is placed on the front region of the barrel (not shown) of the weapon. The embodiment of the impact protection device shown in the figures is intended to be employed on weapons which are made ready for firing with live ammunition.
A person skilled in the art will realize that the exact configuration of the impact protection device is adapted to the shape of the weapon in question or the flashguard in question, at the same time as the basic features of the impact protection device remain the same.
The impact protect 1 has, in the illustrated embodiment, an outer surface provided with grooves 5 a surrounded by flanges 5 b in order to improve the capability of the device to absorb impact, i.e. as a rule to be temporarily deformed in order to absorb impacts and jolts. In other embodiments, the outer surface is smooth, in which event the material is elastic and its thickness is sufficient to absorb impact. Designing the impact protector 1 a with grooves is a materials saving measure compared with an impact protector with a smooth surface. A distance from the one end region of the impact protector, hereafter referred to as the bottom end portion 15 of the impact protector, a stop member 4 is disposed, which entails that the bottom 150 of the impact protector will, on application of the impact protector, be located a distance from the muzzle of the flashguard 14 . As a result, the bottom end portion forms a “deformation zone” ahead of the muzzle, the deformation zone absorbing impact from the weapon from the front.
It will be apparent from FIG. 4 that the impact protector 1 a has two recesses 13 on the inside of the impact protector, which form projections 9 on the outside of the impact protector and which are disposed in register with one another. The tension with the recesses 13 is to be able to facilitate application and removal of the impact protector 1 a by pressing on the projections 9 . When the projections are depressed, the cross-section of the impact protector changes its configuration so that the impact protector will be easier to mount on or dismount from the flashguard 14 . Learning a reliable technique of applying or dismounting the impact protector is facilitated by the placing of the projection on the outside of the impact protector and by the fact that the simplest way of mounting and dismounting the impact protector is to use the above-described technique. What is to be avoided above all is that anyone places a hand on the bottom of the impact protector and attempts to force it in place on the flashguard. This is a dangerous operation since a shot fired inadvertently will pass through the hand.
On its inside, the impact protector 1 is provided with a number of rigidifying lands 17 . In the end portion of the impact protector which is opposed to the bottom end portion 15 , the lands 17 are bevelled at the muzzle of the impact protector in order to facilitate mounting in place of the impact protector. As a rule, the lands are located substantially at right angles to the bottom 150 . When the impact protector is applied on the flashguard, the lands are oriented substantially parallel with the longitudinal direction of the barrel of the weapon. While the lands 17 shown in FIG. 4 are disposed in the longitudinal direction of the impact protector, in other embodiments they make an angle with the longitudinal direction of the barrel. In yet further embodiments, there are no lands at all.
In the illustrated embodiment, the impact protector 1 a moreover serves the function of a muzzle guard. Each year, a number of accidents occur with hand firearms depending upon the fact that the bore is not completely clean when a shot is fired. What is blocking the bore is often material, snow, etc which has entered from outside into the bore as a result of careless handling on, for example, transport of the weapon. If a shot is fired, the blockage in the barrel of the gun will cause increase of pressure in the barrel which, in the worst case scenario, will burst. The pressure increase may also result in a fire plume striking the marksman's face.
The function of the muzzle guard is partly to prevent foreign matter from entering the barrel, and partly to prevent injurious pressure from building up. For this function, the bottom 150 of the impact protector 1 a is generally formed as a membrane. The membrane is of lesser thickness than the remaining material of the impact protector. The thickness of the membrane is selected such that the membrane ruptures before harmful pressure has built up in the barrel if a shot is fired by mistake with the muzzle guard mounted in place. The intention is, naturally, to remove the impact protector before the gun is fired, in which event the impact protector can be hung on the bracket 2 as shown in FIG. 2 . In certain embodiments, indications of fracture are provided in the form of grooves, and in others the membrane is of a thickness which decreases towards its centre.
The bracket 2 which is included in the embodiment of the impact protection device 1 shown in the figures has an arcuate portion 8 which is intended to be secured around the flashguard 14 by being clamped in place as a snap coupling. The bracket 2 is manufactured from a heat-resistant material, which withstands the temperature which the flashguard may reach in the event of automatic fire. The bracket 2 is moreover provided with a hook 7 which displays a through-going, keyhole-shaped aperture 16 in that part of the bracket which faces away from the flashguard. Furthest out on the hook 7 there is, on certain embodiments, a ridge 10 which improves the retention of the impact protector 1 a.
The brace 3 of elastic material, for example rubber, is press/fit connected in its one end in the aperture 16 in the bracket 2 , while the other end of the brace 3 is secured in an aperture 6 disposed on a projecting portion of the impact protector 1 a . By stretching the brace in order to reduce its diameter and pressing its one end portion 32 into the narrower part of the keyhole-shaped aperture 16 , the brace 3 is secured to the bracket 2 . Prior to this, the brace 3 has been passed in through the aperture 6 in the impact protector 1 a . The head 31 of the brace 3 is overdimensioned which prevents it passing through the aperture 6 . The projecting portion of the impact protector 1 a will be clamped between the head 31 and the suitably provided flange 33 in the brace.
When firing with live ammunition, the impact protector 1 a is removed by pressing on the projections 9 and sliding off the impact protector. The impact protector 1 a is then suspended on the hook 7 as shown in FIG. 2, the weapon being ready for action. By the form and placing of the brackets 2 and the impact protector 1 a it will be a natural and simple movement to remove the protector 1 a and suspend it in the bracket 2 , and vice versa. Thanks to the brace 3 , the impact protector 1 a will not be dropped even if it comes loose from the hook 7 . The protector 1 a is simple to mount in place and dismount even in darkness, thanks to the projections 9 . A person skilled in the art will perceive that the brace 3 and its securing in the various parts may be put into effect in other ways in other embodiments and that the figures show but one example of how this may be done. Even when the impact protector 1 a is suspended in the bracket 2 , impact damping is afforded in one direction.
In one alternative embodiment of the impact protection device 1 use is made of the impact protector 1 a alone, i.e. without the bracket 2 . The impact protector 1 a is, in this instance, stored in another manner than that described above when it is not mounted on the barrel of the firearm.
When firing with blank ammunition, the impact protection device 1 intended for firing with live ammunition is removed by snapping off the bracket 2 from the flashguard 14 . As a result of the design and construction of the impact protection device, the device is still held together as a unit.
FIGS. 9 and 10 show an alternative embodiment of the impact protection device. In FIG. 9, the bracket 30 is shown in one embodiment which differs from the bracket 2 described above in three respects. First, the corners 44 of the arcuate portion 8 are rounded and/or the edge between the corners is rounded (not shown in the figure), secondly, the inside of the arcuate portion 8 has been provided with a rib 39 , and thirdly the keyhole-shaped aperture has been replaced by elongate aperture or elongate gap 38 .
The intention with the rounded corners is that the bracket 30 be easier to mount on and dismount from the flashguard 14 . In order to counteract the risk that the bracket 30 is less secure in place because of the rounded corners, the inner side of the arcuate portion 8 is provided with a longitudinal rib 39 . The rib 39 intimated in FIG. 9, results in the arcuate portion 8 of the bracket 30 being clamped harder against the flashguard 14 .
In the embodiment illustrated in FIG. 10, the brace 41 constitutes an integrated part of the impact protector 1 a made of elastic material, for example rubber. Normally, the. brace 41 is thus formed simultaneously with the impact protector 1 a . In other embodiments, the brace 41 is formed as a separate part which, with the aid of welding, gluing, etc, is secured to the impact protector 1 a in the normal manner.
In the formation of the brace 41 , it is provided at its free end with an upwardly curved and relatively configurationly stable portion 43 which terminates with a head 42 . The performing of the brace 41 with its upwardly curved portion 43 entails that the brace 41 runs freely in the longitudinal gap 38 of the bracket 30 . Normally, the length of the brace 41 is adapted such that the impact protector 1 a does not come loose from the flashguard 14 until the impact protector 1 a is pulled by hand forwards and thereby stretches out the elastic brace 41 .
In yet a further alternative detailed design (not shown) the flanges 40 of the impact protector 1 a which are located furthest back (the flange is located on the end opposite to the bottom of the impact protector) are provided with a recess which fits around the curved portion of the hook 7 . As a result, it is possible to move the impact protector 1 a further in on the hook 7 , which in turn entails that the impact protector is better fixed on the hook.
A person skilled in the art will perceive that the detailed minor forms which vary between the embodiments may be combined in a number of different ways.
When firing with blank ammunition and using the weapon Automatic Carbine No. 5, a blank firing device 25 (FIGS. 6-8) is fixedly screwed on the weapon ahead of the flashguard 14 .
One problem is that the blank firing device 25 rapidly becomes relatively hot, for which reason the impact protection device must withstand high temperatures. In the choice of material and design and construction, the inventors have them taken as their point of departure that the impact protection device must withstand a temperature of at least 300° C.
In the embodiment illustrated in FIGS. 6-8, an impact protector 1 b which comprises two parts is included in the impact protection device. The first part constitutes a mechanically rigid inner part 18 , hereinafter generally referred to as inner part 18 . The other part is an elastic outer part 19 , hereinafter generally referred to as outer part 19 . Both the inner and outer parts consist of heat-resistant material.
The inner part 18 is, in the illustrated example, of plastic, for example a thermoplastic, and comprises two identical halves which are placed over a blank firing device 25 disposed on the weapon in order to surround it at least in a region most proximal the muzzle of the blank firing device. The outer part 19 of plastic material is then passed on the inner, harder part 18 . The outer part 19 here forms a sleeve which holds the inner part 18 in place. In design, construction and choice of material, it has thus been insured that the outer part 19 is sufficiently elastic to be able to be passed on the inner part 18 . Once the outer sleeve has arrived in place, the outer and inner parts form the impact protector 1 b whose function corresponds to that previously described with reference to FIGS. 1-7.
The two halves which form the inner part 18 have been provided with pins 34 a and holes 34 b in which the pins enter when the halves are laid together. The form of the inner part 18 is adapted so that it adheres to the form of the blank firing device 25 . The inner part 18 has a number of heels 22 , 23 which are turned to face towards the blank firing device 25 when the inner part is placed on the blank firing device. It is only these heels 22 , 23 which are in direct contact with the possibly hot blank firing device 25 , otherwise there is an air gap between the inner part 18 and the blank firing device 25 . In the illustrated example, the inner part 18 is in contact with the blank firing device 25 in twelve restricted regions, i.e. there are twelve heels 22 , 23 .
In order to lead off heat, the inner part 18 has, in the illustrated embodiment, a mesh or grid-like design, but is mechanically rigid. Each half which forms the inner part 18 has a number of rib-like elements which are oriented in the axial direction (longitudinal direction) of the device, and a number of rib-like elements which are oriented transversely of the longitudinal direction (cross-wise). There may be, for example, three elements in the transverse direction and five elements in the longitudinal direction. In alternative embodiments, the inner part is more in the form of a shell with a large number of airholes for leading off heat.
The outer part 19 is made of the same material as the impact protector 1 a and has the same fundamental construction as the impact protector 1 a for firing with live ammunition in accordance with the foregoing. The only major difference, apart from the rigid lower part 18 is that the impact-absorbing part 19 normally has no bottom corresponding to that described for the impact protector 1 a . When firing with blank ammunition, no muzzle guard is needed.
The outer part 19 has been provided with grooves 24 a and flanges 24 b in order to provide better impact absorption and in order to save material. In a number of embodiments, the outer part 19 has a smooth surface. In all embodiments, the thickness and elasticity of the material are selected analogous with that previously disclosed for the impact protector 1 a so that impact is absorbed in a satisfactory manner. The outer part 19 is designed such that the edge of its front portion 29 lies a distance ahead of the front edge of the blank firing device 25 , in order to absorb impacts which comes straight from in front.
The outer part 19 has two recesses 27 (FIG. 7) in register with each other and which form projections 26 on the outside. In a plane which, in cross-section, has been turned through 90° in relation to a plane which passes centrally through the recesses 27 , the outer part 19 has recesses 21 for receiving pins 20 provided on the outer surface of the inner part 19 . The pins 20 have been designed so that their upper surface inclines somewhat forwardly in order to facilitate application of the outer part 19 . When the projections 26 are pressed, the outer part 19 is deformed, the recesses 21 disengaging from the pins 20 and the outer part 19 may be taken off. Also when the outer part 19 is to be placed on the inner part 18 , the projections 26 are depressed. In such instance, it must be ensured that the recesses 21 and the pins 20 are in register with each other. The inner part 18 has guides 36 which project out from its outer surface and are intended to enter into grooves 35 in the inner surface of the outer part 19 . This ensures correct orientation between the inner part 18 and the outer part 19 .
For dissipating heat, the outer part 19 is also provided with holes 28 in certain embodiments. In the front portion, the outer part 19 is in contact with material in the inner part only at one or a few regions 37 , whereby good ventilation will be obtained.
In the blank firing alternative, the impact protection device is normally in place the whole time and is only removed for weapon care.
When the impact protection device is to be mounted in place for firing with blank ammunition, the two identical halves which form the inner part 18 are laid around the blank firing device 25 . In such instance, the pins 34 a on the one half 18 will enter into holes 34 b in the other half. Thereafter, the outer part 19 is passed on the inner, united part 18 by pressing the projections 26 , ensuring that the guides of the inner part 18 enter into the grooves 35 of the outer part 19 . The outer part is passed on so far that the pins 20 on the inner part 19 enter into the recesses 21 in the rear portion of the outer part 19 . On removal of the impact protection device, the projections 26 are pressed for lifting the recesses 21 of the outer part from the pins 20 of the inner part. It is then possible to remove the outer part 19 and thereafter separate the inner part 18 .
The above detailed description has referred to but a limited number of embodiments of the present invention, but a person skilled in the art will readily perceive that the present invention encompasses a large number of embodiments within the scope of the appended Claims.
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An impact protection device ( 1 ) for a weapon which is disposed, in use, to surround the barrel of the weapon at least in its muzzle region. The device has material portions which resist in mechanical forces applied against the weapon in these portions so that the portions are deformed. In order to improve the impact absorption and also for purposes of saving material, the impact absorbing part ( 1 a ) is provided with grooves and flanges ( 5 ). The form of the impact-absorbing part is adapted to the form of each respective weapon. Three variations are provided, one for surrounding the barrel of the weapon, another for surrounding a flashguard ( 14 ), and a third for surrounding equipment for firing blank ammunition.
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The present invention relates to a method and apparatus for measuring out by weight.
BACKGROUND OF THE INVENTION
Apparatuses for measuring out by weight are known that generally comprise carousel having a rotatably mounted platform supporting a series of weighing members above which filling nozzles are disposed that are connected to a feed member. The opening and closing of the filling nozzles is controlled by a weighting processor unit connected to the weighing members. Receptacles to be filled are brought one after another onto a weighing member and they are filled while the platform is rotating, prior to being removed therefrom.
Given the space occupied by the devices for installing empty receptacles and for removing receptacles that have been filled, filling cannot be performed over an entire turn of the platform, but only over a fraction of a turn. In general, filling takes place over an angular sector of about 270° which corresponds to a maximum filling time that is a function of the speed of rotation of the platform. This speed of rotation of the platform is itself given by the throughput desired from the installation as a whole. In present systems, it is common to require an installation to have a filling throughput that may be as high as several hundred receptacles per minute.
In present systems, the weight of substance inserted into a receptacle is controlled either by timing or by weighing. When control is by timing, a first estimate is made of the time required for inserting a determined weight of substance into a receptacle, then the weight actually inserted into receptacles is checked, and the length of time the filling nozzles are opened is adjusted as a function of the difference between the weight as actually measured and the reference weight desired in the receptacle. Thus, in order to be able to adjust the actual filling time it is necessary to provide an adjustment period of time at the end of filling corresponding to some angular sector and during which the filling nozzles may be opened or closed. This adjustment period of time is used to a greater or lesser extent depending on whether filling actually takes place more slowly or more quickly than initially expected. This adjustment period of time must be taken from the maximum available filling time such that the actual filling time is less than the maximum filling time.
When filling is directly controlled by weighing, the weighing member switches off the filling operation when the weight inserted in the receptacle reaches a determined threshold. The actual time taken for filling therefore varies, in particular as a function of the viscosity of the substance. Under such circumstances, it is thus also necessary to provide an adjustment period of time at the end of filling during which the filling nozzles are closed or are kept open depending on whether or not the reference weight threshold has been reached. As before, it is therefore not possible to make continuous use of the maximum filling time.
In either case, it is therefore necessary to provide the platform with a speed of rotation that allows normal filling to take place over an angular sector that is smaller than the maximum angular sector, e.g. over an angular sector of 240° rather than 270°. Given that the maximum flow rate through a filling nozzle is necessarily limited, the existence of an adjustment period of time necessarily puts a limit on the speed of rotation of the platform so as to ensure that enough time is available for normal filling while travelling through an angle of 240°. The throughput of the installation is thus correspondingly limited.
In addition, when the substance is semisolid, it is necessary to exert pressure thereon to cause it to leave the filling nozzle. The jet of substance transmits this pressure to a greater or lesser extent to the top of the substance already in the receptacle, depending on the viscosity of the substance, and thereby giving rise to an error in the data obtained by the weighing member. When filling is directly controlled by weighing, i.e. When the filling nozzle is closed on the weight reaching a determined threshold, such errors can be unacceptably large.
The object of the invention is to provide a method and an apparatus enabling filling throughput to be increased relative to existing devices, without loss of accuracy.
SUMMARY OF THE INVENTION
According to the present invention, this object is achieved by a method of weighing out comprising the following steps: inserting a substance into a receptacle with at least one filling stage of fixed duration during which filling is performed at a flow rate servo-controlled to a reference flow rate by a servo-control relationship between a flow rate error and a setting applied to a flow rate control member; measuring the weight of substance contained in the receptacle after filling; comparing the weight of substance contained in the receptacle with a reference weight; and adjusting the reference flow rate as a function of a difference between the weight of substance contained in the receptacle and the reference weight.
Thus, since the time taken for filling is constant, the entire filling zone is used on each occasion, so the speed of rotation of the platform can be increased so that the filling zone is travelled through in the specified fixed time. In addition, when filling is monitored as a function of flow rate rather than of weight, it is possible to eliminate those magnitudes that usually disturb weighing, in particular the pressure of the jet and the tail-back of the substance that has already left the filling nozzle, thereby making it possible to perform correction systematically and with great accuracy.
In an advantageous version of the invention, when the method includes at least two filling stages at different reference rates, at least one of the reference flow rates is adjusted as a function of the difference between the weight of substance contained in the receptacle and the reference weight. Thus, when the method includes filling stages at very different flow rates, a small difference in the weight of the substance contained in the receptacle relative to the reference weight can be corrected by acting on the smaller flow rate while a large difference is preferably compensated by acting on the greater flow rate.
The method of the invention is preferably implemented by means of weighing out apparatus comprising a feed member connected to at least one filler nozzle via a flow rate control member, a receptacle disposed beneath the filler nozzle and supported by a weighing member, and a weighing processor unit connected to the flow rate control member and to the weighing member to form a servo-control loop applying a setting to the flow rate control member so as to maintain a flow rate of substance through the filler nozzle at a reference flow rate, which flow is servo-controlled during a fixed length of time, comparing the weight of substance inserted into the receptacle with a reference weight, and adjusting a parameter of the servo-control loop as a function of a difference between the weight of substance inserted and the reference weight.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a weighing out apparatus of the invention; and
FIG. 2 is a flow chart illustrating the method of the invention.
DETAILED DESCRIPTION
With reference to FIG. 1, the apparatus of the invention includes a feed member 1. For example, the feed member may be a tank carried by the rotary platform of a carousel or it may be a tank separate from the carousel and connected thereto via a duct including a rotary joint. Flow from the feed member may be assisted by a centrifugal pump.
The feed member 1 is connected to a series of filler nozzles 2 (only one of which is shown in the FIGURE) via respective flow rate control members 3, each disposed upstream from a corresponding filler nozzle in the flow direction of the substance. The flow rate control members 3 may be variable-section valves or Archimedes' screws controlled by variable-speed stepper motors, with the speed of a motor determining the flow rate driven by an Archimedes' screw, in particular with a semisolid substance such as mayonnaise or a non-homogeneous substance such as a sauce with solid pieces in it.
A weighing member 4 is disposed vertically beneath each filler nozzle, and a receptacle is placed on each weighing member at the beginning of a filling cycle.
The weighing member is connected to an input 7 of a weighing processor unit 6 having another input 8 via which it receives initial data specific to the substance to be packaged. The initial data may, in particular, comprise the reference flow rate and the duration of each filling stage, together with the servo-control relationship that exists between a measured flow rate error and the reference flow rate that the weighing processor unit should be applying to the flow rate control member. It will be understood that this servo-control relationship varies depending on the fluidity of the substance. In particular, if the flow rate control member is a variable-section valve, the same flow section does not provide the same flow rate (e.g. 50 grams per second) for all substances be they liquid or semiliquid, and even with the same substance, flow rate may vary with variations in the pressure applied upstream from the flow rate control member, or with variations in the temperature of the substance (which affects its viscosity). The initial data thus contain either the servo-control relationship between the flow rate error and the setting to be applied to the flow rate control member in direct form, or else it contains parameters such as the nature of the substance, its temperature, and its feed pressure, and the weighing processor unit is then provided with calculation members enabling it to establish the servo-control relationship between the reference flow rate and the setting it actually needs to apply to the flow rate control member. As mentioned above, the setting applied depends on the type of flow rate control member used. For example, it may be given by the size of the flow section of a variable-section valve, or by the speed of rotation for a motor driving an Archimedes' screw. The outlet from the weighing processor unit 6 is connected to the flow rate control member to form a servo-control loop.
In addition, the weighing processor unit 6 is fitted in conventional manner with a clock and with a calculation unit enabling it to determine at all times the effective filling rate of a receptacle by comparing the increase in weight of the receptacle with the time that has elapsed since the last time its weight was measured. Given that modern weighing members have an extremely rapid reaction time, of the order of 1,000-th of a second, the pressure of the jet of substance has practically no time to change in the interval between two weight measurements, and as a result the measured difference in weight is indeed representative of the quantity of substance that has been inserted into the receptacle during the time interval under consideration, with an extremely accurate measure of the real flow rate thus being obtained.
As measured above, the initial data concerning the reference flow rate and the duration of each of the filling stages is applied to the weighing processor unit as a function of the substance to be packaged. For example, if it is desired to package 1 kilogram of a liquid that is liable to foam on striking the bottom of a receptacle suddenly, it is preferable to provide an initial filling stage at a low flow rate so as to insert a small amount of substance without causing it to foam, e.g. a first stage at a flow rate of 100 grams per second and lasting for half a second, followed by a filling stage proper at a higher flow rate, e.g. at 500 grams per second for 1.8 seconds, and finally an end-of-filling stage again at a low rate in order to enable the flow to be stopped accurately. For example, the final stage may be at a rate of 100 grams per second and may last for half a second.
The filling method then takes place as shown in FIG. 2, i.e. a receptacle is initially placed on the weighing member which transmits the empty weight of the receptacle as measured to the weighing processor unit. The first stage is then performed, e.g. by opening the flow rate control member 3 to deliver a flow rate D1 during a time ti. In the example mentioned above, D1=100 g/s and t1=0.5 s, with the initial setting applied to the flow rate control member being a function of the reference flow rate obtained by applying the servo-control relationship as initially input or calculated by the weighing processor unit, as mentioned above. The weighing member measures the apparent weight at regular intervals, e.g. once every hundredth of a second, i.e. it measures the force applied on the weighing member, which force is the result not only of the weight of the empty receptacle plus the substance it contains, but also of the pressure due to the jet of the substance. This information is applied to the weighing processor unit which takes the difference between the new value and the value obtained at the preceding instant and divides the difference by the time lapse. If the effective flow rate as determined in this way is different from the reference flow rate D1, a correction is instantly applied to the flow rate control member by giving it a new setting, as obtained by applying the above-mentioned servo-control relationship to the flow rate error. Once the time t1 has elapsed, the weighing processor unit applies a new setting to cause the flow rate control member to deliver the substance at a reference rate D2 for a time t2. As before, if the real rate is different from the reference rate, then the weighing processor unit changes the setting applied to the flow rate control member so that the real flow rate becomes equal to the reference rate. The same takes place during the third filling stage.
When filling is completed, the weighing member sends a total weight measurement signal to the weighing processor unit without interference from the pressure of the jet of substance. By taking the difference with the empty weight of the receptacle, the weighing processor unit calculates the net weight of substance inserted into the receptacle and compares this net weight with the reference weight, i.e. 1 kg in the present example. If the net weight differs from the reference weight, then at least one of the reference flow rates is adjusted so as to compensate this difference during the next filling operation. For example, in the example under consideration, if the weight turns out to be only 998 g, then the reference rate during the last stage is raised to 54 g/s, thereby automatically changing the initial setting applied to the flow rate control member at the beginning of said stage. If the effective net weight differs considerably from the reference weight, it may then be desirable to change the reference flow rate during the second filling stage rather than the reference flow rate during the third filling stage. Which reference flow rate to change can be decided on the basis of a difference threshold between the real net weight and the reference net weight so as to avoid changing the reference flow rate during the third filling stage too much: for example, if the difference between the real net weight and the reference net weight at the end of a first filling operation is 90 g too much, e.g. because the substance is much more fluid than expected, then there is no way in which the third filling stage could be adjusted to compensate for this excess, and it is preferable to reduce the reference flow rate during the second filling stage, bringing it down to 450 g/s, while keeping constant the servo-control relationship between the measured flow rate and the set rate applied to the control member so that servo-control at a rate of 450 g/s for a period of 1.8 s makes it possible to deliver 900 g of substance in fact.
It may be observed that because filling is performed over a constant length of time, it is possible to make use of all of the angular sector that is available for filling. Thus, in the above example where the total filling duration is 2.8 seconds, and assuming that the angular sector available for the complete filling operation is 270°, it is possible to drive the platform of the carousel at a speed enabling it to perform one revolution in 3.7 seconds, i.e. at 16.2 revolutions per minute (rpm). For a machine fitted with ten filler nozzles, the total throughput then obtained is 162 receptacles filled per minute. In contrast, in existing devices where it is necessary to leave an adjustment period of time at the end of filling, and assuming that the minimum filling time is 2.8 seconds as in the above case, then an angular sector of only 240° is available, and the time taken to travel along this sector must again be 2.8 seconds, which means that the platform takes 4.2 seconds to perform a complete turn. The platform can therefore rotate at 14.2 rpm only, and for an installation fitted with ten filler nozzles, the total throughput will be only 142 receptacles per minute. It can thus be seen that the invention makes it possible to increase the throughput of an installation significantly compared with existing installations.
Although the invention is described above on the basis that the reference flow rate is adjusted if the real net weight does not match the reference net weight, the method of the invention can also be implemented in any directly equivalent form, i.e. by acting on one of the parameters in the servo-control relationship between the measured flow rate and the setting given to the flow rate control member. In particular, it is possible to act on the gain of the servo-control loop formed by the weighing member 4, the weighing processor unit 6, and the flow rate control member 3. Under such circumstances, for the same reference flow rate, changing a parameter in the servo-control loop changes not only the initial setting given to the flow rate control member, but also the reactions of said member during servo-control such that while keeping the filling time constant it is possible to correct the real net weight inserted into a receptacle. The changes performed on the parameters of the servo-control loop may either on the gain of the loop or on the comparison performed between the real flow rate and the reference flow rate, e.g. by taking an average of the real flow rates (weighted to a greater or lesser extent) prior to making the comparison with the reference flow rate and applying a new setting to the flow rate control member.
Naturally the invention is not limited to the embodiment described and various embodiments can be provided without going beyond the ambit of the invention. In particular, although the invention has been shown diagrammatically as having a filler nozzle disposed above the neck of a receptacle, it is also possible to use a moving or "dipping" filler spout which is initially inserted into the receptacle and which is then raised progressively during filling. Such a procedure is possible with the invention, whereas using a dipping spout in weighing out machines where the flow of substance is switched off by a threshold weight being reached gives rise to considerable inaccuracy because of the buoyancy thrust due to the filler spout being immersed in the substance and which has a measurable effect on the weighing performed by the weighing member.
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The method comprises the following steps: inserting a substance into a receptacle with at least one filling stage of fixed duration during which filling is performed at a servo-controlled flow rate using a servo-control loop including a weighing member, a weighing processor unit, and a flow rate control member; measuring the weight of substance contained in the receptacle after filling; comparing the weight of substance contained in the receptacle with a reference weight; and adjusting the servo-control relationship as a function of a difference between the weight of substance contained in the receptacle and the reference weight. An apparatus is provided to accomplish the above functions.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Application No. 13/290,929, filed Nov. 7, 2011 incorporated by reference in its entirety.
BACKGROUND
[0002] The present invention is generally directed to the manufacture of medical devices. More specifically, the present invention includes a system and method for manufacturing bilayer adhesive patches that are to be bonded to a medical device that is formed in such a manner that patching is required to complete the manufacture of the device.
[0003] Current manufacturing processes to make many medical implantable devices involve forming thin silicone elastomer shells by dipping or molding a thin layer of silicone material on a male mandrel. For example, in the manufacture of breast implants, the outer silicone membrane is formed on a male mandrel. The membrane, typically called a “shell,” is removed from the mandrel by cutting a small hole in the shell so that the shell can be removed from the male mandrel without deforming or tearing the shell. Through the hole, the surrounding edges of the shell can then be grasped to stretch and peel the remainder of the shell from the male mandrel more easily. After the shell is off of the mandrel the small circle or hole must be patched to close the shell so as to provide full containment integrity to the shell so that it may then be filled with a filling material, such as a silicone gel.
[0004] Current processes of making bilayer patches for medical and cosmetic implants and prosthetics are more difficult, costly, and time-consuming than they need to be. Patches for devices such as breast implants formed from silicone usually have a first layer that is vulcanized, which is then applied to a second layer that is unvulcanized.
[0005] Vulcanization generally refers to the process of crosslinking the silicone polymer based material to form a dry, non-adhering material with good elastomeric memory. The vulcanized layer is thin, typically less than 0.5 mm and preferably less than 0.2 mm. Forming thin layers with sticky unvulcanized silicone elastomer bases is difficult and typically done by calendering or solvent based knife-coating, with subsequent devolatilization and vulcanization on a sheet of base plastic such as Teflon® (sold by DuPont), polyester or polyethylene.
[0006] The unvulcanized portion or layer of the bilayer patch, typically less than 0.5 mm thick, is typically applied to the vulcanized layer by calendering unvulcanized silicone into a thin layer and then applying that layer to the vulcanized layer described above. Calendering refers to the process of forming a uniform thickness thin layer by pressing uncured malleable elastomer systems between rotating cylinders or rollers. It is difficult to peel thin layers off of the rollers used for calendering without tearing or breaking the fragile thin unvulcanized layer. Accordingly, this process often results in a high loss factor. Alternatively, the unvulcanized layer can be applied to the vulcanized layer by a solvent dispersion technique and subsequently devolatilizing the assembly before proceeding with applying the patch to the shell to close the opening cut into the shell to remove shell from the mandrel. After the vulcanized and unvulcanized layers are joined, they are typically supported on a thin plastic sheet.
[0007] Regardless of how the vulcanized silicone layer and unvulcanized silicone layer used to form the patch are combined, once combined both sides are typically covered with a thin layer of a thermoplastic polymer such as polyethylene. The polyethylene covered bilayer sandwich is then cut into the desired size and shape for the patch.
[0008] Consistent with current modern manufacturing procedures, the patches are then transferred to another work area in which an assembler manually peels off the polyethylene coating and applies the patch to the shell by placing in into the shell, vulcanized side away from the hole and unvulcanized side facing the hole. Vulcanization and bonding are typically achieved by applying heat and pressure to the assembly.
[0009] Another technique that has been investigated for the manufacture of thin patches is the use of injection molding to form the patch. Injection molding of silicone elastomers and plastics is common practice and a well-developed art, though it may also be used for other materials. A wide variety of products are manufactured using injection molding, which vary greatly in their size, shape, complexity, and application.
[0010] “Green strength,” a measure of tack, deformability, elastic memory and malleability of the unvulcanized silicone elastomer base is a relevant limiting factor to injection molding. Moderate green strength silicone materials typically used in forming silicone elastomer shells do not easily lend themselves to typical mixing systems such as two roll milling (calendering) or pumpable paste static mixer systems.
[0011] Green strength can be a good indication of processing behavior and a moderate to high green strength is desirable in processing operations in which it is important to maintain the integrity of a shape piece of material, particularly for the unvulcanized layer.
[0012] Thick preforms of high green strength unvulcanized silicone, typically formed by continuous extrusion and chopping, are commonly used in industrial processes. However, injection molding of thin preforms having moderate green strength and tack is not known to have been done before commercially for this application on account of the adhesion between a thin preform of unvulcanized silicone and common mold materials (e.g. aluminum or steel) being too strong to provide a reliable release that preserves the integrity of the thin preform upon removal from the mold. Injection molding of thin preforms is not commercially practical when losses due to the preforms being damaged, deformed, or partially stuck to the mold are too costly.
[0013] There is a need for an improved method for forming thin bilayer silicone patches that is less expensive, less labor and time intensive, and that reduces the loss factor of material waste. For example, the traditional process of removing the polyethylene coating is tedious and transporting the patches from one work station to the next for processing creates delays, inefficiencies, and increased costs for labor and facilities. It would be desirable to provide an improved method for forming implant and prosthetic patches in which the patch assembler is able to mold the patches on demand at a single work station. It would be especially desirable to provide a method for injection molding of thin preforms that preserves the integrity of the preforms upon removal from the mold. The present invention satisfies these and other needs.
SUMMARY OF THE INVENTION
[0014] In its most general aspect, the present invention provides a process for molding patches for medical and cosmetic implants and prosthetics more efficiently with less material and economic waste. The method provides several improvements over current techniques used in the art of manufacturing patches. For example, the method avoids problems inherent in calendering very thin materials as are required to form the patches.
[0015] In a more specific aspect, the present invention provides a way to injection mold unvulcanized and mating vulcanized preforms of very thin materials of low green strength while preserving their integrity upon removal from the mold. According to one aspect of the present invention, this is accomplished by first spraying a mold, including a conventional mold, with a low surface energy release agent that coats the mold and facilitates removal of the preform from it. According to another aspect of the present invention, this is accomplished by using molds in which the portions of the mold that make contact with the preform are formed of different materials than are conventionally used, for example, low surface energy plastics rather than aluminum or steel. Non-contact portions of the mold may or may not still be formed of conventional materials including aluminum or steel.
[0016] In another aspect, the present invention provides a process for combining the layers that makeup a patch, specifically the unvulcanized layer and the vulcanized layer. Such a bilayer assembly may be used as formed or subsequently cut into a desired patch shape. In one aspect, patches are molded on demand at a single work station, eliminating the steps of combination through calendering or rolling squeegee technique, coating, and peeling.
[0017] Another aspect of the present invention provides a process through which the vulcanized layer may be transferred directly to the unvulcanized layer while the unvulcanized layer remains on a cold mold. The combined layers are together peeled off the cold mold.
[0018] In still another aspect, the present invention provides a method of forming a patch that includes: forming a layer of an unvulcanized material to a cold mold having contact surfaces comprising a low surface energy release agent; applying a second layer of a vulcanized material over the first layer of the cold molded unvulcanized material while cold molded layer is still on the cold injection mold; allowing the second vulcanized layer to attach to the unvulcanized layer; removing the combined vulcanized and unvulcanized layers from the cold injection mold; and cutting the bilayer combination into a desired shape for a patch.
[0019] According to one aspect, the combination of the unvulcanized layer attached to the vulcanized layer is less than 0.5 millimeter thick. In another aspect, the unvulcanized layer is less than 0.5 millimeter thick. In still another aspect, the unvulcanized material has a low green strength.
[0020] In still a further aspect, the vulcanized layer is formed by calendering and subsequent crosslinking of the polymer material. According to one aspect, the vulcanized layer is formed by injection molding on a hot injection mold having contact surfaces comprising a low surface energy release agent. According to still another aspect, the vulcanized layer is less than 0.5 millimeter thick.
[0021] In still another aspect, the contact surfaces comprising the low surface energy release agent are formed by applying a coating of the low surface energy release agent to the contact surfaces of the hot or cold injection mold. According to another aspect, the contact surfaces of the hot or cold injection mold are made of a material that has a low surface energy.
[0022] In a further aspect, the low surface energy release agent is a fluorinated polymer. In yet a further aspect, the low surface energy release agent is polyvinylidene fluoride. In another aspect, the low surface energy release agent is polyvinylidene chloride, and in yet another aspect, the low surface energy release agent is polyp-xylylene). In still another further aspect, the low surface energy release agent is polytetrafluoroethylene, and in yet another aspect, the low surface energy release agent is a plastic.
[0023] In another aspect, the method further, includes forming a label or bar code on at least one layer that will be visible on the patch. According to one aspect, the label is an identifying label that may be used for tracking a manufacturing history of an implant or prosthesis to which the patch is applied.
[0024] In still another aspect, the method further includes forming an aperture in the patch through which a filler material may be supplied to an implant or prosthesis upon which the patch is applied, the aperture configured to be sealed after an implant or prosthesis is filled.
[0025] In yet another aspect, the method includes forming special contours on the patch designed to minimize the transition between the edge of the hole in the shell and the edge of the patch.
[0026] In another aspect, the method includes forming special contours on or in the patch to minimize the flow under pressure between the outer edge of the patch and the edge of the hole in the shell.
[0027] In still another aspect, the invention includes a method of forming a patch, comprising: injection molding a vulcanized polymer layer using a first mold plate; injection molding a unvulcanized polymer layer using a second mold plate; removing the vulcanized polymer layer from the first mold plate; disposing the vulcanized polymer layer onto the unvulcanized layer while the unvulcanized layer is still on the second mold plate. compressing the vulcanized polymer layer and the unvulcanized polymer layer until the vulcanized polymer layer adheres to the unvulcanized layer to form a patch; and removing the patch from the second mold plate.
[0028] In an alternative aspect, the second mold plate has a contact surface upon which the unvulcanized polymer layer is formed that is formed from a low surface energy material. In another aspect, the low surface energy material is selected from the group consisting of polytetrafluoroethylene, and polyvinylidene fluoride.
[0029] In yet another aspect, the second mold plate has a contact surface upon which the unvulcanized polymer layer is formed, the contact surface formed from a release agent bonded to the second mold plate. In still another aspect, the release agent is a low surface energy material. In another aspect, the release agent is a fluorinated polymer. In yet another aspect, the release agent is selected from the group consisting of polyvinylidene fluoride, polyvinylidene chloride, and poly(p-xylylene).
[0030] In another aspect, the invention may include applying a release coating to a contact surface of the second mold plate upon which the unvulcanized polymer layer is formed. I an alternative aspect, the release coating is a fluorinated polymer. In still another alternative aspect, the release agent is selected from the group consisting of polyvinylidene fluoride, polyvinylidene chloride, and poly(p-xylylene).
[0031] In still another aspect, the invention includes forming a layered patch, comprising: injection molding an unvulcanized layer by molding the unvulcanized layer against a first mold having a low surface energy contact surface; forming a vulcanized layer; applying the vulcanized layer over the unvulcanized layer while the unvulcanized layer is still on the first mold; adhering the vulcanized layer to the unvulcanized layer; removing the adhered vulcanized and unvulcanized layers from the first mold; and cutting the adhered vulcanized and unvulcanized layers into a desired shape for a patch.
[0032] In another aspect, the forming vulcanized layer includes injection molding; in an alternative aspect forming the vulcanized layer includes calendering; and in still another aspect, forming the vulcanized layer includes hot injections molding to cure and vulcanize the vulcanized layer.
[0033] In yet another aspect, injection molding the unvulcanized layer includes using a cold injection molding process. Alternatively, injection molding the unvulcanized layer includes using a cold mold.
[0034] In still another aspect, the low energy surface of the mold is created by coating a surface of the mold with low surface energy material. In an alternative aspect, the low energy surface of the mold is created by bonding a release agent to a surface of the mold. In yet another aspect, the mold having a low energy surface is formed from a material having a low surface energy. In one alternative aspect, the low surface energy material is a fluorinated polymer; in another alternative aspect, the low surface energy material is polyvinylidene fluoride; in another alternative aspect, the low surface energy material may be polyvinylidene chloride, poly(p-xylylene), or polytetrafluoroethylene.
[0035] In yet another aspect, forming the vulcanized layer includes solvent casting.
[0036] In another aspect, injection molding the unvulcanized layer includes molding a contour into the unvulcanized layer. In still another aspect, injection molding the unvulcanized layer includes molding forming means for providing an insertion point in the patch for filling an implantable silicone breast prosthesis with fluid. In an alternative aspect, the fluid is a silicone gel.
[0037] In yet one more aspect, the present invention includes an implantable silicone breast prosthesis manufactured using any of the aspects of the invention set forth above. Alternatively, the present includes a patch formed using any of the aspects of the invention described previously.
[0038] Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a flow chart illustrating a prior art process of making patches.
[0040] FIG. 2 is a flow chart illustrating a process of making patches in accordance with an embodiment of the present invention.
[0041] FIG. 3 shows a conventional injection mold, hot or cold, being coated with a low surface energy release agent in accordance with an embodiment of the present invention.
[0042] FIG. 4 shows an injection mold, hot or cold, having contact portions made of a low surface energy release material in accordance with an embodiment of the present invention.
[0043] FIG. 5 shows an injection mold, hot or cold, formed of a low surface energy release material in accordance with an embodiment of the present invention.
[0044] FIG. 6 is a cross-sectional view showing a vulcanized layer being applied to a hot injection mold having a low surface energy release material between the mold and the vulcanized layer.
[0045] FIG. 7 a cross-sectional view showing the vulcanized layer, after removal from the hot injection mold, being transferred to and applied over an unvulcanized layer on a cold injection mold, the cold mold also having a low surface energy release material.
[0046] FIG. 8 a cross-sectional view showing the vulcanized layer making contact with the unvulcanized layer on the cold injection mold.
[0047] FIG. 9 a cross-sectional view showing the combination of the vulcanized layer and the unvulcanized layer bonded together being pulled off of the cold injection mold having a low surface energy release material.
[0048] FIG. 10 is a graphical representation of one embodiment of a process used to cut the combination of the vulcanized layer and the unvulcanized layer into the desired shape for a patch and application of the patch to the implant or prosthetic shell at a single work station.
[0049] FIG. 11 is a graphical flow diagram illustrating the steps of forming the layers through injection molding, combining the layers, peeling the layers off the mold, cutting the combined layers into a patch, and applying the patch to the implant all being performed at a single work station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] In one of its various embodiments, the present invention provides a process of making patches for medical and cosmetic implants and prosthetics in which the patches can be made on demand and applied to the implant, prosthetic, or a shell thereof or precursor thereto at a single workstation. This process reduces material losses from calendering and saves labor and facilities costs due to the elimination of coating (before cutting) and peeling the coating off (after cutting) steps and the ability to concentrate the process at a single workstation.
[0051] Another aspect of the invention involves coating the mold material used to injection mold the layers that form the patch with a low surface energy release agent in order to facilitate removal of the layers given the low green strength and propensity for adhesion of thin preform materials. The low surface energy release agent may be, for example, a fluorinated polymer, polyvinylidene fluoride, polyvinylidene chloride, polyp-xylylene), and like compositions.
[0052] Alternatively or additionally to coating the mold material with a low surface energy release agent, the portions of the mold that make contact with the preform material that forms the patch layer (“contact portions”), may themselves be made of a selected material to facilitate removal. For example, contact portions of the mold may be made of a low surface energy plastic, polytetrafluoroethylene (PTFE), polyvinylidene fluoride, or like materials. Or, the entire mold may be made of one of these materials mentioned above to facilitate removal of thin preforms with low green strength and high adhesion.
[0053] Prior to bringing the layers together the vulcanized layer is preferably formed by a hot injection mold while the unvulcanized layer is preferably formed by a cold injection mold. The vulcanized layer is then peeled off the hot injection mold and transferred to and applied over the unvulcanized layer on the cold injection mold. Once the layers are properly in contact with each other the combination can be pulled from the cold injection mold.
[0054] The preferred patch is typically made from the combination of a layer of 0.2 mm thick vulcanized silicone with a layer of 0.2 mm thick unvulcanized silicone. One desirable application for the thin preform injection molding process is to make patches for breast implants. For this application, the vulcanized layer is made of a special silicone that is so sticky it must be solvent cast into thin films or injection molded from solvent free paste.
[0055] The vulcanized layer may be transferred to the unvulcanized while it is still hot from the curing process in order to promote adhesion. The weight of the hotter vulcanized layer over the unvulcanized layer may be enough to promote bonding and adhesion between the two layers that will securely combine the layers with time. However, light pressure may also be applied to encourage the vulcanized and the unvulcanized layers to come together to form a singular combination layer. Light pressure may be applied, for example, by blowing air or an inert gas on the layers as the vulcanized layer cools over the unvulcanized layer. The layers may be allowed to rest together for up to, for example, but not limited to, twenty (20) minutes to mate until they are securely attached to each other.
[0056] The patches and methods of producing patches described herein are suited for patching holes in a shell that is a precursor to an implant. Typically, a hole is intentionally created in a shell in order to more easily remove it from a mandrel on which it is formed. After a shell is patched, filler material may be injected into the implant shell through the patch to form a completed implant ready for implantation. Or, in the case of some implants and tissue expanders, the device may be inserted without filler material or with less than the final amount of filler material which can be added after implantation through a port in the patch. Common filler materials for breast implants, for example, include silicone gels and saline solutions.
[0057] Optionally, a label may be formed on the patch during the molding process. The label may be two or three dimensional. The label may be formed by painting onto a layer used to form the patch or it may be embossed on a layer through surface topography provided on the injection mold or mandrel used to form the patch. The label may be an identifying label that provides tracking information as to the manufacturing history of the implant that may be useful in recognizing, reporting, and ameliorating any issues that may arise due to particular implants. If each patch receives a unique label, the label may be formed by a unique three-dimensional identifier (e.g. a sticker, a magnet, etc.) that is applied to an injection mold or mandrel before the patch is formed thereon such that a three-dimensional design will be imprinted into the patch.
[0058] To provide appropriate background to the process of patching described herein, the process of fabricating implant shells is outlined with a focus on shells for breast implants or mammary prostheses. Breast implant shells are generally formed on mushroom-shaped mandrels by applying a liquid dispersion of a silicone elastomer to the mushroom-head structure of the mandrel. The silicone dispersion used to form the shell may be applied by any one of several methods including dipping or dip-molding, rotational molding (see, for example, U.S. Pat. No. 6,602,452, incorporated by reference herein in its entirety), spraying, brushing, painting, and the like.
[0059] In many situations it is preferable that the mandrel have a textured or porous surface that is transferable to the surface texture of the shell. Implants having surface texture, variable surface topography, or micropillars have been shown to provide several post-implantation advantages inside a patient's body that reduce post-surgical complications and improve a body's acceptance and tolerance of the implant. See, for example, European Patent No. 0416846 and European Patent No. 0710468, both of which are incorporated by reference herein in their entirety.
[0060] Exemplary materials for mandrels include a hard resinous polymeric material such as epoxy or polyester (e.g. polyethylene terephthalate), polyvinylidene fluoride, polyacetal (homo or copolymer), polytetrafluoroethylene, perfluoroethylene or other fluoropolymers. Mandrels may also be formed of inert metals such as nickel or stainless steel, or ceramics.
[0061] In manufacturing the shell, the mandrel may be successively coated with several layers of the shell material dispersion with devolatilization to ensure silicone is deposited in the proper thickness. After the desired number of layers of liquid shell material are applied to the mandrel, the mandrel coated with shell material is cured at elevated temperatures such as, for example, 90 to 250 degrees centigrade, depending on the particular polymers in the dispersion, for 0.5 to 6 hours. The cured elastomer shell is then allowed to cool on the mandrel before a hole is created in the shell to peel it off the mandrel.
[0062] As shown in FIG. 1 , in accordance with the traditional process 100 for forming patches for implant shells several steps are required which take place across several separate works stations. The process typically begins at Box 102 with the calendering of vulcanized and unvulcanized layers used to form the patches. The thin calendered layers are manually peeled off of the rollers used for calendering at Box 104 . It is not uncommon for layers to be torn, damaged, or partially destroyed during this peeling process and accordingly the loss rate is generally higher than desirable and contributes to the inefficiency of the traditional process.
[0063] Next, the calendered layers are spread onto a thin plastic sheet at Box 106 . The layers are then cured with heat under pressure in Box 108 .
[0064] The separately calendered and cured vulcanized and unvulcanized layers are then combined together through further calendering or by aligning the sheets which are then combined using a rolling squeegee technique in Box 110 . One or both sides of the combined layer sandwich are then coated with a thermoplastic polymer at Box 112 . The thermoplastic polymer applied to cover the combined layer sandwich may be, for example, polyethylene. However, other thermoplastic polymers other than polyethylene may also be used as a coating on the combined layer sandwich.
[0065] Subsequently, the thermoplastic polymer covered sandwich of combined layers (one layer vulcanized, another layer unvulcanized) is cut into the size and shape desired for an implant shell patch at Box 114 . The patches may then be transferred to another work station in Box 116 . At that work station, an assembler manually peels the thermoplastic polymer cover off of the patch with tweezers in Box 118 . Finally, with the thermoplastic cover removed, the patch is applied to a shell to form an implant using standard heat and pressure techniques at Box 120 .
[0066] As shown in FIG. 2 , broadly and in general terms, in accordance with the process 200 according to one of several embodiments of the present invention, an unvulcanized materials is injected into a mold assembly having a contact surface covered with a low surface energy release agent at Box 202 . The unvulcanized layer is then injection molded on the injection mold at Box 204 . The injection mold used may be a cold injection mold or a hot injection mold. Typically, the mold assembly used for injection molding the unvulcanized layer is a cold injection mold.
[0067] At Box 206 , a separate vulcanized layer is then applied over the unvulcanized layer on the mold assembly. A period of time should be allowed, and possibly also some physical pressure applied, to allow the vulcanized layer to securely attach to the unvulcanized layer on the mold in 208 .
[0068] Once the two layers are firmly adhered to each other upon the mold assembly used to injection mold the bottom unvulcanized layer, the combination of layers is removed from the injection mold at Box 210 .
[0069] The combination of layers is then cut into the desired size and shape for patches at Box 212 , The patches are then applied to a shell on demand in Box 214 . Each of the above steps may be performed at a single work station.
[0070] As shown in FIG. 3 , in accordance with an embodiment 300 of the present invention, a conventional injection mold, hot or cold, is coated with a low surface energy release agent. The conventional injection mold includes molded part 302 , molten plastic 304 , raw plastic 306 , clamping unit 308 , mold assembly 310 , injection unit 312 , and injection molding machine 314 . The enlarged view of the mold assembly 310 illustrates using a sprayer 316 to apply a coating 318 of a low surface energy release agent on the surface of the mold assembly that will make contact with the molten plastic 304 to form a molded part 302 . As shown in FIG. 4 , the coating 318 of a low surface energy release agent has been applied upon all contact surfaces of the mold assembly 310 .
[0071] As shown in FIG. 5 , in accordance with another embodiment of the present invention, a conventional injection mold is modified such that the mold assembly 310 is formed entirely of a material 418 that is a low surface energy release agent. Alternatively, the mold assembly 310 may be formed such that all contact surfaces include a material 418 that is a low surface energy release agent. In either of these embodiments, a coating is not needed because the mold assembly itself, or at least the contact surfaces thereof, are already formed of a low surface energy release material.
[0072] As shown in FIG. 6 , a heat curable and/or vulcanizable material is injected into a hot injection mold assembly 311 upon which a coating 318 of a low surface energy release agent has already been applied. A vulcanized layer 502 is then formed by curing and vulcanizing the vulcanizable material, such as a silicone elastomer within the hot mold assembly.
[0073] As shown in FIG. 7 and FIG. 8 , the vulcanized layer 502 from the hot injection mold assembly 311 is transferred to a cold injection mold assembly 313 , upon which a coating 318 of a low surface energy release agent has been applied, the cold injection mold assembly 313 already having an unvulcanized layer 504 formed thereon over which the vulcanized layer 502 is applied. The unvulcanized layer 504 was formed by injecting a suitable material, such as a silicone elastomer or its precursors, into a cold mold assembly. The mold assembly is then opened up, and the vulcanized layer 502 applied over the unvulcanized layer 504 while the unvulcanized layer 504 remains in the mold assembly. Referring now to FIG. 8 , the thin vulcanized layer 502 , conforms to the shape of the mold and thus also to the shape of the unvulcanized layer 504 . It will be apparent to those skilled in the art that while the process is described with reference to mold plates having a particular shape formed therein, any shape may be molded into the various layers, or the layers may be formed in such a manner that they are essentially flat.
[0074] As shown in FIG. 9 , the vulcanized layer 502 adheres to the unvulcanized layer 504 on the cold injection mold 313 , mating the layers to each other. The bilayer assembly comprising vulcanized layer 502 and unvulcanized layer 503 may then be peeled off of the mold as illustrated, maintaining the integrity of the bilayer patch assembly.
[0075] Referring now to FIG. 10 , upon peeling the combined layers off of the mold assembly, the adhered layers 602 can be used as formed or cut into the desired shape and size for the implant shell patches. A cutout section 604 , or patch, of the combined layers is then transferred over to an implant shell 700 on a mandrel 710 and applied over a hole 720 in the shell. This entire process, from cutting the adhered layers into sections to patching the hole in the implant shell on a mandrel, can occur at a single work station 900 .
[0076] FIG. 11 illustrates how all steps of the process from forming the vulcanized layer on a hot injection mold assembly as in FIG. 6 , to transferring the vulcanized layer to an unvulcanized layer on a cold injection mold assembly as in FIG. 7 , to applying the vulcanized layer over the unvulcanized layer already on the cold injection mold as in FIG. 8 , to peeling the adhered layers off the cold injection mold assembly as in FIG. 9 , to cutting the adhered layers into patch sections and applying over a hole in an implant shell on a mandrel as in FIG. 10 , may be performed at a single work station 900 .
[0077] According to one embodiment, the injection molding process used requires the use of an injection molding machine, raw material, and a mold. The process outline that follows assumes fabrication of a plastic part as a representative example but is not intended as being limited to fabrication of plastic parts.
[0078] First, if the contact surfaces of the injection mold are not composed of a low surface energy release material or the mold is not formed of a low surface energy release material, the contact surfaces of the mold should be coated with a low surface energy release agent. Any known manner of coating the mold surfaces may be used to apply the low surface energy release agent coating, including painting on the coating, spraying on the coating, dipping the mold into a solution of coating, condensing vapors of the coating material onto the mold, and the like. Alternatively, the release surface may be highly polished to facilitate release of the material from the molds.
[0079] Next, the mixed unvulcanized silicone elastomer components are loaded into the injection molding machine and then injected into the preheated mold, where the silicone elastomer components are cured and vulcanized into the final part. The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes.
[0080] The main stages of the injection molding process are well known in the art and include clamping, injection, and ejection. Clamping refers to the step of securely closing and locking the two halves of the mold by the clamping unit prior to injection of any material into the mold. In the injection stage, the material used to form the molded object, which may be a viscous fluid like material such as an uncured silicone, is fed into the injection molding machine, and advanced towards the mold by the injection unit. The molding material is generally is forced into the cavity of the mold under high pressure to ensure proper filling of the mold cavity.
[0081] The mold plates in the injection molding machine may be heated or cooled, dependent upon the material being used and the desired properties of the finished molded article. In one embodiment of the present invention, the vulcanized layer is formed by heating the mold plate to cure and vulcanize the silicone material injected into the mold. The unvulcanized layer, in contrast, is injected into a cold plate so that the silicone may cure without vulcanizing.
[0082] In the ejection stage, the molded part or article, is often ejected from the mold. This ejection process is not typically used in the various embodiments of the present invention. Rather, the thin vulcanized and unvulcanized silicone layers are carefully peeled from the mold cavity.
[0083] As described previously, use of a low surface energy release material for construction of the mold plates, or which is applied to a standard metal mold plate, to promote release of the molded article is particularly advantageous when forming the thin layers of vulcanized and unvulcanized silicone of the present invention. Use of such a release agent allows removal of the thin layers of unvulcanized silicone having low green sheet from the molds while reducing the incidence of damage to the layers during the removal step.
[0084] Further, the use of injection molding apparatus and method that provides for easy release of the vulcanized and unvulcanized layers allows for the combination of multiple manufacturing steps so that the entire process of manufacturing a patch may be carried out at a single work station by a single operator. Such a process provides for a reduction in product loss due to damage, increased productivity and lower manufacturing costs.
[0085] The present invention is not limited to the embodiments described above. Various changes and modifications can, of course, be made, without departing from the scope and spirit of the present invention. Additional advantages and modifications will readily occur to those skilled in the art. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A method for injection molding thin materials (sub-millimeter) having low green strength could make certain manufacturing processes significantly more efficient yet has heretofore been unavailable. Provided herein is a method that enables injection molding of thin materials by using a mold with contact surfaces having a low surface energy release agent disposed thereon. The low surface energy release agent may be applied as a coating on a conventional mold or the mold itself or just the contact surfaces thereof may be formed of a low surface energy release material. The method finds particular applicability in making special contour patches for medical and cosmetic implants and prosthetics. A preferred approach involves injection molding a thin layer of unvulcanized material on a cold mold, injection molding a thin layer of vulcanized material on a hot mold, transferring the vulcanized layer to the unvulcanized layer on the cold mold, and removing the combined layers.
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FIELD OF THE INVENTION
[0001] This invention concerns a continuous casting method with rolls and the relative device, used in the field of continuous casting to cast steel strips by means of a pair of counter-rotating rolls.
[0002] To be more exact, the invention concerns a casting method with rolls with upward extraction wherein there are shearing means provided associated with the ends of the rolls and able to define the width and finish of the edges of the strip in a substantially continuous manner.
BACKGROUND OF THE INVENTION
[0003] In the field of continuous casting of plane products such as strips, the state of the art includes the technique of casting with rolls and with upward extraction wherein a pair of counter-rotating cooled rolls is partly immersed in a container into which the molten metal is fed.
[0004] The rolls, rotating in a reciprocally opposite direction, cause a solidified skin to form on their respective surfaces; these skins join together and form the product which is extracted upward.
[0005] This casting technique with rolls and upward extraction has considerable potential in the production of high quality strips: it makes possible to guarantee high productivity, limited costs and savings in the labor force compared with traditional techniques.
[0006] With the product extracted upward it is possible to obtain higher casting speeds, up to 4 meters per second and more, since the angle of immersion and therefore the contact surface between the steel and the roll can be as much as twice what can be obtained with a downward extraction of the metal. Moreover, with this solution it is possible to solve the problem of lateral containment of the molten steel in proximity or in correspondence with the ends of the rolls.
[0007] All attempts to use sealing means of a mechanical or magnetic type in plants with a downward extraction have met with considerable problems, both economical and functional-technological, which have often made impossible to propose such a solution.
[0008] In plants with an upward extraction, the lateral containment made with magnetic means appears potentially more effective and entails fewer problems and difficulties, both technological and with regard to the process.
[0009] However, there has been a manifest need to find solutions which allow to further improve the efficiency of the process, increasing productivity and the speed of extraction while maintaining high quality of the cast product, and optimizing in the whole the functioning and the plant costs of the whole casting line.
[0010] The present Applicant has devised, tested and embodied this invention in the light of this necessity, and to obtain further advantages as will be shown hereafter.
SUMMARY OF THE INVENTION
[0011] The invention is set forth and characterized in the respective main claims, while the dependent claims describe other characteristics of the main embodiment.
[0012] The purpose of the invention is to obtain a continuous casting method and device with counter-rotating rolls and upward extraction which on the one hand solves the problem of lateral containment of the metal in correspondence with the ends of the rolls, and in which on the other hand the procedure of the final shaping of the strip is optimized, at least in terms of width and edge finishing.
[0013] This purpose is obtained with an economical, functional and simple solution which can be applied substantially in every type of installation.
[0014] The invention provides to use a substantially conventional casting device, comprising at least a container to contain the molten metal inside which two counter-rotating rolls, cooled and facing each other, are partly immersed, and define the gap through which the cast product is extracted.
[0015] According to the invention, the device comprises shearing means arranged in cooperation with the periphery of the rolls, at least a first shearing mean being associated with one end of the rolls and a second shearing mean being associated with the other end of the rolls.
[0016] The shearing means are able to section the strip, partly solidified on the surfaces of the rolls, in correspondence with its edges so as to define the width thereof. The material sectioned in correspondence with the edges by the shearing means falls back into the container and returns to the molten state, and is therefore immediately available for the continuation of the casting process.
[0017] The shearing means, in a preferential embodiment, can cooperate directly with the ends of the rolls and use the ends as a reference and positioning element.
[0018] In this case, the width of the strip extracted always corresponds substantially to the length of the rolls used.
[0019] In another solution, the shearing means are located above and in an inner position with respect to the ends of the rolls, and have at their lower part a shaped conformation able to cooperate with the curved cavity defined by the coupled faces of the rolls. In this case, the strip extracted can have a desired width, less than the length of the casting rolls.
[0020] In another embodiment again, the shearing means can translate along the rolls, parallel to their axis, in order to define on each occasion the width of the strip to be cast.
[0021] The shearing means can be of any suitable type.
[0022] In a preferential embodiment, the shearing means are of the type able to define a cutting edge which already has the finished characteristics required to the finished product.
[0023] In this embodiment therefore, it is possible to eliminate, or at least reduce, further trimming and/or finishing operations and the relative equipment, downstream of the continuous casting machine.
[0024] A preferential but non-restrictive embodiment provides substantially fixed shearing blades, arranged orthogonal or inclined with respect to the axis of extraction of the cast strip. Another embodiment provides to use rotary shearing blades.
[0025] Further alternative embodiments which can be used in the field of the invention provide laser systems, oxygen lance cutting systems or other systems; one or other of the shearing systems is adopted according to the type of steel to be sheared, the productivity required and the level of finishing desired.
[0026] The shearing means are associated with cooling systems so as to prevent overheating thereof, due to the continuous contact with the steel solidifying on the surfaces of the rolls.
[0027] In one embodiment of the invention, the end walls of the rolls comprise, or cooperate with, means able to prevent the partly solidified steel from sticking to said walls, making then difficult for the shearing means to remove the steel.
[0028] In a first embodiment, said means consist of lubricating products which are applied on the walls and prevent the steel from sticking thereto.
[0029] In another embodiment, said means consist of pneumatic elements able to blow inert gas through orifices in the walls; the jets of inert gas prevent the solidified metal from sticking to the walls and encourage the metal to fall and be subsequently removed by the shearing means.
[0030] In a further embodiment, said means consist of elements able to generate high frequency vibrations in said lateral walls. In another embodiment, said means consist of elements able to heat and re-melt the solidified steel stuck to the lateral walls.
[0031] In yet another embodiment, said means consist of coils able to generate a repulsive magnetic field on the liquid steel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] These and other characteristics of the invention will be clear from the following description of the preferred form of embodiment, given as a non-restrictive example with reference to the attached drawings wherein:
[0033] [0033]FIG. 1 shows schematically a line to produce strips and/or sheets adopting a continuous casting device with rolls according to the invention;
[0034] [0034]FIG. 2 a is a schematic transverse section of the continuous casting device according to the invention;
[0035] [0035]FIG. 2 b is a schematic view from above of FIG. 2 a;
[0036] [0036]FIGS. 3 a and 3 b show two different embodiments of the device in FIG. 2 a;
[0037] [0037]FIG. 3 c shows a variant of FIGS. 3 a , 3 b;
[0038] [0038]FIG. 4 shows a longitudinal section of a detail of the casting device in FIG. 2 a;
[0039] [0039]FIGS. 5 a and 5 b show different embodiments of the detail in FIG. 4;
[0040] [0040]FIG. 6 shows schematically a section from A to A of FIG. 2 b.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] In FIG. 1 the reference number 38 denotes generally a line to produce strip 13 obtained starting from a continuous casting device with rolls, denoted by the reference number 10 .
[0042] The device 10 comprises a pair of counter-rotating rolls 11 , arranged with their respective axes 111 parallel and in an adjacent position to define a gap 12 through which the strip 13 to be produced is extracted upward.
[0043] The distance between the axes 111 of the rolls 11 can be adjusted so as to define the desired thickness of the strip 13 produced by the device 10 .
[0044] The preferential, though not restrictive, value of the thickness of the strip 13 emerging from the device 10 is between 0.5 and 10 mm.
[0045] Downstream of the device 10 there is an assembly of rolls 14 , used for extraction and possibly straightening purposes, through which the strip 13 is progressively taken to a horizontal position to be then sent to the rolling line.
[0046] In this case, the rolling line comprises a cropping shears 15 which can also be used as an emergency shears, a descaling assembly 16 , between 1 and 3 finishing stands 17 , a cooling assembly 18 , a flying shears 19 and a carousel coiler 20 .
[0047] The continuous casting device 10 consists of a container 21 suitable to contain the molten metal 22 , inside which the metal is poured through a measuring tundish 23 fed by a ladle 24 . The ladle 24 is associated with conventional handling and discharge means 25 mounted on a turret 26 .
[0048] The container 21 advantageously has a bottom and lateral walls made of and/or at least partly lined with refractory material.
[0049] The container 21 is associated with a sealing cover 36 which defines a substantially closed environment inside which an inert atmosphere is created which prevents any possible phenomenon of oxidation of the molten or partly solidified metal.
[0050] The cover 36 can cover the rolls 11 totally or only partly, as in FIG. 3 b.
[0051] The molten metal 22 can consist of any type of steel, iron, alloys or other suitable metal, and the feed from the tundish 23 may be governed by appropriate means able to ensure that a substantially constant level is maintained in the container 21 . The loading zone of the metal 22 can be separated from the zone of the container 21 beneath the rolls 11 by dividing walls, so that the unloading of the molten metal 22 does not generate any turbulence in correspondence with the meniscus.
[0052] In the embodiment shown in FIGS. 2 a and 2 b , in cooperation with the ends of the rolls 11 , there are shearing means 27 , one for each side on the length of the rolls 11 , the function of which is to section that part of the forming strip 13 which exceeds the length of the rolls 11 .
[0053] In other words, in the device 10 it is provided that the two semi-skins are formed freely on the surface of the relative rolls 11 without being confined laterally until, in correspondence with the line of contact, or kissing point, 30 , they form the strip 13 due to reciprocal sticking, which is then extracted upward.
[0054] Before being discharged from the rolls 11 , just above the line of contact 30 , the strip 13 is subjected to sectioning by the shearing means 27 , which act on the edges of the strip 13 in correspondence with the ends of the rolls 11 .
[0055] Said sectioning action may take place in a zone below the highest point of the circular surface of the rolls 11 , or above said highest point (FIG. 3 c ).
[0056] The shearing means 27 are able to remove lateral parts 37 of solidified metal which exceed the length of the rolls 11 . The lateral parts 37 , thrust by the pressing action exerted in correspondence with the kissing point, are separated from the central body of the strip 13 and fall back into the container 21 (FIG. 6), melt again and mix with the molten metal 22 contained in said container 21 .
[0057] The shearing means 27 therefore carry out two functions simultaneously and continuously: they define the width of the strip 13 extracted and contain it laterally.
[0058] By means of an appropriate configuration and management, the shearing means 27 can have a further function, which is to finish the edges; this obviates the need of appropriate subsequent processing upstream or downstream of the finishing stands 17 , and therefore the relative equipment does not need to be installed, and the waste deriving from said trimming operations carried out downstream is eliminated.
[0059] These functions are performed continuously without interfering with the continuous process of casting and extraction, which can thus ensure very high productivity, up to 2 Mton per year, and extremely high casting speeds, up to 4 meters per second and more.
[0060] In the embodiment shown in FIGS. 2 a and 2 b , the shearing means 27 consist of fixed blades 28 with their respective cutting edge 29 substantially orthogonal to the edge of the strip 13 emerging from the rolls 11 . In the variant shown in FIG. 3 a , the shearing means 27 consist of fixed blades 128 with their cutting edge 129 inclined with respect to the edge of the strip 13 .
[0061] In the other variant shown in FIG. 3 b , the shearing means 27 consist of a pair of circular rotary blades 228 associated with an axial drive shaft, while in the further variant shown in FIG. 3 c , the shearing means 27 consist of two pairs of rotary blades 228 arranged above the rolls 11 .
[0062] The shearing means 27 can be of the vibrating type, in order to encourage the sectioning operation. Moreover, the shearing means 27 are associated with appropriate cooling systems, for example with circulating water, jets of air or other types, which prevent them from overheating caused by their prolonged contact with the metal being extracted.
[0063] According to other variants which are not shown here, the shearing means 27 comprise laser devices, or oxygen lance cutting devices, or other systems.
[0064] In the embodiments shown in FIGS. 3 a and 3 b , the shearing means 27 are arranged resting on the ends of the rolls 11 , which thus perform a reference function, and the width of the strip 13 extracted is substantially equal to the length of the rolls 11 .
[0065] According to a variant which is not shown here, the shearing means 27 cooperate from above and in contact with the surface of the rolls 11 , so as to ensure in any case the hydraulic seal of the molten metal 22 ; moreover, they can slide axially along the rolls 11 so as to define on each occasion a desired width of the strip 13 to be extracted.
[0066] According to other variants which are not shown here, the shearing means 27 can be associated with sharpening devices which intervene periodically to restore the cutting edge after a certain period of use.
[0067] To prevent the partly solidified metal from sticking to the lateral walls 33 defined by the ends of the rolls 11 , and therefore to obviate the problem of removing it with the shearing means 27 , the casting device 10 comprises anti-sticking means associated with the lateral walls 33 .
[0068] In the embodiment shown in FIG. 4, the anti-sticking means consist of a high-frequency mechanical transducer 31 installed inside each roll 11 in a compartment 32 made adjacent to the end of the roll 11 .
[0069] The function of the mechanical transducer 31 , which in this case is represented by a spring with a relative oscillator element, is to keep the walls 33 vibrating, preventing the solidified metal from sticking thereto and so facilitating the subsequent shearing operation.
[0070] The transducer 31 can be of any conventional type, for example piezoelectric, magnetostrictive, or any other type suitable for the purpose.
[0071] According to the embodiment shown in FIG. 5 a , the anti-sticking means comprise electromagnetic devices 34 installed in said compartment 32 adjacent to the wall 33 and able to generate a repulsive magnetic field on the liquid metal which prevents the solidified metal from sticking to the sides of the wall 33 and causes it to re-melt.
[0072] In the further embodiment shown in FIG. 5 b , the anti-sticking means consist of a pneumatic system 35 arranged inside said compartment 32 and able to deliver an inert gas through a plurality of holes or slits, not shown here, made in the wall 33 and/or in the curved wall of the compartment 32 .
[0073] The inert gas substantially prevents the solidified metal from coming into contact with and sticking to the wall 33 immersed in the liquid bath 22 .
[0074] It is obvious that modifications and additions can be made to this invention, but these shall remain within the field and scope thereof.
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Continuous casting method and device ( 10 ) with rolls for plane products such as strips ( 13 ), wherein counter-rotating rolls ( 11 ) are partly immersed in a container ( 21 ) containing molten metal ( 22 ), said rolls ( 11 ) being arranged parallel and adjacent to define a gap ( 12 ) through which the strip ( 13 ) to be produced is extracted upward, said strip ( 13 ) being formed by the union of two semi-skins which are formed on the respective surfaces of said rolls ( 11 ) and are joined together in correspondence with a line of contact ( 30 ), said method providing that shearing means ( 27 ), arranged substantially in cooperation with the periphery of said rolls ( 11 ), act on the sides of said strip ( 13 ) to define at least the width of said strip ( 13 ) extracted from said rolls ( 11 ).
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This is a continuation of co-pending application Ser. No. 482,623 filed on Apr. 6, 1983, now abandoned.
FIELD OF THE INVENTION AND REVIEW OF THE PRIOR ART
Recycling of waste paper is possible only after most of the non cellulosic contaminants have been removed from the fiber mass. These contaminants may have been introduced during the printing steps (carbon black, pigments, ink vehicles, ink fixating polymers, etc. . . ), during converting, (varnishes, coats, binders, wrapping, etc. . . ) and later during the collecting phase (metallic pieces, plastics, soils and dirt of any kind).
Removing of the contraries generally occurs based on chronological dimensional sequences, through screening, magnetic separation, first in dry conditions and later in aqueous suspension.
The fiber mass is then screened through perforated plates and finer contraries are removed by centrifugal and centripetal cleaners.
The ink particles are not substantially removed during the preceding steps, and this operation is achieved in two steps: (a) detaching the ink particles from the fiber surface, through the combined action of chemicals, temperature and mechanical shear forces and (b) removing these particles from the pulp slurry.
Generally, all the contraries including the ink particles, are released from the fibers during the defibering phase. The waste paper is treated in a pulper, under alkaline conditions at 50°-60° C. temperature, in order to be well defibered and transformed into a pumpable slurry. An alternative to this process is to operate the pulper in cold conditions, then thicken the pulp above 15% consistency, then heat the pulp with steam at 60° C. introducing at that point the de-inking and bleaching chemicals. The pulp then remains in a reaction tower during 2-3 hours without any mechanical action.
The first drawback of these techniques is that all contaminants are submitted to the thermal treatment, including the ones which have low melting points, such as binders, hot melts, plastics and other "stickies". By this way, they become dispersed and cannot be removed any more by the conventional means, and will precipitate again on paper machine elements such as doctor blades, wires, felts, pipe walls, etc. . . , creating operating problems and loss of efficiency.
A second drawback is that these ink-releasing techniques have a weak action on the modern inks such as the rotooffset inks, where ink vehicles are made of synthetic resins which form an insoluble polymer on the surface of the fibers. The same consideration applies for xerocopy printed paper and varnished papers, where temperatures in the range of 60° C. will provide neither any softening of the ink vehicles nor any weakening of the bondings between the fibers and these vehicles.
An other limitation of these techniques is that it is not possible to increase the temperature of the ink releasing step, because the combination of the alkalinity and the temperature during a long time will result in an unacceptable yellowing of the pulp, specially if some groundwood is present in the mixture to be treated.
Ink removing techniques in use to-day are essentially two: floatation and washing.
In flotation, the diluted fiber slurry is intensively mixed with air after a hydrophobe ink collector has been added. Then stock is naturally deaereted and air bubbles collect the ink particles during the upwards travel to the surface. The resulting black foam is then collected and treated separately through centrifuges, then disposed of;
In washing, a very old and well known process, the finest dispersed particles are removed through several dilutions and squeezing cycles, generally arranged as a counter-current cascade configuration. The effluent of the first squeezing sequence contains all the free fine ink particles, but also a great quantity of fine cellulosic fibers and most of the mineral fillers, and are sewered and treated according to the local pollution regulations.
Some other ink removing techniques exist, such as solvent extraction but have not been followed by wide indutrial application, due to high production cost and low quality of the produced pulp.
In the U.S. Pat. No. 4,076,578 Puddington et Al. recall the fundamental concept of de-inking: (a) releasing ink from the paper fiber by mean of chemico-thermomechanical treatment and (b) separating of dispersed ink particles from the pulp, then proposes a different method to achieve this goal, through absorption of the ink particles onto the surface of solid particles, followed by the removal of said particles from the pulp, and then removal of the ink from those solids.
Nowadays, none of the above mentioned processes has asserted itself because each of them presents some drawbacks.
The flotation is a low consistency process (between 1% and 2%) and thus involves high volumes of pulp, with consequent high investment cost. Also, the nature of this process is essentially physico-chemical and thus its stability is greatly related to the sability of the composition of the waste paper, the type of fibers (chemical or mechanical), the type and content of mineral filler, the calcium ion concentration. Consequently, the brightness of the de-inked pulp shows undesired high fluctuations. These brightness variations are also accompanied by all composition variations coming together with the raw material (waste paper), without any possibility of control or continuous measurement and monitoring.
To-day, it is generally admitted that the first condition for the good operation of a modern fast papermachine is the constancy of operating parameters, the most important one being the composition of the stock feeding the machine. Unfortunately, it is not possible to control the composition of a waste paper lot as easily as a virgin pulp bale. For this reason, the efficiency decrease of high-speed paper machines using high percentages of flotation de-inked pulp is mainly caused by the uncontrolled variations of the stock composition rather than by the brightness (or de-inking efficiency) variations. This problem can be solved using selected classified waste paper, at a price which makes the de-inked pulp uncompetitive respect to the virgin pulp, assuming that such type of waste is available.
Finally, the flotation process needs to be continuously controlled, on a three shift basis, by highly specialized chemical experts using sophisticated instrumentation and laboratory, thus appreciably increasing the production cost.
The washing process involves simpler, cleaner, and easier to control equipment, in particular when washing occurs at consistencies between 3% and 15%.
This process does not require any specialized control and it is admitted that not only the quality (cleanliness and strength) of the washed pulp is definitely higher than for the floated pulp, but this quality is much more constant and less sensitive to raw material variations of composition, thus offering a higher "runability" of the pulp in the paper machine room.
In fact, the principle of washing on a perforated plate statistically says that elements having a smaller size than the plate openings should pass through the plate. It appears that the variations of composition of the stock to be de-inked (fines, groundwood, mineral fillers) will reverberate on the fraction lost through the plate, giving a final product almost constant in quality, if not in quantity. This principle allows for the use of unselected waste paper, a lower quality product having a much lower cost and higher availability.
On the other hand, this process needs a much higher quantity of water, and produces the equivalent higher quantity of effluents which still contain a great quantity of valuable products, cellulosic short fibers, mineral fillers, mixed together with the undesired ink. Besides that direct loss, it is necessary to consider the indirect cost due to the abatement of the pollution created by the solids contained in the effluents.
In conclusion, it can be said that if flotation de-inking presents high investment and operating cost together with low constancy of the quality of the final product, washing de-inking also shows a high similar cost of the product due to both the intrinsical low yield of the process and the pollution abatement cost.
In order to minimize the negative aspects of each one of these basic processes, their supporters have proposed several combinations of them, keeping in mind to produce only one de-inked pulp starting from one waste paper mixture.
In the French patent application No. 79 19392, M. Fritz Zeeb of Voith Cy. suggests to remove the fine fibers fraction together with the mineral fillers from a flotation de-inked pulp, using screens and strains arranged as washing elements. This process, which is only summarily described without any example, seems to add up both costs and drawbacks of flotation and washing.
In the TAPPI magazine, vol. 63, No. 9, September 1980, M. Lothar Pfalzer of the same Voith Cy., while recalling the same concept (page 116, FIG. 3), specifies that the fine fiber fraction and mineral fillers are centrifugated and then disposed of and lost. It also appears from this publication that the effluent is totally sedimented after having been floculated by addition of aluminum sulfate, but it is also specified that a good dispersion of the ink particles can be obtained at high and well controlled pH. These two statements are rather contradictory and make this concept hardly applicable in practice.
M. Pfalzer also suggests the opposite philosophy (page 114, FIG. 1), which consists of a total flotation followed by a total sedimentation of the effluents of a conventional washing process. For the same reasons as above, which are: the low yield of the washing process, the non-compatibility between ink dispersing high pH and aluminum sulfate sedimentation low pH, the addition of the costs and drawbacks of each individual process, this proposal has not been applied on an industrial scale.
In the French patent application No. 78 29637, M. Calmanti of Montedison Cy. suggests in a more simple way to separate the ink particles from the fine fibers and the mineral fillers contained in the effluents of a washing process, by means of a simplified flotation process where no chemicals are added. It is also stated that the chemicals added at the begining of the process (pulping stage) will also provide for the ink collecting function. In this process, the so-called "clarified" effluents which actually contain most of the fibers and mineral fillers lost during the washing step, are totally recycled ahead of the process.
A tentative application of this process had to be quickly abandoned for two reasons. At first, it has not been possible to obtain a satisfactory selective removal of the ink during the flotation, because of the antagonistic functions of the two chemicals mixed together at the pulper: (a) dispersing of the ink needed during washing, (b) coagulation of the ink needed during flotation. So, too much fibers and fillers were floated together with the ink resulting in a quick overloading of the sewer system, and immediate shut down of the plant.
Second, it has not been possible to recirculate continuously ahead of the washers, an effluent which contains most of the fines and fillers lost by the same washers. This total recirculation has quickly resulted in (a) a drop of the brightness due to the poor ink removal efficiency and (b) an unacceptable drop of the hydraulic capacity of the thickening elements. Both can be attributed to the saturation of the circuit with fines and fillers, dimensions of which are of the same order of magnitude than the ink particles.
In the Italian patent application No. 26944 A/80, M. Calmanti recalls the same principle, where the effluents at a concentration of 0,14% would be selectively floated with the only addition of air, and then totally recycled ahead of the process together with their suspended solids. M. Calmanti nevertheless suggests to install a "quick" flotation, a third flotation, installed ahead of the washing process. This configuration does not seem to bring any answer about the two basic previous problems; (a) how is it possible to have the best dispersion together with the best coagulation, (b) how is it possible to avoid the saturation, the clogging of the thickening elements, and the loss of the ink removal efficiency, due to the recirculation of the fines and the fillers together with the effluent.
GOALS OF THE INVENTION
The present invention aims to provide a practical and integral industrial process which allows to produce, in a continuous way and starting from a mixture of unselected waste papers, three separate products, namely:
(a) a totally cleaned and de-inked pulp having constant and controlled brightness and fiber classification, having a very low and constant fillers content;
(b) a totally cleaned and de-inked pulp having a fine fiber classification and a very high fillers content, these two parameters being variable in both quality and quantity;
(c) an effluent which does not practically contain suspended solids, which has not been submitted to any pH reversion, which does not contain any floculation or sedimentation chemical agent, and thus is immediately and totaly re-usable as the dilution and washing liquid during the ink removal step of the de-inking phase.
A further aim of this invention is to provide a practical and advantageous improved method for de-inking these grades of printed papers and boards which cannot be correctly de-inked by conventional methods.
An other aim of this invention is to provide a practical and advantageous method which allows high quality paper and board at high speeds using the low quality waste grades which could not be used for such noble purpose when treated by conventional methods.
The invention is also directed to the application of modified and purposely adapted ink removal processes, such as washing, selective separation, flotation, coagulation, filtration, onto the high ink-content slurry produced by the primary ink removal process.
The invention also aims to allow for the use in paper making of the by-products of a washing de-inking process, either on the paper machine which will use the primary pulp, or on a different paper machine.
An object of this invention is to provide a to create a constant and controlled composition of the pulp used for paper making, which can be different from the composition of the incoming waste paper mixture. This object is achieved by pumping controlled flows of each one of the two components and mixing them ahead of the paper machine(s) in the desired percentage; the capacities of the chests act as buffers between waste paper and paper machine stock compositions.
An other object of this invention is to increase the value of the by-product (the secondary pulp) by the fact that good long fibers can be extracted from the main line in order to optimize the operation both of the selective separation of the ink and of the filtration on fiber mat.
A further object of this invention is to accomplish the selective separation of the ink at a stage where this ink is highly concentrated (approximately three times more than in the main pulp), thus increasing the efficiency of the chemicals.
An ulterior object of this invention is to achieve the selective separation of the ink (which is the more delicate operation of the whole recycling process), in a satellite circuit of reduced capacity (approximately one third of the flow through the main line), thus being easier to operate and requiring lower investment cost.
This invention then aims to insure the highest possible constancy of quality of the primary pulp, by the fact that the variations of fines and fillers contents will instantaneously reverberate on the fraction produced by the satellite circuit, which in turn can also be stabilized by mean of a thorough mixing and high retention time in the final buffer chest.
With these and other aims and objects, the nature of which will become more apparent, a fuller understanding of this invention will be gained by reference to the following detailed description and the appended claims.
DESCRIPTION OF THE INVENTION
The following detailed description, together with the attached schematic flow-sheet, refers to one preferred practical application of the invention, although other procedures can also be applied.
Following the flow-sheet, the bales of waste paper (1) are loaded into a pulper (2) by means of a loading mechanism, together with the recycled water and eventual caustics in order to bring the pH at values above 7. It is possible but not mandatory to introduce part or all of the quantity of dispersing chemicals required by the ink-releasing action, during the pulping operation.
The pulp is then diluted using recycled water and pumped through one or several stages of screens and cleaners (3) in order to release contraries and contaminants from the paper surface, and further remove them from the pulp slurry.
When the de-inked pulp is used for high quality paper production or on high-speed machines, such as light weight coating base or newsprint, this operation must be done in the same way it is done with chemical or mechanical virgin pulps, using the same equipment and operating parameters. In particular, the best results have been obtained through a combination of pressurized slotted screens equipped with 0.3 mm. slot width working at 1% consistency followed by 4 inch size cleaners working at 2,8 bars pressure drop and 0,6% consistency in the first stage.
It is anyhow of paramount importance that the temperature of the stock be kept as low as possible so that the low melting point contaminants will remain rigid and will not extrude through the slotted screens and thus be eliminated by the screens. This pulp is then thickened (4) to the consistency required by the ink releasing process. The effluents produced by this thickening stage can easily be recycled, as they are cold and do not contain much fibers and very little ink. At the beginning of the following ink-releasing step (5) chemicals are mixed together with the fiber suspension. Caustics are added in order to raise the pH up to 9-10, together with oxydizing agent (such as hydrogen peroxide), and stabilizers (such as sodium silicate), and dispersing agents (surfactants, etc. . . ). The basic parameters of this process, - temperature, pressure, specific energy, chemicals dosing - will be determined in order to insure the optimum detachment of the ink particles from the surface of the fibers together with their finest dispersion inside the pulp.
In the following examples, this operation has been made in a kneader, also called triturator, which permits the temperature to be brought to the desired value (i.e. above the melting point of the ink vehicles) within few seconds and simultaneously applies very strong shear forces at high consistency and in presence of de-inking agents.
The principle of the operation is that at first, the combined actions of ink-releasing chemicals and temperature (90°-130° C.) will soften the ink vehicles and weaken the bondings between the same and the fibers, and then the combined actions of ink-dispersing chemicals and intense shear forces will detach and finely disperse these particles inside the fiber suspension. The high consistency (20-30%) allows to treat very low volumes of pulp in small machines during a very short time (2-3 minutes), thus avoiding the yellowing of the pulp and increasing the efficiency of the chemicals.
This pulp then remains 5 to 20 minutes in a latency chest (6), at a consistency between 2% and 5%. It may then be deflaked (7) in order to thoroughly separate the fibers bundles one from the other, and thus facilitate the ink removal from the slurry.
The fibrous suspension finally goes through the ink removal process (8) which can be advantageously composed of multi-stage, counter-current, high consistency washing. The number of stages is choosen according to the quantity of ink to be removed and to the desired final brightness. The extraction of the water is conducted through strains of perforated plates, the dimensions of the openings of which will be selected in order to allow for a given quantity of fibers to be carried away together with the effluent, thus ensuring the optimum operation of both the following ink selective separation process, and the final filtration of the recovered satellite secondary pulp.
In case a filler-free secondary pulp is desired, the effluents from the washing step (8) can advantageously be strained again on one or several fine mesh filters (9). By this means, it is possible to remove at each filter stage up to 80% of the mineral fillers contained in that slurry. In such a case, the finest fraction must be sent to a conventional alkaline clarifier (10) and then be disposed of. The clarified fraction is then returned ahead or after the following ink selective separation step (11), according to the operating parameters of this last process (consistency, temperature), and according to the required brightness.
The necessary chemicals are also introduced ahead of this step. In case this process is a selective flotation, ink collectors such as fatty acids or their sodium or calcium soaps can be added, taking care to insure a mixing time of about 5 minutes at a temperature of about 35° to 45° C.
It may be worthy to recall that the dispersing agent used during the washing step has a negative effect both on the coagulation produced by the collecting agents during the flotation step, and on the drainability (freeness) of the fibrous suspension during the filtration step. It will be good to inactivate or neutralize these agents for example by precipitation with calcium chloride or calcium hydroxide. The precipitation of the sodium silicate will also contribute to increase the brightness of the secondary pulp through the formation of a precipitated mineral filler. It has also been observed that the quantity of mineral fillers removed together with the foam during the flotation step may vary from 30% up to 70% according to the operating parameters of the process: flotation time, temperature, pulp consistency, dosing and type of chemicals. The rejected foam containing the ink is then pumped to centrifuges or filter-presses and disposed of. The loss of solid particles has been observed to be between 10% and 20% of the flow of secondary pulp, which means about 3% to 6% of the total quantity of pulp feeding the washing step (8).
It has also been observed that the maximum efficiency of the ink removal has been reached at much higher consistencies that the ones recommended by the suppliers of the cells. For example, a cell designed to work at 1% has shown best results between 1,5% and 2%. This peculiarity allows for the treatment of lowest quantities of effluents, using higher consistencies during washing, and larger holes in the extractors perforated plates.
When the requested concentration for the ink selective separation process is higher (say 0,5% or more) than the maximum concentration which can be given to the effluent of the washing step, some heavy stock can be advantageously extracted from the latency chest (6). In this case, the small quantity of long fibers added to the secondary pulp will help in forming the filtering mat in the final filtration step (12).
The selective separation of the ink (11) can also be a process based on adsorption of the ink upon the surface of non-soap solids, as recommended by Ira Puddington et Al. in the U.S. Pat. No. 4,076,578.
The de-inked slurry leaving the process (11) is then filtered on fibrous mat up to at least 4% consistency, possibly above 10% in order to remove from the final secondary pulp the maximum possible quantity of dissolved salts.
In case this pulp contains a very high quantity of ground-wood fines and fillers (such as mixtures of newsprint and magazine paper), the pH ahead of the filtration step has to be dropped down to values below 8, by addition of sulfuric acid (preferably to aluminum sulfate), under intense mechanical agitation (as could be the suction side of a centrifugal pump), and after some long fibers extracted from the washed final primary pulp has been added to the the satellite slurry to be filtered.
It has been observed that the application of equipment such as Polydisk or Waco Filters to the thickening process (12) has permitted to produce clear filtrate having less that 100 ppm suspended solids and consequently totally re-usable in the pulping (2), cleaning (3) and washing (8) processes without any further clarification.
The final thickened secondary pulp leaving (12) must then be brought to a pH compatible with the following use by addition of sulfuric acid or aluminum sulfate, always under intense mechanical agitation, and can be stored in a buffer chest according to the final use.
EXAMPLES
The following examples will illustrate three different applications of the general procedure previously described, using different mixtures of waste paper and producing different grades of paper and board. Measurements of brightness were made with an Elrepho meter with 457 nm. light filter, according to I.S.O. standards. Chemicals dosings are expressed in percent by weight of the chemical at 100% concentration relative to the weight of total solids in the line where said chemical is added. Sodium silicate is considered at 38° Be and the Removink F and L as supplied.
EXAMPLE 1
The raw material is a mixture of over-issued newspapers and telephone books (white and yellow pages) in a ratio approximately 50/50. The de-inked pulps are used for the production of newsprint and telephone directory papers (white and yellow), on only one high speed paper machine.
In this installation, the pulper has a capacity of 46 m 3 containing 2.700 kg of waste paper. Each batch takes 30 min. Dilution water is coming from the effluent of the thickening process (4) and make-up is made using clear filtrate from the Polydisk filter (12). One percent of sodium hydroxide is added in the pulper together with 1% of a de-inking agent such as Removink L 8001 supplied by Chemicarta SPA, Milano. When this cold pulping operation is finished, the stock is pumped through turboseparator, screens and cleaners, at consistencies starting around 4% and ending at about 0,6%.
The turboseparator is equipped with a perforated plate having 3 mm. diameter holes and the rejected stock is then sent to a vibrating flat screen also having 3 mm. holes, the rejects of which are disposed of.
The accepted stock from the turboseparator is then diluted from 3% down to 1% before it passes through pressurized slotted screens fitted with 0,30 mm. slot width. The rejected stock is processed through a second stage screen having the same slot size, and rejects of the same go to a vibrating flat screen, rejects of which are disposed of.
The accepted stock from the first stage of screens is then diluted down to 0,6% consistency and processed through a conventional battery of 4 stages of Triclean cleaners. The light and the heavy rejects of the 4th stage are disposed of.
The total loss of both high and low consistency turboseparating, screening and cleaning is varies between 6% and 9% by weight, depending upon the
degree of contamination of the waste paper.
No more stickies or hot melts can be seen in the pulp, and a visual inspection is confirmed by the Sommerville test, which shows less than 0,2% of shives. At that point, the pulp is totally cleaned and the only remaining contaminant is the printing ink. The pulp is then thickened up to 30% consistency in two steps, using a disk filter up to 10-12% and then a screw press up to 30%. Characteristics of the pulp are: brightness=40°-45° ISO, freeness=50°-55° SR, filler content=6-8%, temperature=20°-25° C. The ink releasing step (5) is achieved in a kneader under the following operating conditions: temperature=95°-98° C., sodium hydroxide=1,5% , sodium silicate=4% , hydrogen peroxide=1,8% , specific energy=80 KW.H/Ton during 3 minutes. The brightness of the pulp at the end of the treatment is 50°-55° ISO, and freeness is 60°-65° SR. The pulp is then diluted using all the flow of effluents coming from the second stage of washers, then squeezed up to 12% in the first washing stage.
These washers are composed of inclined screws (better known as Rice-Barton or Baker's screws), where the pulp is drained under continuous and vigorous agitation through perforated plates having 1,4 mm. diameter holes, in order to produce an effluent having approximately 0,8-1% consistency.
The thickened stock is then processed through two other similar counter current washing steps and the final usable pulp presents the following characteristics: brightness=59°-60° ISO, freeness=46°-50° SR, filler content 2-3%, consistency=12-14%. This pulp represents 78% by weight of the quantity of pulp feeding the washers (8). The balance 22% is going to the satellite circuit with the first stage effluent which shows: brightness=35°-40° ISO, filler content=20-25%, freeness=80° SR.
The capability for the ink of being removed from the fibers contained in the effluent has beenverified in the laboratory as follows: an effluent sample has been hyperwashed under fresh water shower on a 200 mesh wire ,and a handsheet has been made, showing a brightness of 56° ISO, which is very similar to the brightness of the final primary pulp. This effluent has then been mixed together with 4% of a special ink-collecting agent purposely designed for this application by Chemicarta SPA, Milano, and kept for 5 min. under agitation at 30° C.
The mixture is then processed through one single stage conventional flotation cell, Voith open type, during 15 min.. The loss of weight through the cell is 15-20%, which means only 3-4,5% respect to the total quantity of pulp entering the washers. We have found that addition of 0,5% to 1% of calcium chloride or calcium hydroxide together with the collector, ahead of the flotation, helps controlling the foam and the ink coagulation when low ash content pulps are processed.
The total alkalinity is then dropped down to pH=7-8 with addition of 1% of sulfuric acid on the suction side of the centrifugal pump feeding the disk filter (12). At this point, the pulp shows a brightness=53°-56° ISO, a filler content=15-20% and a freeness=78°-80° SR.
The disk filter (12) is a Polydisk filter sized according to a specific filtering factor=20 liters/min./m2. Besides this unusual value, it is also necessary to feed the mat-peeling showers with air instead of water, in order to reach the maximum possible consistency of the discharged pulp.
Using the above mentioned parameters, a final consistency of 8% to 10% could be obtained and the clear filtrate shown less than 100 ppm average suspended solids, measured on paper filter, black label.
The pulp is then brought to pH=6 and sent to a buffer chest having 8 hours total retention time. From this point, it is then pumped to the mixing chest of the paper machine at controlled flow rates according to the paper grade actually produced and in function of the mean composition of the secondary pulp.
The clear filtrate from the Polydisk filter is then totally recycled in order to dilute the stock ahead of the third washing stage and make-up is provided by fresh industrial water which does not contain aluminium ions.
The application of such a process in a paper mill having one single paper machine offers the following advantages:
(a) possibility to maintain constant freeness and ash content during a grade run, independently from the incoming waste paper characteristics, thus allowing the paper machine to run at maximum speed and efficiency;
(b) possibility to achieve very quick grade change, exactly as whenusing virgin pulp and fillers, without the need to intervene a long time before in the waste paper plant, thus permitting an easier and more constant operation of that plant;
(c) possibility to always use the highest possible quantity of recycled fibers in the paper, by the free disposal of each one of the two fractions and their use in the optimum way.
(d) possibility to produce totally cleaned pulps having the same standards of cleanliness than virgin pulps and thus offering the highest possible runability in the paper machine room, particularly being free of any "sticky" or "hot melt" or ink vehicle free particle.
EXAMPLE 2
The raw material is a mixture of printed continuous stationary , old books and office file, in a ratio 50/50.
The de-inked pulp is used to produce, on three distinct paper machines: (a) light weight machine-glazed wrapping papers, (b) fine papers for writing and printing, including wood containing printing grades, (c) stationary and continuous print-out papers.
The operation is similar to example (1) up to the thickening step (4), although it is not necessary to add any chemical agent--caustics or de-inking agent--during the pulping step (2). When entering the ink-releasing step (5), the pulp has a brightness=60° ISO, a freeness=40°-45° SR, and a filler content=20%.
The ink-releasing equipment is the same as for example (1) but operating parameters are as follow: Removink L8001=0,3%; hydrogen peroxyde=0,5%, sodium hydroxyde=1%, sodium silicate=3%. All other parameters remain unchanged. At the end of the process, the pulp has shown a brightness increase of 2° ISO and freeness did not show any appreciable variation.
The pulp is then washed by mean of three washing stages as for example (1), but the design of the perforated plates are different: the first stage is fitted with 2 mm. diameters holes, the second and the third stages are equipped with 1,4mm. diameter holes. Also the feed consistency of the washing stages is different, being 2,5%. With these parameters, the final washed primary pulp has shown following characteristics: brightness=75° ISO, filler content below 3%, freeness 27°-30° SR.
The effluent leaving the first washers has a consistency between 1% and 1,2%, a filler content=60%, brightness=50° ISO, and freeness=70° SR.
The flotation cell used in this application is a high consistency Swemac type, and heavy stock has been pumped from chest (6) and mixed together with the effluent before the flotation, in order to raise the consistency up to 1,5%. In this way, the two lines (primary by washing and secondary by flotation) have exactly the same solids flow rate, or the same capacity in tons/day, but produce two pulps having opposite characteristics. This extraction also procures long fibers which will help the final filtration (12).
This extraction could have been done using washed pulp and this would have increased the brightness of the secondary pulp. But in such a case, the washing equipment would have to be sized for 30% more capacity, which is not a worthy choice in our case.
The flotation is then conducted with only 2% of the same collector (Removink F) and the retention time through the cell is only 10 min., thus producing a loss of weight of 10% (which means 5% of the total pulp).
After acidification at pH=8 ahead of the disk filter, the pulp shows a brightness=70° ISO, a filler content=35-40%, a freeness=65°-70° SR.
The Polydisk filter can be sized using a filtering factor=25 liters/min./m2, and produces an effluent containing 70-100 ppm suspended solids. The other steps of this application are similar to the ones described in example (1).
The application of such a process in a paper mill having several paper machines as in this example is offering the following advantages:
(a) possibility to produce a pulp having physical and cleanliness characteristics similar to the ones of a virgin chemical pulp, thus usable for the production of fine light weight papers, with good Yankee dryer glazing capabilities;
(b) possibility to produce a pulp having physical and optical charcteristics of a mixture of fine chemical and/or ground-wood pulp, and mineral fillers, thus usable for the production of printing papers where high opacity and smoothness are requested.
(c) possibility to mix these two pulps together in a ratio which can be very much different from the original one coming together with the raw material.
EXAMPLE 3
The raw material is a mixture of low quality printed waste, containing old books, office waste and stationary, and some newspapers and magazines, in variables proportions.
The mill has one multiply board machine, and produces high quality folding box board, which can be on-machine coated and must show an excellent multicolour offset printing aptitude. The white top liner is composed of 100% de-inked primary pulp and the underliner uses the secondary pulp, mixed with other pulp .
Pulping is conducted in a continuous way with the same parameters as for example 1. The cleaning and screening treatment (3) is simplified and composed of centrifugal high-density cleaners, followed by a turbo-separator, working at 3% consistency. The following thickening stage is also simplified and composed of inclined screws producing pulp at 15% consistency, followed by a screw press. The finest contaminants will be detached and better dispersed during the ink-releasing step (5) and then carried away with the effluent during the washing stage. They will remain in the secondary pulp thus contributing to add weight and volume to the board, as the underliner does not need to be particularly cleaned.
The pulp entering the ink-releasing and dispersing step shows a brightness=50° ISO, a filler content=25-30%. The operating parameters are the same as for example (1), but the brightness drops down to 46°-48° ISO.
The following washing step has only two stages, which are fed at 2,5% consistency. The perforated plates of the inclined screws have 1,6 mm. diameter holes, and it has been found that the characteristics of the effluent are very similar to the one of example 1.
The washed primary pulp shows a brightness=68° ISO, a filler content=4% and a freeness=45°-50° SR. The fine cleaning of the primary pulp is achieved with the cleaners and the screens installed ahead of the board machine, which is sufficient to reach the desired quality. It must be said that the contaminants have been thoroughly dispersed in the kneader (5) and most of them have left this primary pulp during the washing step.
The satellite circuit is also simplified because the brightness of the underliner has only a third-order influence on the final brightness of the coated board. We have observed that a brightness of the underliner secondary pulp in the 50° ISO range was sufficient to insure the required brightness 80° ISO of the coated board, providing that the top liner primary pulp has 70° ISO. Thus, the flotation time has been reduced below 10 min. and the dosing of the collector has been kept below 2%. We have also observed that it was possible to run without any chemical when lower quality grades are produced, but no compromise can be applied on the dispersion effect, because black spots in the underliner are always visible even through the coated top liner.
The application of such a process to the production of stratified board is offering the following advantages:
(a) possibility to totally replace chemical pulp or high quality selected unprinted waste paper by a low value and large availability raw material;
(b) simplification of the main line by eliminating the fine screening and cleaning equipment;
(c) increase of the total yield, by transferring in the secondary pulp (and then in the underliner or in the middle ply) all finely dispersed contaminants which are not acceptable in the top liner.
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A waste paper recycling process relates to the treatment of a mixture of waste paper containing non-cellulosic contraries and printing inks, in order to release the contraries from the fibers and further to separate them from the stock in order to produce re-usable pulp for the production of paper and board.
The invention has to do with new and useful improvements in methods for first removing the non-ink contraries from the fibrous mass and second releasing and then removing the ink particles from the said fibrous mass.
The invention is directed to the treatment of the fiber slurry produced during the ink separation stage, after the ink releasing stage has been applied. One aim of the process is to allow both the use of the fibers and the mineral fillers contained in that slurry, for pulp and board making, and the use the solids-free water contained in the same slurry as the washing liquid in the previous ink-separation treatment, thus closing the fibers and the water circuits.
This process includes chemical and thermo-mechanical treatments, starting under alkaline conditions, which may become neutral at the end of the process.
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BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor memory device, and more particularly to a data output buffer circuit having a negative voltage protecting circuit.
In general, semiconductor memory devices include a data output buffer circuit which outputs internal data to the exterior of the memory device, and a data input buffer circuit which inputs data from the exterior of the memory device. FIG. 1 shows the structure of a conventional data output buffer circuit and FIG. 2 shows a waveform illustrating operational characteristics of the data output buffer circuit shown in FIG. 1. Signal φTRST (hereinafter, it is referred to as an output reset signal φTRST) can cause a data output terminal DQ to change from a floating state (i.e. high impedance state) into an output state. When output reset signal φTRST is in a low state 21 as shown in FIG. 2, data output to a data output line DB is output as shown in 22 and data output to an inverse data output line /DB is output as shown in 23. When the output reset signal φTRST is input as a logic "low" state signal as shown in 21 of FIG. 2, NAND gates 11 and 12 of FIG. 1 output signals of logic "high" states, and inverters 13 and 14 respectively invert and output the signals output from the NAND gates 11 and 12. Since NMOS transistors 15 and 16 are both turned OFF, the data output terminal DQ of FIG. 1 maintains a high impedance state (generally, in a condition of 1.4 V TRI in case of transistor-transistor logic TTL), as shown in FIG. 2.
If the output reset signal φTRST is changed to a logic "high" state signal, the logic states of NAND gates 11 and 12 are determined in accordance with outputs of the data output lines DB and /DB. Accordingly, if a logic "high" state signal is received by the data line DB as shown in 22 of FIG. 2 and a logic "low" state signal is received by the inverse data line /DB as shown in 23 of FIG. 2, the NAND gate 11 outputs a logic "low" state signal and the NAND gate 12 outputs a logic "high" state signal. NMOS transistor 15, acting as an output transistor inputs the logic "high" states signal received from the inverter 13 at the gate electrode thereof and is turned ON. NMOS transistor 16 inputs the logic "low" state signal received from the inverter 14 at the gate electrode thereof to thereby be turned OFF. Accordingly, a logic "high" state signal is generated at the output terminal DQ as shown in 24 of FIG. 2. Reciprocally, if a logic "low" state signal is received by the data line DB and a logic "high" state signal is received by the inverted data line /DB, the NAND gate 11 outputs a logic "high" state signal and the NAND gate 12 outputs a logic "low" state signal. NMOS transistor 15, acting as an output transistor inputs the logic "low" state signal received from the inverter 13 at the gate electrode thereof and is turned OFF, and the NMOS transistor 16 inputs the logic "high" state signal received from the inverter 14 at the gate electrode thereof and is turned ON. Accordingly, a logic "low" state signal is generated at the output terminal DQ.
A conventional output terminal DQ of a data output buffer circuit constructed as described previously can be connected to the other memory components. While not connected to other data output buffer circuit components when the data input/output lines are isolated from each other typically on output terminal is shared by multiple data output buffer circuits (such as a×4 construction where 4 data output buffer circuits share a single output terminal.) FIG. 3 shows data output terminal DQ shared by two data output buffer circuits.
Data input and output on a common data line are distinguished according to the logic state of the output enable signal generated to an output enable (/OE: output enable) terminal. If a logic "low" state signal output enable signal is input to the output enable terminal, the data input/output line (DQ line) is used as a data output line. Then, the output reset signal φTRST which controls the data output buffer circuit can go to the logic "high" state. The logic state of the data output terminal DQ is then determined as described above according to the state of the internal data lines DB and /DB. Reciprocally, if the logic "high" state signal is input to the output enable terminal, the output reset signal φTRST goes to the signal logic "low" state, thereby changing the data output buffer circuit to a high impedance state (floating state), and the data input/output line (DQ line) is used as a data input line. When the data input buffer circuit which is connected in common to the data input/output lines is enabled, data is input to the data input/output line within the semiconductor memory device. While FIG. 3 shows two data output buffer circuits connected to the data input/output line (DQ line), FIG. 3, does not show the connection of the data input buffer circuit to the data input/output line. Further, the data input/output lines are connected to external devices, as described above, which external device may be structured with an interface having GTL, LVTTL or TTL structures.
When the negative voltage is used in the external device connected to the data input/output lines, current consumption greatly increases in the data output buffer circuit constructed as shown in FIG. 1. FIG. 4 shows the output terminal of the data output buffer circuit which is constructed as shown in FIG. 1, where the current is in the high impedance state. That is, the output reset signal φTRST is input at the logic "low" state and therefore NMOS transistors 15 and 16 are turned OFF. When a plurality of the data output buffers share a single data input/output line, selection of one of the data output buffer circuits has not occurred in this state, although the data input/output line may have been selected to perform an input function. If an undesired negative voltage is generated at the data output terminal DQ, an undesired electrical current path is formed. That is, when interfaced with external devices using a negative voltage, when the negative voltage flows to the data input/output line, the data output buffer circuit forms an undesired electrical current path. For example, if a negative voltage of -2V is input to the data output terminal DQ, 0V of a ground potential V SS level is applied to the gate electrode of the NMOS transistor 15, but the gate-source voltage Vgs goes to 2V since the source electrode is connected to the data output terminal DQ. Accordingly, the negative voltage applied to the data output terminal causes the NMOS transistor 15 of the data output buffer circuit to turn ON while in a high impedance state and forms the electrical current path shown in FIG. 4. Assuming that a threshold voltage V T of the NMOS transistor 15 is 1V and the power supply voltage V CC is 5V, Vgs-V T becomes smaller than the drain-source voltage Vds and NMOS transistor 15 operates in the saturation region.
If the data output buffer circuit undesirably operates in the high impedance state, electrical current is unnecessarily consumed which may adversely affect operation of the memory device, including operating power levels. FIG. 5 shows the operation state of the NMOS transistor 15 when it inputs a negative voltage to the data output terminal DQ. A channel illustrated by the hatched region is formed at the side of the source electrode, and in a region "c," where no channel is formed, a drift electrical current flows. The application of a negative voltage to the data output terminal DQ increases the voltage difference between the drain electrode and the source electrode, and therefore, in the region where the channel is not formed, impact ionization results and substrate current is substantially increases. As a result, the level of the substrate voltage V BB is increased, and due to this level change of the operating power, abnormal operations may result in the semiconductor memory device.
Another conventional data output buffer circuit which overcomes these problems is shown in FIG. 6 and is disclosed in detail in U.S. Pat. No. 4,678,950 to MITAKE. In the data output buffer circuit constructed as shown in FIG. 6, output data DT is applied from the data line DB to a NMOS transistor 64 acting as a pull-up transistor, and inverted output data DTB is applied from the inverted data line /DB to a NMOS transistor 66 acting as a pull-down transistor. A control signal φS causes the data output buffer circuit to enter the high impedance state. NMOS transistor 64 is connected between the power supply voltage V CC and the data output terminal DQ, and has its gate electrode connected to a node N1 to input output data DT. NMOS transistor 66 is connected between the data output terminal DQ and the ground potential V SS , and has its gate electrode connected to node N2 to input output data DTB. NMOS transistor 61 is connected to the node N1 and has a gate which inputs output control signal φS. NMOS transistor 62 is connected between a source electrode of the NMOS transistor 61 and the ground potential V SS , and has a gate connected to the data output terminal DQ. NMOS transistor 63 is connected between the node N1 and the data output terminal DQ, and has a gate connected to the ground potential V SS . NMOS transistor 65 is connected between the node N2 and the ground potential V SS , and has a gate which inputs the output control signal φS.
In operation, if the output control signal φS is input at the logic "high" state, NMOS transistors 61 and 65 are turned ON, thereby decreasing to ground level the potentials on the nodes N1 and N2. Thus, a logic "low" state signal is applied to gate electrodes of the NMOS transistors 64 and 66.
If the potential on node N1 was at the logic "high" state in the previous state, the data output terminal DQ would also be in a logic "high" state. In this state, if the output control signal φS is input as a logic "high" signal, NMOS transistor 61 turns ON, and, due to the "high" level logic potential on the data output terminal DQ, the NMOS transistor 62 is turned ON. Accordingly, the potential on the first node N1 becomes lower then the threshold voltage of the NMOS transistor 64. Conversely, if the potential on the node N2 was at a logic "high" level in the previous state, since the NMOS transistor 65 is turned ON upon receipt of the output control signal φS, the potential on the node N2 will change to potential lower than the threshold voltage of the NMOS transistor 66.
Once the NMOS transistors 64 and 66 are both turned OFF, the potential of the data output terminal DQ will fall to the logic "low" state and the data output buffer circuit described above enters a high impedance state. In the high impedance state, if a negative voltage is applied to the data output terminal DQ, since the voltage Vgs of NMOS transistor 64 is increased due to the negative voltage, the NMOS transistor 64 will momentarily turn ON. However, since the NMOS transistor 63, which is connected between the node N1 and data output terminal DQ, and has its gate electrode connected to ground potential V SS turned ON, the potential on the node N1 will change to the potential of the data output terminal DQ. Accordingly, since the potential on the node N1 equals the potential of the output terminal DQ, the voltage Vgs of the NMOS transistor 64 will go to 0V, thereby turning OFF the NMOS transistor 64. In other words, since the node N1 and the data output terminal DQ are linked with each other through a subthreshold region of the NMOS transistor 63, the voltage Vgs of the NMOS transistor 64 becomes 0V. Accordingly, since the electrical current path formed by the NMOS transistor 64 is cut off, abnormal operations due to impact ionization generated in the NMOS transistor 64 as shown in FIG. 5, can be prevented.
However, when using the data output buffer circuit having a negative voltage protecting unit as described above, desired electrical current path will still be formed if the memory device is connected in common with other memory devices as shown in FIG. 7. Referring to the operational waveform of FIG. 8, assume that a first memory and a second memory as shown in FIG. 7 respectively each include a data output buffer circuit constructed as shown in FIG. 6, share the data input/output lines of the system, and then output data using an interleave method. When data is output from the data output buffer circuit of the first memory, the second memory has to be in a high impedance state, and when data is output from the data output buffer circuit of the second memory, the data output buffer circuit of the first memory has to be in a high impedance state. In the operational waveform of FIG. 8, /RAS A , /CAS A , /OE A and φSA represent signals for controlling the first memory, and /RAS B , /CAS B , /OE B and φSB represent signals for controlling the second memory.
Assuming that the first memory is accessed, operation in which first output data DT is input as logic "low" state data and then changed to logic "high" state data will be explained hereinafter. If the /RAS A shown in 80 of FIG. 8, /CAS A shown in 82 and /OE A shown in 84 are enabled, thereby accessing the first memory, and inputting first output data DT is as logic "low" state data, the NMOS transistor 64 is turned OFF and the NMOS transistor 66 is turned ON, thereby generating the logic "low" state signal in the data output terminal DQ as shown in section LD1 of 88 of FIG. 8. When first output data DT is changed to a logic "high" state, first output data DT is input as logic "high" state data, the NMOS transistor 64 is turned ON and the NMOS transistor 66 is turned OFF, and therefore the voltage of the data output terminal DQA starts to increase as shown in a section HD1 of 88 of FIG. 8. In this state, if the accessing operation of the first memory is stopped and an accessing operation of the second memory is performed, /RAS A , /CAS A and /OE A are disabled, and the φSA is changed to the signal of the logic "high" state. At the same time, /RAS B , /CAS B and /OE B are enabled, and φSB is changed to logic "low" level signal. In this changed state, the logic "high" potential of the power supply voltage V CC level is applied to the node NA1 of the first memory, and the voltage of the data output terminal DQA starts to increase as shown in a section HD1 of 88 of FIG. 8. At this time, the first memory is changed to the high impedance state by the signal φSA applied to the transistors 61 and 62. Accordingly, the potential of the data output terminal DQA of the first memory starts to decrease again as shown in 88 of FIG. 8.
However, when the potential of the data output terminal DQA has not been sufficiently increased as shown in section HD1 of 88 of FIG. 8, since the transistors 61 and 62 have not yet sufficiently discharged the voltage of the node NA1, there is a possible undesired electrical current path shown by the dotted line in FIG. 7 according to the state of the second memory, since the node NA1 can undesirably remain high. This undesired electrical current path can exist because the voltage of the data output terminal DQA of the first memory is higher than the ground potential V SS as shown on 88 of FIG. 8 and is lower than the threshold voltage of the NMOS transistor 62. Since the path for discharging the voltage of the node NA1 is not formed in the first memory, the NMOS transistor 62 is turned OFF or is incompletely turned OFF. Since a logic "high" voltage level was generated at the node NA1 by first output data DT, the NMOS transistor 64 remains in the turned ON state.
In the state described above, if a logic "low" state signal is output to the data output terminal DQB from the second memory, the undesired electrical current path through the NMOS transistor 64 of the first memory and the NMOS transistor 76 of the second memory is formed. Accordingly, this undesired electrical current path remains until logic "high" state data is output to the data output terminal DQB from the second memory. Further, even if the node NA1 of the first memory is sufficiently discharged, when logic "low" state data is output through the data output terminal DQB of the second memory, the node NA1 will have a floating state. As a result, the voltage on node NA1 may undesirably change due to coupling or leaking currents and result in abnormal operation.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a data output buffer circuit in a semiconductor memory device capable of preventing abnormal operation due to a negative voltage applied to an output terminal of the data output buffer circuit.
It is another object of the present invention to provide a data output buffer circuit in a semiconductor memory device capable of stabilizing an output terminal to a high impedance state by detecting a level of the output voltage.
It is still another object of the present invention to provide a circuit capable of stably maintaining an output state in a stand-by state by detecting a voltage level of the data output terminal in a data output buffer circuit of a semiconductor memory device which shares data input/output lines with other semiconductor memory devices.
The present invention includes a voltage detection unit between a data output buffer terminal and the gate of a transistor which is used to dissipate a high level voltage on the internal data line. This detection unit thus prevents an undesired electrical path from existing due to the construction of the data output buffer circuit. In one embodiment, the detection unit consists of an NMOS and PMOS transistor connected in series and having a shared node connected to the voltage dissipating transistor. In another embodiment, there is also connected an invertor between the shared node and the gates of the NMOS and PMOS transistors.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent and will become better understood by reference to the following detailed description of the invention considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIG. 1 is a circuit diagram illustrating a conventional data output buffer circuit;
FIG. 2 shows a waveform illustrating operational characteristics of the conventional data output buffer circuit illustrated in FIG. 1;
FIG. 3 is a circuit diagram illustrating two output terminals of semiconductor memory devices connected to a common data output line;
FIG. 4 is a view illustrating an electrical current path by a negative voltage in the data output buffer circuit constructed as shown in FIG. 1;
FIG. 5 is a circuit diagram illustrating an undesired electrical current path that can form in the NMOS transistor 15 of FIG. 4;
FIG. 6 is a circuit diagram illustrating another conventional data buffer circuit which overcomes some of the disadvantages of the data output buffer circuit shown in FIG. 1;
FIG. 7 is a circuit diagram illustrating an undesired electrical current path that can form when multiple data output buffer circuits shown in FIG. 6 are connected to a common data output line;
FIG. 8 shows a waveform illustrating the operational characteristics of the FIG. 7 circuit which can result in the generation of undesired electrical current path illustrated in FIG. 7;
FIG. 9 is a circuit diagram illustrating a first embodiment of a data output buffer circuit according to the present invention; and
FIG. 10 is a circuit diagram illustrating a second embodiment of a data output buffer circuit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The term "output control signal φS" used in the present invention represents a signal for rendering a data output buffer circuit to a high impedance state. The terms "first output data DT" and "second output data DTB" (also called output data DT and inverted output data DTB) represent data output from data lines DL and /DL, respectively. In a high impedance state an output terminal of the data output buffer circuit is floating to present a very high impedance to the data buffer output terminal.
Referring now to FIG. 9, output data DT is data input from a data line DB, and inverted data DTB is data input from the data line /DB. The control signal φS causes the data output buffer circuit to enter a high impedance state. NMOS transistor 96 is connected between the power supply voltage V CC and data output terminal DQ and has a gate electrode which is connected to a first node N1 that inputs output data DT. NMOS transistor 96 is a switching unit that performs a pull-up function of the voltage on the data output terminal DQ. NMOS transistor 98 is connected between the data output terminal DQ and the ground potential V SS , and has a gate electrode which is connected to a second input node N2 that input the inverted output data DTB. NMOS transistor 98 is a switching unit that performs a pull-down function of the voltage on the data output terminal DQ. NMOS transistor 95 is connected between the first input node and the data output terminal DQ, and has a gate electrode connected to the ground voltage V SS . NMOS transistor 95 is a third switching unit that cuts off an electrical current path formed through the NMOS transistor 96 when a negative voltage is input to the data output terminal DQ.
PMOS transistor 91 is connected between the power supply voltage V CC and a first connection node N3, and has a gate electrode connected to a second connection node N4. NMOS transistor 92 is connected between the first connection node N3 and the data output terminal DQ, and has a gate electrode connected to the second connection node N4. An inverter 99 is connected between the first connection node N3 and the second connection node N4, and is tripped in accordance with a voltage level of the data output terminal DQ detected at the first connection node N3 to thereby control the voltage level of the second connection node N4. The PMOS transistor 91, the NMOS transistor 92 and the inverter 99 are voltage detection units which detect the voltage level of the data output terminal DQ to thereby output the detected result to the first connection node N4.
NMOS transistor 93 is connected to the first input node N1, and has a gate electrode connected to the first connection node N3. NMOS transistor 94 is connected between a source electrode of the NMOS transistor 93 and the ground potential V SS , and has a gate electrode which inputs the output control signal φS. NMOS transistors 93 and 94 are fourth switching units which cut off the electrical current path of the NMOS transistor 96 according to the voltage level detected at the data output terminal DQ in the high impedance state. The NMOS transistor 97 is connected between the second input node N2 and the ground potential V SS , and has a gate electrode which inputs the output control signal φS.
If the output control signal φS is input at a logic "high" state, the NMOS transistors 94 and 97 are turned ON. Since the first connection node N3 is precharged to the power supply voltage V CC during an initial state, the NMOS transistor 93 is turned ON and, accordingly, the potential levels of the first input node N1 and the second input node N2 are lowered to ground potential level. As a result, a logic "low" state signal is applied to the gate electrodes of the NMOS transistors 96 and 98. Accordingly, in a normal state, with a "high" logic level φS signal, the data output terminal DQ maintains the ground potential V SS level. Therefore, the ground potential V SS is applied to the data output terminal DQ, and accordingly the voltage of the connection node N3 is continuously maintained to the logic "high" level. Inverter 99 inverts the voltage of the connection node N3 to thereby apply an inverted voltage to the second connection node N4. PMOS transistor 91 therefore maintains a turned-ON state and the NMOS transistor 92 maintains a turned-OFF state, thereby maintaining the voltage of the first input node N1 at the logic "low" level.
When a negative voltage is applied to the data output terminal DQ in the high impedance state, the first input node N1 and the second connection node N4 maintain ground potential V SS . Accordingly, all the NMOS transistors 96, 95 and 92 are turned ON. If the NMOS transistor 92 is turned ON, the potential of the connection node N3 is lowered by the negative voltage. As a result, if the voltage input to the inverter 99 is lower than the trip voltage, the inverter 99 outputs a logic "high" state signal. PMOS transistor 91 is thus turned OFF by the output of the inverter 99, thereby cutting off the electrical current path formed in the PMOS transistor 91 and the NMOS transistor 92. As a result, the potential of the connection node N3 goes to the logic "low" state, and NMOS transistor 93 is completely turned OFF. At this time, NMOS transistor 95 performs the operations as described previously. Thus, the voltage of the first input node N1 is maintained under the threshold voltage of the NMOS transistor 96 due to the resistance that results from NMOS transistors 93, 94 and 95. Accordingly, when a negative voltage is applied to the data output terminal DQ, no electrical current path is formed through the NMOS transistor 96.
When a plurality of data output buffer circuits share a data input/output line, the operation previously described with reference to the prior art will be redescribed with reference to the present invention. In this operation, first output data DT is output as logic "high" state data and then changed to the high impedance state. A voltage rise on the data output, such as illustrated at HD1 of 88 of FIG. 8 is generated. The voltage on the data output terminal DQ is a positive voltage having a voltage level higher than the ground voltage V SS and lower than the threshold voltage. Since the connection node N3 has been precharged to the power supply voltage V CC level, the NMOS transistor 93 becomes the turned-ON state. Further, the NMOS transistor 94 is turned ON by the output control signal φS. Accordingly, an electrical current resulting from output data DT signal of the logic "high" level at the first input node N1 from the previous state flows through the NMOS transistors 93 and 94. Thus, the voltage on the first input node N1 rapidly changes to ground potential V SS . Accordingly, the NMOS transistor 96 is turned OFF, and an undesired electrical current path is not formed through the NMOS transistor 96. As a result, the data output buffer circuit is not affected by the output state of other memories commonly connected to that data input/output line.
Accordingly, in the data output buffer circuit as previously described, when the voltage on the data output terminal DQ is a ground potential V SS level or is generated as a positive voltage in the high impedance state, the voltage of the input node N1 can always be maintained at the ground potential level. When the voltage on the data output terminal DQ is a negative voltage, by causing the voltage on the input node N1 to be equal to the voltage on the data output terminal DQ, an undesired electrical current path is not formed in the high impedance state and, accordingly, excess current consumption can be prevented. Furthermore, by controlling the input node N1 so it is not in a floating state, abnormal operations can be prevented.
FIG. 10 shows another embodiment of the data output buffer circuit constructed according to the present invention. In FIG. 10, the components except for the output voltage detection unit are constructed as shown in FIG. 9. The output voltage detection unit is embodied by a PMOS transistor 101 and an NMOS transistor 102. PMOS transistor 101 is connected between the power supply voltage V CC and connection node N3 and has a gate electrode connected to the ground potential V SS . NMOS transistor 102 is connected between the connection node N3 and the data output terminal DQ, and has a gate electrode connected to the ground potential V SS .
This embodiment detects the output voltage of the data output terminal DQ in the high impedance state as follows. If the voltage level of the data output terminal DQ is at a ground potential V SS level, the PMOS transistor 101 maintains a turned-ON state, thereby maintaining the voltage level of the input node N1 at the ground potential V SS level. Further, even when the output voltage of the data output terminal DQ is generated as a positive voltage, the voltage of the connection node N3 is maintained at the logic "high" level, thereby maintaining the first input node N1 at the ground level. Even when a negative voltage is applied to the data output terminal DQ, the NMOS transistor 102 is turned ON and, therefore, the voltage level of the connection node N3 is changed to the DQ level. Accordingly, NMOS transistor 93 is turned OFF, and therefore the voltage level of the first input node N1 is equal to the voltage level of the data output terminal DQ due to the presence of the NMOS transistor 95. Accordingly, the data output buffer circuit of FIG. 10 operates the same as the data output buffer circuit of FIG. 9.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art which this invention pertains.
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A voltage detection unit between a data output buffer terminal and the gate a transistor which is used to dissipate a high level voltage on the internal data line. The detection unit thus prevents an undesired electrical path from existing in the data output buffer circuit. In one embodiment, the detection unit consists of an NMOS and PMOS transistor connected in series and having a shared node connected to the voltage dissipating transistor. In another embodiment, there is also connected an invertor between the shared node and the gates of the NMOS and PMOS transistors.
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[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/935,020, filed on Jul. 23, 2007, the disclosure of which is hereby incorporated by reference.
[0002] Ideally, a duty-cycled wireless data network should be energy efficient, reliable, and responsive. Energy efficiency is an important performance metric since wireless devices are typically battery powered and an energy-inefficient radio requires frequent battery change or recharging. Battery replacement may be costly not only because of the labor cost involved in accessing the deployment sites such as remote areas and changing or recharging the batteries, but also in providing communications during an outage for critical systems.
[0003] The contributors to energy consumption of a wireless device include radio transmission, radio receiving, idle listening, and other processing. If the traffic load is low, the energy spent on radio transmission and receiving accounts only for a small portion of the total energy consumption, and idle listening together with other processing accounts for the rest of the total energy consumption. Therefore, for wireless data networks such as a typical wireless sensor network where the traffic load is light, significant energy savings can be achieved by putting the radios in the sleep mode most of the time and waking them up only when there is a need for potential communication. This methodology is called duty cycling.
[0004] To make duty cycling work properly, it is crucial to synchronize the wake up times of wireless devices since two wireless devices can communicate only if they rendezvous at the right time instants. Various medium access control (MAC) protocols have been proposed in prior art to enable correct rendezvous. Two examples are BMAC, and UBMAC. In BMAC, the transmitter uses a long preamble that is longer than the time interval of the wake up cycle so that the receiver is guaranteed to wake up during the transmission of a packet. In UBMAC, the transmitter estimates when the receiver will wake up and transmits the packet just before the receiver wakes up.
[0005] In existing MAC protocols, for a single wake up, a receiver receives at most one packet. This has two ramifications on the performance of the network. One is energy efficiency. For example in the case of BMAC, if multiple packets are ready for transmission at a transmitter, overhead costs are incurred every time a transmission happens. Therefore, each packet introduces a fixed communication overhead, which is the transmission of a preamble of the length of the wake up interval. The other ramification is the delay introduced by the transmission of multiple packets. The amount of time that it takes to transmit multiple packets is at least equal to the number of packets times the duration of a wake up cycle. Additionally, in existing designs for energy-constrained wireless systems, when duty cycling is used, all the nodes in the network adopt the same duty cycle. That is, all nodes spend the same portion of time in the sleep mode as in the wakeup mode. This may not tap the full potential of energy efficiency and responsiveness, especially for heterogeneous wireless networks where some nodes have ample energy resources whereas others nodes do not. That is, the heterogeneity in the energy resource of the nodes could play an important role in determining the duty cycle of the nodes.
[0006] Another important performance metric is reliability. Wireless communication links are inherently unreliable. As a result, a transmitted packet may get lost. In general, the network performance is improved by introducing reliability enhancement mechanisms at each wireless link. Such enhancement mechanism may include the well known techniques of Stop and Wait, and Selective Repeat. However, for mesh duty-cycled wireless data networks, no such mechanisms have been considered up to now because these types of networks are new and involve unique constraints that have not been addressed by prior art methods. It is worthwhile to find an efficient way to introduce such known mechanisms to duty-cycled wireless data networks.
[0007] A third important performance metric is responsiveness. In a duty-cycled wireless data network, the wireless devices wake up periodically, and the period is usually preset for the sake of simplicity. For some wireless applications, such as environmental monitoring, a fixed duty cycle provides good enough performance. However, in some other applications, such as intrusion detection, the timing requirement is much more stringent, and the use of a fixed duty cycle may not be sufficient.
SUMMARY
[0008] The present disclosure is directed to a significant improvement of the energy efficiency, reliability, and responsiveness of duty-cycled wireless data networks by enabling the transmission of a train of packets, adding sophisticated feedback mechanisms to data transfer at each wireless link, and using a dual mode of network operation to handle both delay sensitive traffic and delay insensitive traffic.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other aspects will now be described in detail with reference to the following drawings.
[0010] FIG. 1 illustrates a simplified pictorial representation of the concept of duty cycling.
[0011] FIG. 2 depicts a simplified pictorial representation of one embodiment of the present disclosure utilizing the transmission of a train of packets without reliability enhancement mechanisms.
[0012] FIG. 3 illustrates a simplified pictorial representation of one embodiment of the present disclosure utilizing the transmission of a train of packets with Stop-and-Wait ARQ.
[0013] FIG. 4 depicts a simplified pictorial representation of one embodiment of the present disclosure utilizing the transmission of a train of packets with Selected Repeat ARQ.
[0014] FIG. 5 illustrates a simplified pictorial representation of one embodiment of the present disclosure utilizing the dual mode network operation.
[0015] FIG. 6 illustrates a simplified pictorial representation of an embodiment of a packet format for the messages used for the dual mode network operation.
[0016] FIG. 7 illustrates one embodiment of the present disclosure utilizing two-level sleeping duty cycling for a heterogeneous wireless network.
DETAILED DESCRIPTION
[0017] For many wireless data networks such as a sensor network, one of the most important performance metrics is energy efficiency since the wireless devices are typically battery powered and if the radios are not energy efficient, power management issues may seriously impair the performance of the network.
[0018] At a wireless communication device, the contributors to the energy consumption are radio transmission, radio receiving, listening, and other processing. In some wireless data networks like a wireless sensor network, the need for data transfer is not persistent at all times. For example, data are transmitted periodically, e.g., once every ten minutes, or data are transmitted only when some rare events such as an intrusion are detected. In either case, the actual traffic load on the network is low, and most of the time the radios are idle. In such wireless data networks, the proportion of the energy spent on the actual radio transmission and receiving is small, as opposed to that spent on listening and other processing. One typical way to conserve energy is to reduce the energy spent on listening by putting the radios into the sleep mode most of the time and waking them up only when there is a need for communication. This prior art technique is referred to as duty cycling, and is illustrated in FIG. 1 . The time intervals when the radio is awake 100 are generally much smaller than the time intervals when the radio is asleep 120 .
[0019] The benefit of duty cycling does not come free of cost. To enable duty cycling, it is necessary for the radios to know when to wake up and when to transmit since a communication is possible only if the transmitter and the receiver can rendezvous at the same time. Various protocols have been proposed in the literature in an attempt to enable efficient rendezvous. Two prior art examples are BMAC and UBMAC.
[0020] In BMAC, UBMAC and other existing MAC protocols, during a wake up interval, a receiver receives one packet. This has two ramifications on the performance of the network. The first ramification is energy efficiency. For example, in the case of BMAC, if multiple packets are ready for transmission at a transmitter, the overhead occurs every time a transmission happens. Each packet introduces a fixed communication overhead at the transmitter. The overhead includes the transmission of a preamble of the length of the duty cycle, and a variable communication overhead associated with receiving for an average period of half a wake up cycle at the receiver. The other ramification is the delay associated with the amount of time that it takes to transmit multiple packets which is typically equal to the number of packets times the duration of a wake up cycle.
[0021] To overcome these problems associated with existing protocols, the present disclosure is directed to a transmission scheme where a train of packets is transmitted for each wake up interval. With reference to FIG. 2 , a preamble 200 precedes a common physical layer header 210 . The physical layer header may include the number of data packets for this train (three in this example) and other information related to the packet such as the modulation scheme. Individual data packets 220 - 240 follow the header. The data packets may not be the same length. Depending on how much information is contained in the common physical layer header, each data packet may or may not include its own physical layer header. For example, if the common physical layer header contains the information needed to decode each data packet, then each data packet may skip their respective physical layer header. The size of the packet train should be less than the sleep interval so that other nodes in the network can get a fair share of the bandwidth.
[0022] The present disclosure also addresses the issue of reliability. The wireless communication links are inherently unreliable and therefore, it is expected that a packet may get lost during transmission. The present disclosure addresses this reliability issue by including an acknowledgement of receipt at each wireless link. Because in a multi-hop wireless data network, a packet to be relayed has already traversed a number of hops in the network, and the network has already spent some energy on this packet, it is important to make uses of the resources already spent. If this packet is lost, the energy spent on the all the transmissions of this packet is wasted. The present disclosure addresses these issues by implementing reliability enhancement mechanisms at the Medium Access Control (MAC) layer. Mechanisms such as Automatic Repeat reQuest (ARQ), Stop-and-Wait, Go-Back-N (GBN) and Selective Repeat, may be used in conjunction with link enhancement mechanism resulting in both improved reliability and augmented energy efficiency.
[0023] For example, with respect to FIG. 3 , Stop-and-Wait is used for link enhancement. Each data packet 300 - 320 has a sequence number and the Stop and Wait mechanism ensures that each data packet is received in proper order. For example, after the first data packet 300 is received, Node B transmits and acknowledgement 330 to Node A. Upon receipt of the acknowledgement 330 , Node A transmits the second data packet 310 . Likewise, upon receipt of the acknowledgement 340 of the receipt of the second data packet 310 at Node B, Node A transmits the third data packet 320 and awaits acknowledgement 350 from Node B. In another embodiment, advanced acknowledgement schemes such as Go-Back-N (GBN) and Selective Repeat could be used for improved throughput and energy-efficiency.
[0024] FIG. 4 illustrates an embodiment utilizing the Selective Repeat link reliability mechanism. For example if Packet 2 is lost 400 , this information is fed back to the sender (node A) 410 after packet 3 420 is (the end of the train) received. Node A then retransmits packet 2 430 , which is subsequently acknowledged by the receiver (node B) 440 .
[0025] Another performance metric is responsiveness. In a duty-cycled wireless data network, the wireless devices wake up periodically, and the period is usually preset and fixed for simplicity as previously discussed. For many wireless applications, such as environmental monitoring, a fixed duty cycle provides good enough performance. However, in some other applications, such as intrusion detection, the timing requirement is much more stringent, and the use of a fixed duty cycle may not be sufficient.
[0026] To address the problem associated with lack of responsiveness of the current duty cycled wireless data networks, the present disclosure provides for a dual-mode network operation scheme. Normally, the wireless nodes operate in the Normal Mode, which is characterized by a fixed and long wakeup cycle. If an emergency is detected, the portion of the network involved in delivering the emergency information transitions to the Emergency Mode, which is characterized by a much shorter wake up cycle or the lack of duty cycling at all.
[0027] The Emergency Mode may provide two options. In one aspect, each node in the portion of network involved in the delivery of the emergency information shortens it duty cycle, i.e., wakes up more frequently. In another aspect, each such node stays awake throughout the delivery of the emergency information.
[0028] To make the network operate seamlessly between the two modes, the present disclosure provides two methods which may be implemented. First, during the emergency period, the portion of the network involved in the delivery of the emergency information is identified to smoothly transition the network between the two modes while maintaining energy efficiency.
[0029] Second, when a communication node changes its duty cycle, it should notify this change to all of its neighbors so that the communication links remain available through neighboring nodes. For example, the adoption of a shorter wake up cycle or stopping duty cycling may significantly increase the energy consumption of a node. Therefore, for energy efficiency reasons, it may be useful to limit the duty cycle change only to the nodes that have to make such change.
[0030] FIG. 5 . illustrates an embodiment of efficiently changing duty cycle at selected nodes. FIG. 5A shows a pre-computed path available to route traffic from the Source 500 to the Destination 510 . The path may be in a tree or a mesh network topology. FIG. 5B illustrates one embodiment showing that an emergency occurs and the Source 500 decides to report this to the Destination 510 . First, it sends a 1-hop broadcast alert message to all of its neighbors. The circle 503 indicates the communication range of the Source 500 . Three 1-hop, or adjacent, neighbors receive this alert message, and update their stored information on the new duty cycle of the sender of this alert message, which in this case is the Source 500 . Among these neighbors, node A 520 is in the next hop to the Destination 510 . Node A may decide to transition to the Emergency Mode by broadcasting an alert message to its own neighbors. This process repeats and eventually, all nodes on the path (Nodes 500 , 510 , 520 , 530 , 540 , 550 ) participate in the Emergency Mode, and in addition, the neighbors of these nodes (Nodes 505 , 515 , 525 , 535 , and 545 ) are notified of the change.
[0031] FIG. 6 illustrates an example message format. The message contains the sender 600 of this message, and the intended receiver 610 of this message (next hop). Also contained are the IDs of the original source 620 and the final destination 630 of the upcoming emergency traffic. The message type 640 differentiates whether this is an alert message, or a cancel message, which will be described shortly. The sequence number 650 is used to identify duplicate messages. The “Type of Duty Cycle Change” field 660 indicates whether to shorten the duty cycle interval or simply stop duty cycling.
[0032] After the emergency information is completely delivered, the nodes in the Emergency Mode should fall back to the Normal Mode to conserve energy. To enable this fall back, the Source initiates another message, a cancel message. The cancel message is sent to the same set of nodes to which the alert message is sent, namely, the nodes on the path, and their 1-hop neighbors. The way the cancel message propagates is the same as the alert message. For example, if a node is participating in the Emergency Mode, it will in turn broadcast a 1-hop cancel message. For a cancel message, the “Message Type” in FIG. 6 will be “Cancel”.
[0033] If a node is in the paths of two streams of traffic which have different duty cycle requirements, the node will disregard the duty cycle requirement of lower quality of service.
[0034] The nodes in a wireless network may not be identical. In fact, they may have drastic differences in certain aspects, such as energy resource and processing power. The nodes may also possess differences in functionality which may require differing duty cycles. Such a wireless network is called a heterogeneous wireless network. For a heterogeneous wireless network, it is natural to consider a hierarchical architecture that consists of backbone nodes and non-back bone nodes. In this disclosure, the energy resource available to individual nodes is the defining criterion of classifying a node as a backbone node or a non-backbone node. Specifically, for a pre-determined energy threshold, a node is called a high energy node if its remaining energy is greater than the threshold and is called a low-energy node if otherwise. High energy nodes rotate to serve as backbone nodes based on network conditions and energy level at individual nodes. Network conditions are updated periodically through neighbor discovery or synchronization. If the network is dense, in order to avoid draining energy from only a few fixed nodes, periodically or adaptively, topology control techniques (or network reconfiguration) can be applied to select a set of high energy nodes to serve as backbone nodes based on the energy level at those nodes. Non-backbone nodes will be sleeping except when synchronization is needed. The objective of topology control is to select enough backbone nodes so that the network is connected.
[0035] Once the backbone network is selected, routing can be done by selecting paths within the backbone nodes which minimizes energy consumption. Once topology and routing are determined, data transmission can take place over the backbone network by selecting appropriate medium access control (MAC) modality and time synchronization algorithm. In this disclosure, a two-level design of scheduling can be utilized. As shown in FIG. 7 , the non-backbone nodes do duty cycling by waking up periodically during intervals 710 . The backbone nodes also wake up during the same time intervals 700 . The two types of nodes exchange information during those same intervals 700 and 710 . However, The non-backbone nodes are not responsible to relay traffic for other nodes, whereas the backbone nodes are responsible to relay traffic for other nodes. The backbone nodes may perform some MAC layer transmissions and receiving 720 .
[0036] The neighbor discovery, topology control and quality of service routing are conducted at a relatively long time scale 730 , for example, in minutes or hours, while synchronization 740 and MAC 750 are done at a relatively short time scale. Thus, in one embodiment, for a heterogeneous wireless network: (1) Due to node heterogeneity, a hierarchical architecture consisting of backbone nodes and non-backbone nodes is used. Only backbone nodes are responsible for relaying data. (2) The network is frequently reconfigured so that nodes can serve as backbone nodes adaptively based on energy level or in an alternate fashion with a relatively long period. The length of such a period is a design parameter, which is determined by the frequency of the network conditions change. (3) Synchronization and MAC are done at a relative short time scale. (4) There are two types of availability schedules, one for backbone nodes and one for non-backbone nodes. Non-backbone nodes are not used for relaying data where backbone nodes are used.
[0037] It may be emphasized that the above-described embodiments, particularly any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.
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A system and method for medium access control in a wireless communication network including the use of packets having a header and plural data portions, acknowledgement request features, corrupt packet identification, and adaptive duty cycling.
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BACKGROUND OF THE INVENTION
Natural gases and liquid (liquified) hydrocarbons are known to contain acid gases such as carbon dioxide and one or more sulfur containing components such as carbonyl sulfide, hydrogen sulfide, mercaptans and the like, many of which must be removed to make the hydrocarbons suitable for the many uses, such as polymerizations, combustion, and the like, because of the deleterious effect these gases have on catalysts, air quality, etc.
Carbonyl sulfide (COS) is contained in natural gas in small quantities i.e., 50-500 ppm and in liquid (liquified) hydrocarbon streams in concentrations in the 1-100 ppm range. The specification level in treated products is in the 1 ppm range or less for natural gas and most liquid streams. There are several processes available for removing COS to these levels. However, some specifications for liquid (liquified) hydrocarbon products are in the 50-1000 ppb range. For example, ethylene and propylene for polyethylene and polypropylene manufacture respectively, normally have a 50 or less ppb limit. There are no known techniques for removing COS to these low levels, e.g. ppb, which are commercially viable. The removal of carbonyl sulfide (COS) is very poor in caustic solutions. No more than 10-15% removal can be expected in conventional caustic solutions used in the conventional designed contactor.
There are, of course, several processes which employ physical solvents and or solvents which aid in the hydrolysis of COS to its component CO 2 and H 2 S, but most of these processes have high make-up rates because the solvents and/or co-solvents are soluble in the liquid hydrocarbons to varying degrees requiring excessive make-up and thus are uneconomical in commercial processes.
In addition most of the materials for removing the COS to the ppm level usually form products which are either impure and command a very poor price or are objectionable from the environmental standpoint.
While mercaptans (RSH) are contained in some natural gases essentially all refinery liquid (liquified) hydrocarbon streams contain mercaptans. The specifications for refinery use and for polymerization reactions employing these products usually require the mercaptan level to be in the 1-20 ppm range.
The known art for the removal of mercaptans consists of one to three stages of contact with an aqueous caustic solution containing some type of solubilizer. Many patents have issued on this concept, most of which have expired. A separate unit is required for these operations. An example of one such process is the Merox Process requiring a separate unit in which the mercaptans are converted to their disulfides. The Merox solution is a caustic solution which contains a proprietary catalyst which is necessary for the economic conversion of RSH to RSSR. The art as practiced does not use unformulated or catalyst containing solution caustic for RSH removal since removal is poor in caustic alone, particularly with respect to removal of the higher molecular weight mercaptans, e.g., butyl and higher alkyl mercaptans.
The advantages and disadvantages of using monoethanolamine MEA in a refinery for removal of acid gases include some of the following:
Advantages
1. It has the capability of producing the lowest level of H 2 S and CO 2 in the product but has little or no selectivity required for tail gas sulfur producing processes.
2. It can be partially reclaimed in the event of thermal degradation or build-up of heat stable salts but often the high MEA usage rates result from these reclaiming operations (necessitated by the irreversible reaction of COS and MEA) as well as losses to the products because of MEA's solubility in the products.
3. It can hydrolyze COS and thus the product meets farily low COS specifications.
Disadvantages
1. It has high heats of reaction with H 2 S and CO 2 .
2. It lacks selectivity and in applications where this is a preference, energy requirements are further increased.
3. It has a higher solubility in liquid hydrocarbon streams than many other amines.
4. Corrosion potential limits solution strength to about 15% by weight.
5. A portion of the COS removed reacts irreversibly with the MEA causing losses.
When diethanolamine DEA is considered as a replacement for MEA, its advantages and disadvantages include some of the following:
Advantages
1. It has lower heats of reaction.
2. It has a slight selectivity for H 2 S over CO 2 .
3. It is slightly less soluble in liquid hydrocarbons.
4. It can remove COS in some cases to acceptable levels.
Disadvantages
1. It has insufficient selectivity for tail gas treating.
2. Reclaiming is not a common, straight-forward process.
3. It forms irreversible products with CO 2 creating losses of the absorbent.
4. It doesn't produce treated gas specifications as low as MEA.
A refinery choosing methyldiethanolamine MDEA as a replacement for MEA and/or DEA does so based on the following advantages out-weighing the disadvantages:
Advantages
1. It has still lower heats of reaction than either MEA or DEA.
2. It has the required H 2 S to CO 2 selectivity required for tail gas treating and other gas streams containing CO 2 and H 2 S.
3. It is slightly less soluble in liquid hydrocarbons.
4. It is more resistant to chemical degradation.
5. It is not corrosive.
6. Solution strengths up to 50% can be used for added acid gas removal capacity.
Disadvantages
1. It doesn't produce treated gas specifications as low as MEA or DEA.
2. It isn't known for its ability to remove COS.
3. Reclaiming is feasible but somewhat more difficult than MEA but not as complex as DEA.
4. Solvent cost is higher.
It would be advantageous to have a plant designed to remove all of these acid gases to the aforesaid levels producing a hydrocarbon product useful in the many latter processes. Such a designed acid gas treating plant liquid (liquified) and gas are indicated by the trade in the term gas treating plant is described consisting of a series of unit operations which integrate into the existing processes both from the mode of operation and the equipment which is used to produce commercially soluble products for polymerizations, combustions and the like.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention a natural or synthetic gas stream or liquid (liquified) hydrocarbon stream as for example, a C 3 /C 4 stream from a refinery debutanizer which contains acid gases such as H 2 S, CO 2 , COS (carbonyl sulfide), mercaptans (methyl, ethyl, propyl, butyl and even higher alkyl moieties) can be freed of these undesirable components by:
(1) Treatment of the gas or liquid stream with a formulated aqueous absorbent consisting of a selective H 2 S absorbent, e.g. methyldiethanolamine (MDEA) and a highly active COS absorbent/hydrolyzer, e.g. diisopropanolamine (DIPA) wherein the H2S is selectively absorbed and COS hydrolyzed to H 2 S and CO 2 , the products being absorbed by the selective H 2 S absorbent in the desired selective range. The formulated absorbent is regenerated (stripped of H 2 S) and returned to the absorber. Some make up of COS absorbent/hydrolyzer is necessary when liquid (liquified) hydrocarbons are treated because of solubility of these classes of compounds in the liquid hydrocarbons.
The so treated gas stream or liquid hydrocarbon will be found to have between 30 and 80 percent of the COS removed as compared with only 10-30 percent when a selective amine is used alone.
Further, by employing a selective H 2 S absorbent at this stage of the process the H 2 S to CO 2 ratio picked up by the absorbent can be adjusted to provide a regenerator gas product suitable for economical operations of most commercial sulfur recovery processes, e.g. a Claus Unit. In addition, since the COS is partially converted to H 2 S and CO 2 , later treatments to remove the other acid gases are able to produce less contaminated waste streams, many of which can be after-treated to useful products and the treating solutions regenerated to provide more economical operations. Substantially any of the secondary and/or tertiary alkanolamines can be employed in this step, each having a recognized advantage under the operating parameters of absorber operations, feed stream conditions and available battery utilities. The exemplary discussions employ methyldiethanolamine which based on the ratio of H 2 S and CO 2 in the feed stream provided a regenerator off-gas with an H 2 S to CO 2 ratio to fit an existing Claus Unit operating parameters in the refinery. Other sulful conversion processes, as well as a similar process on a different scale, may require other ratios of H 2 S to CO 2 which will dictate the selection of the selective absorbent. The selectivity of the various absorbents, particularly the amines and more particularly the secondary and tertiary alkanolamines are well documented in the literature and one can be found without undue experimentation to give the most effective use of existing equipment.
In addition, by using a selective H 2 S absorbent formulated to contain an organic liquid COS solvent (absorbent) the losses of both solvent absorbents is reduced since most selective H 2 S sorbents are less soluble in liquid (liquified) hydrocarbon streams and smaller quantities of the COS sorbent are possible thus reducing its losses.
(2) Treatment of the resulting product gas or product liquid (liquified) hydrocarbon stream with an aqueous formulated alkali (caustic)-primary alkanolamine solution wherein the contact time is such to remove 50-80 percent of the remaining COS but "slip" most of the mercaptans. The concentration of caustic is in the range of 5 to 50% by weight and the alkanolamine preferably a primary alkanolamine, in from about 0.5 to 20% by weight, the remainder of course being water. It has been found advantageous to employ a single stage contactor. The COS being converted herein to Na 2 S and Na 2 CO 3 , which mixture may be used to generate S° and CO 2 or used per se in several industrial processes, e.g. paper production.
(3) The gas or liquid stream from the 2nd step is then contacted with a 5 to 50 and preferably a 10-25 percent by weight of an unformulated aqueous alkali solution (NaOH) in a "structured" packed zone of several stages, preferably a minimum of six stages. Here essentially all of the mercaptans are removed as well as an additional 70-90 plus percent of the remaining COS. The waste stream from this treatment may be regenerated in known manners.
(4) Following these treatments the hydrocarbon stream, if liquid, is washed with water to remove residual alkali, and again, if a liquid stream as for example from a debutanizer, is further split into its components, e.g. C 3 and C 4 and the C 3 or the product gas, if from a natural or synthetic source, is "polished" substantially free of COS, which of course goes with the lower boiling components (C 3 ) or remains in the gas streams, by contacting it with a final formulated aqueous alkali/alkanol amine solution in a structured multi stage contactor.
The product is finally washed to remove any traces of alkali or alkanolamine and is found to be substantially free of sulfur containing organic and inorganic acid gases, COS in the range of less than 1000 ppb and usually less than about 100 ppb.
It is of course to be understood that any of the above steps may be eliminated, bypassed or included, with greater or reduced contact times, recirculation rates and/or strength H 2 S if more sulfur removal is required or less sulfur removal is acceptable.
The formulated solutions employed in accordance with the present invention are of two general scopes:
(a) an aqueous solution of (i) a selective hydrogen sulfide absorbent such as methyldiethanolamine, and (ii) a COS absorbent/hydrolyzer under the conditions of selective H 2 S absorbtion such as diisopropanolamine; and,
(b) an aqueous solution of an alkali metal hydroxide containing various amounts of at least one alkanolamine.
In addition it is advantageous to employ "structured" packing having a high surface-to-volume ratio, such as Goodloe knitted packing, in the formulated alkali/alkanolamine treatment steps.
The percent removal of each component is related to the strength of the treating solutions, the contact time, and the loadings are dependent on the circulation rates.
The first step treatment, the combined primary H 2 S removal step and COS initial hydrolysis step, is carried out in a multi stage contactor or absorber designed to provide a contact time of the gas or liquid (liquified) hydrocarbons with the formulated H 2 S/COS absorbent-hydrolysis solution of from about 50 to 120 seconds. Such contact times give enhanced COS removal, maximize the selective removal of H 2 S vis-a-vis CO 2 , minimize solubility of the COS hydrolyzer in liquid hydrocarbon and yet permit H 2 S loading of about 0.2 moles H 2 S per mole of selective H 2 S absorbent.
Temperature of the selective H 2 S absorbent/COS absorbent-hydrolysis contact should be in the range of 40° to 90° C.
The temperature of the alkali treatments, both formulated and unformulated, ranges from about 40° to 70° C.
The concentration of the components of the various formulations is as follows:
(a) aqueous formulated H 2 S/COS absorbent-hydrolysis solutions of from 5 to about 60% by weight are operable but, preferably these solutions contain 20% to 50% by weight of the H 2 S absorbent and from about 0.5 to about 15% by weight and preferably from about 1% to about 10% of the COS absorbent hydrolyzer.
(b) aqueous formulated alkali/alkanolamine solutions contain 5 to 50% and preferably contain 5% to 25% of the alkali metal hydroxide and 0.5 to 20% and preferably 2% to 15% of the primary alkanolamine;
(c) the aqueous unformulated alkali scrubber solution contains 5 to 50% by weight and preferably 10% to 25% alkali metal hydroxide.
The loading of the H 2 S absorber/COS absorber-hydrolyzer solution is generally held below about 0.25 moles H 2 S per mole absorbent and preferably at about 0.2 moles per mole.
The scope of selective H 2 S absorbents operable in accordance with the present invention is as wide as the known art but for energy conservation, a selective absorbent, a tertiary amine such as methyldiethanolamine or diethylethanolamine is preferred, since total heat duty is about 1/2 that of, for example, MEA at 20% concentrations. Other selective alkanolamine absorbents are well documented relative to heat duty and can be selected on the basis of each installation design, available heating and cooling sources outside the battery of the present invention, and selectively of pick-up.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE illustrates the sulfur removal process of the present invention and concentration levels of selected process streams.
DETAILED DESCRIPTION OF THE INVENTION
In a representative example with specific reference to the drawing which is a schematic of a portion of a light hydrocarbon processing plant of a refinery FIG. 1, a natural or snythetic gas stream or a liquid or liquified petroleum hydrocarbon stream (1) was fed to a multi-stage absorber (A) of conventional design to employ an alkanolamine to remove acid gases. In the representative example the original absorbent was monoethanolamine (MEA). The absorbent stream (2) in accordance with the present invention was a lean formulated selective H 2 S alkanolamine absorbent (methyldiethanolamine containing diisopropanolamine) which replaced the MEA absorbent previously used. The rich sorbent (4) was withdrawn from the bottom of the absorber and contained the absorbents, H 2 S and CO 2 tied-up in the absorbent. A major portion of the COS had been hydrolyzed to H 2 S and CO 2 which were of course picked-up by the sorbents in their selective ratios. The rich absorbent (4) was regenerated in a stripper (B), the resulting hot lean sorbent cooled by cross exchange with the cold rich stream (4), and the lean stream (2) returned to the absorber (A). The off-gas from the stippper, stream (5) contained H 2 S and CO 2 in a ratio which was suitable for sulfur recovery in for example a Claus sulfur unit. The hydrocarbon stream exiting the absorber, stream (3) contained very little H 2 S, the "slipped" CO 2 , the mercaptans and still contained from 70-20 percent of the COS that had been in the incoming hydrocarbon stream (1).
The treated hydrocarbon is sent to a single stage contactor (C) where it is connected with formulated caustic solution (aqueous sodium hydroxide) containing monoethanolamine stream (6). The flow rates are adjusted to provide a pick up of above 50 to 80 percent of the remaining COS and most of the CO 2 (COS+NaOH→Na 2 S+Na 2 CO 3 ) and "slip" a major portion of the mercaptans. The hydrocarbon stream (8) now contains only traces (ppm) of H 2 S, and CO 2 , the major portion of the mercaptans and some residual COS.
This stream, stream (8) was treated with an aqueous caustic solution over a structured packing, e.g. Goodloe woven mesh in column D. Here, the intimate multi-stage contact of the stream with the caustic permits the mercaptans to be converted to their salt form and pass downwardly with the aqueous caustic treating solution while the hydrocarbons pass upwardly and out of the treater.
At this point the major sulfur containing compounds (acid gases) have been removed and in many cases the residual of these gases remaining is insignificant and the hydrocarbons can be used directly in downstream processes. However, should lower level acid gas contents be required the, hydrocarbon stream can be polished to remove the acid gases particularily the COS to parts per billion by a subsequent treatment with a formulated aqueous caustic solution in a contactor packed with a structured packing. For example in the liquid hydrocarbon section of the refinery it is customary to fractionate the treated streams of mixed hydrocarbons and if such is the design it will be obvious that the COS and most other acid gases will go with the lighter fractions of the hydrocarbons. Such treatment will increase the concentration of the acid gases in the light end, in the case of the refinery treating a debutanizer stream, or mixture of C 3 's and C 4 's, the concentration of COS will about double in the C overhead, and if this stream is to be used in the polymerization reactions, must be again treated to remove the COS to less than 50 ppb. By following the steps as herein set forth, COS and total sulfur in hydrocarbon streams can be reduced to less than 50 ppb.
The following data illustrates the significant improvement in acid gas removal from the light hydrocarbons processing streams of one refinery.
A refinery debutanizer product was employed which consist mainly of C 3 and C 4 liquified petroleum gases containing H 2 S, COS and mercaptans (C 1-4+ ). This section of the plant was operated using MEA, then MDEA and finally formulated MDEA with the formulated alkali in accordance with the present invention. The following table documents the results using the various formulated solutions of the present invention compared to the original solutions starting with MEA, changing MEA to MDEA then the formulated MDEA solutions; Example A is projected from experience based on Example 3 using higher concentrations of MDEA and 2% DIPA.
______________________________________Case Number 1 2 3 4______________________________________Solvent MEA MDEA MDEA.sup.1 MDEA.sup.1Conc. wt % 15 20 20 50Circ. rate gpm 1179 1179 1179 462X-Exch. Approach temp 30 30 30 30°F.Reflux H.sub.2 O/acid gas 1.2 1.2 1.2 1.2Heat of Reaction 7419 4304 4304 4304Calc. MMBTUHReflux Latent Heat 6218 5561 5561 5561MMBTUHSensible Heat 17292 16989 16989 6516MMBTUHReboiler duty 30929 51204 26854 16381MMBTUHCOS before contactor 3 3 3(ppm)after contactor (ppm) 2 1 1after caustic scrubber 2.sup.2 0.05-0.1.sup.3 0.05-0.1.sup.3(ppm)______________________________________ .sup.1 formulated with ca 2% DIPA .sup.2 15% NaOH .sup.3 15% formulated NaOH
In another example a synthetic gas stream containing 3.5 volume percent H 2 S, 500 ppm COS, 2500 ppm each of methyl and ethyl mercaptan was feed at 50° C. and 50 psig for COS removal through a high surface area to volume structured packing (Goodloe unit packing) at various liquid to gas ratios (L/G) and temperatures to obtain the effect of L/G and temperature on COS removal in the presence of RSH (mercaptans) and H 2 S by a 10% sodium hydroxide, 90% water solution. The results are listed below as well as a single stage contactor results which illustrates the benefit of the inclusion of such a unit operation in the preferred embodiment of the present invention.
TABLE 1______________________________________Caustic Removal of H.sub.2 S, COS, EtSH, and MeSH % Removal of Acid GasesSolution L/G Temp. COS H.sub.2 S EtSH MeSH______________________________________10% NaOH and .012 50° C. 70 99.9 99.0 99.090% Water Solution .012 55° C. 80 99.9 99.2 99.2 .012 60° C. 92 99.9 99.4 99.4 .016 50° C. 70 99.9 99.0 99.4 .03 50° C. -- 99.9 99.5 99.5 .03 50° C. -- 99.9 99.5 99.5 .034 50° C. -- 99.9 99.6 99.6 .034 50° C. -- 99.9 99.9 99.9 .035 50° C. -- 99.9 99.6 99.6 .041 50° C. 68 99.9 99.6 99.7 .043 94° C. 90 99.9 99.6 99.8 .046 50° C. 80 99.9 99.9 99.9 .047 50° C. 80 99.9 99.8 99.9 .047 85° C. 94 99.9 99.7 99.8 .053 50° C. 90 99.9 99.6 99.6 .053 50° C. 66 99.9 99.6 99.6 .058 85° C. 78 99.9 99.7 99.8 .064 50° C. 82 99.9 99.8 99.9 .064 85° C. 94 99.9 99.7 99.8 .069 50° C. 82 99.9 99.9 99.9 .079 50° C. 80 99.9 99.7 99.8No packing in .012 50° C. 0 95.7 89.2 91.9column same solution______________________________________ 0 indicates 0% removed -- indicates that the component was present but was not analyzed.
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There is disclosed a process for treating liquid (liquifiable) and gaseous hydrocarbons to remove substantially all of the acid gases including COS by contacting the hydrocarbon streams with specific aqueous treating agents in a series of sequential specific limit operations and apparatus.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to automatic transmissions for automotive vehicles, in particular to transmissions comprising planetary gearsets operated by friction control elements.
2. Description of the Prior Art
It is difficult to achieve acceptable shift quality on sequential, i.e., continuous downshifts, such as a 6-4-3 or 5-3-2 downshift, in an automatic transmission because a torque disturbance may occur during the transition from the first to the second portion of the shift. In order to execute the transition smoothly, the offgoing control element, a clutch or brake, for the second shift must slip before the oncoming element of the first shift gains torque capacity.
The shifts are difficult to calibrate robustly. If the offgoing element slips too soon, a neutral interval occurs near the end of the shift. Conversely, if the offgoing element slips too late, a torque bump occurs as the oncoming element of the first shift gains capacity.
To achieve acceptable feel, the oncoming and offgoing elements must be closely synchronized. But precise synchronization is difficult to achieve under all operating conditions.
The period required to execute successive downshifts between adjacent gears using conventional control techniques is unacceptable approximating 1.2 seconds to complete such downshifts. There is a need in the industry for a control strategy that permits successive downshifts to be completed smoothly and within an acceptably short period.
SUMMARY OF THE INVENTION
A method for executing a sequential downshift in a transmission includes disengaging a first element and starting disengagement of a second element, forcing a third element toward synchronous speed by increasing to a low capacity a torque capacity of the fourth element before engaging the third element, and engaging the third and fourth elements.
With this control strategy, there is no need to precisely synchronize the oncoming element of the first shift with the offgoing element of the second shift. Shift time is equivalent to that of a 6-2 direct downshift, providing greater consistency among the power on downshifts.
The control maintains output torque during the ratio change and allows for change of mind to the intermediate gear. Should the driver tip out early enough in the shift, the first oncoming element is applied and the second shift is cancelled. In addition, the final on coming element may be pre-staged to allow a continuous ratio change if the driver tips into a 6-4 or 5-3 downshift in progress.
Early application of the second on-coming element increases energy dissipation. The time the clutch applied, however, is significantly less than during equivalent downshifts using another control strategy.
It is no longer necessary to perform single step interlocked downshifts to achieve high shift quality. Shift time is short and provides greater consistency among downshifts. The control is robust, easy to calibrate and provides fast smooth downshifts.
This control strategy eliminates the need for close synchronization, allowing the offgoing element of the second shift to be released late enough to avoid a neutral interval. In addition, torque from the final oncoming element helps the ratio change to progress through the intermediate gear ratio. This approach maintains output torque and allows for change of mind to the intermediate gear. Should the driver tip out early enough in the shift, the first oncoming element is applied and the second shift is cancelled.
The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
FIG. 1 is a schematic diagram showing the kinematic arrangement of an automatic transmission;
FIG. 2 shows the selective table of friction elements;
FIGS. 3A and 3B schematically represent the Ravigneaux gearset of FIG. 1 ;
FIGS. 4A and 4B schematically represent a simple planetary portion of the Ravigneaux gearset of FIG. 1 ;
FIGS. 5A and 5B schematically represent a compound planetary portion of Ravigneaux gearset of FIG. 1 ;
FIG. 6 is a lever representing the kinematics of the planetary portion of the Ravigneaux gearset of FIG. 1 ;
FIG. 7 is a lever representing the kinematics of the compound planetary portion of Ravigneaux gearset of FIG. 1 ;
FIG. 8 is a lever that represents the Ravigneaux gearset of FIG. 1 and derived from FIGS. 6 and 7 ;
FIG. 9 shows the lever of FIG. 6 with the numeric relationships of a automatic transmission application; and
FIG. 10 is a lever diagram representing the Ravigneaux gearset of FIG. 1 with the numeric relationships of the transmission application of FIG. 9 ;
FIG. 11 is a graph showing an abrupt output torque disturbance in the Ravigneaux gearset of FIG. 1 during a downshift;
FIG. 12 is a graph showing the variation of clutch and brake torques in the Ravigneaux gearset of FIG. 1 during a downshift wherein CL/B gains capacity later than CL/A;
FIG. 13 is a graph showing the variation of clutch and brake torques in the Ravigneaux gearset of FIG. 1 during a downshift wherein CL/A closes rapidly;
FIG. 14 is a graph showing the variation of output torque in the Ravigneaux gearset of FIG. 1 during a downshift wherein CL/B gains capacity earlier than CL/A;
FIG. 15 is a graph showing the variation of clutch and brake torque in the Ravigneaux gearset of FIG. 1 during a downshift wherein CL/B gains capacity earlier than CL/A;
FIG. 16 is a graph showing the variation of element speeds in the Ravigneaux gearset of FIG. 1 during a downshift;
FIGS. 17-20 are lever diagrams in the Ravigneaux gearset of FIG. 1 showing progressive variation of element speeds and element torques during the downshift illustrated in FIG. 16 ; and
FIG. 21 is diagram of the control logic showing the steps for controlling a downshift in a transmission.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 the kinematic arrangement of an automatic transmission. The torque converter 10 includes an impeller wheel 12 connected to the crankshaft 14 of an internal combustion engine, a bladed turbine wheel 16 , and a bladed stator wheel 18 . The impeller, stator and turbine wheels define a toroidal fluid flow circuit, whereby the impeller is hydrokinetically connected to the turbine. The stator 18 is supported rotatably on a stationary stator sleeve shaft 20 , and an overrunning brake 22 anchors the stator to the shaft 20 to prevent rotation of the stator in a direction opposite the direction of rotation of the impeller, although free-wheeling motion in the opposite direction is permitted.
The torque converter assembly includes a lockup or bypass clutch 24 located within the torque converter impeller housing 25 . When clutch 24 is engaged, the turbine and impeller are mechanically connected; when clutch 24 is disengaged, they are hydrokinetically connected and mechanically disconnected. Fluid contained in the torque converter 10 is supplied from the output of an oil pump assembly 30 and is returned to an oil sump, to which an inlet of the pump is connected hydraulically.
Planetary gearing includes a first simple planetary gear set 32 and a second Ravigneaux planetary gear set 34 . The first gear unit 32 includes a sun gear 38 , ring gear 40 , carrier 42 , and planetary pinions 44 , supported on carrier 42 in meshing engagement with sun gear 38 and ring gear 40 . Sun gear 38 is fixed against rotation. Ring gear 40 is continually connected to an input shaft 45 and to an overdrive clutch, i.e., CL/E. Carrier is continually connected to a forward clutch, i.e., CL/A, and to a direct clutch, i.e. CL/B, which is connected to an intermediate brake, i.e., CL/C.
The second gear set 34 includes first and second sun gears 46 , 47 , ring gear 48 , carrier 50 , and first and second sets of planetary pinions 52 , 53 rotatably supported on carrier 50 . Pinions 53 are in meshing engagement with sun gear 47 . Pinions 52 are in meshing engagement with sun gear 46 , ring gear 48 and pinions 53 . Sun gear 46 is continually connected to intermediate brake CL/C. Ring gear 40 is continually connected to an output shaft 58 . Carrier 50 is continually connected to a low-reverse brake, i.e., CL/D, and to CL/E. Sun gear 47 is continually connected to forward clutch, CL/A. Direct clutch CL/B is connected to intermediate brake CL/C and forward clutch CL/A.
Referring to FIGS. 1 and 2 , the first forward gear is produced when clutch CL/A and brake CL/D are engaged. The sun gear 47 is driven at the speed ratio produced by gearset 32 , and carrier 50 is held against rotation. Output 58 is driven at the low reduction ratio of the double planetary gearset 34 .
In the second forward gear, clutch CL/A and brake CL/C are engaged. The sun gear 47 is driven at the speed ratio produced by gearset 32 , and sun gear 46 is held against rotation. Output 58 is driven at the intermediate reduction ratio of the double planetary gearset 34 .
In third forward gear, clutches CL/A and CL/B are engaged. Sun gears 46 , 47 are driven at the speed ratio produced by gearset 32 . Gearset 34 is locked up, and output 58 is driven at the speed ratio produced by gearset 32 .
In fourth forward gear, clutches CL/A and CL/E are engaged. The sun gear 47 is driven at the speed ratio produced by gearset 32 , and carrier 50 is driven at the speed of input 45 . Output 58 is driven at an intermediate speed ratio.
In fifth forward gear, clutches CL/B and CL/E are engaged. Carrier 50 is driven at the speed of input 45 , and sun gear 46 is driven at the speed ratio produced by gearset 32 . Output 58 is driven at an intermediate overdrive ratio through gearset 34 .
In sixth gear, clutch CL/E and brake CL/C are engaged. Carrier 50 is driven at the speed of input 45 , and sun gear 46 is fixed against rotation by brake CL/C. Output 58 is driven at the entire overdrive ratio of gearset 34 .
In reverse drive, clutch CL/B and brake CL/D are engaged. Brake CL/D holds carrier 50 fixed against rotation, and sun gear 46 is driven at the speed ratio produced by gearset 32 . Output 58 is driven at the reverse drive ratio of gearset 34 .
Each upshift from the current gear to the next higher gear or to the gear that it next higher, and each downshift from the current gear to the next lower gear or to the gear that is next lowest is produced throughout by changing only one of the two friction elements that are engaged in the current gear.
A 6-4-3 downshift begins in sixth gear with clutch CL/E and brake CL/C engaged, advances to fourth gear by disengaging brake CL/C, engaging clutch CL/A and maintaining clutch CL/E engaged, and ends in third gear by disengaging clutch CL/E, engaging clutch CL/B and maintaining clutch CL/A engaged.
For the 6-4-3 downshift, the first control element is brake CL/C, the second control element is clutch CL/E, the third control element is clutch CL/A, and the fourth control element is clutch CL/B.
A 5-3-2 downshift begins in fifth gear with clutches CL/B and CL/E engaged, advances to third gear by disengaging clutch CL/E, and engaging clutches CL/A and CL/B, and ends in second gear by disengaging clutch CL/B, engaging brake CL/C and maintaining clutch CL/A engaged.
For the 5-3-2 downshift, the first control element is clutch CL/E, the second control element is clutch CL/B, the third control element is clutch CL/A, and the fourth control element is brake CL/C.
FIGS. 3A-9 illustrate the kinematics of multi-step downshifts produced by the Ravigneaux gearset 34 in relation to a lever analogy. FIGS. 3A and 3B show that gearset 34 is formed by combining the two gearsets shown in FIGS. 4A-4B and 5 A- 5 B.
Let:
N S1 =Number of teeth on sun 1 .
θ s1 =Angular displacement of S 1 .
N S2 =Number of teeth on sun 2 .
θ s2 =Angular displacement of S 2 .
N R =Number of teeth on ring.
From FIGS. 3A and 3B , if carrier 50 is grounded, i.e., held against rotation, and Sun 1 (sun gear 46 ) turns θ s1 radians, the circumferential distance Sun 1 travels is θ s1 *N S1 . Since no slipping occurs between the gears, Sun 2 (sun gear 47 ) must also travel the same circumferential distance (θ s1 *S 1 ), but in the opposite direction. The angular displacement ratio between Sun 1 and Sun 2 can be represented as follows:
θ
s
1
*
N
S
1
=
-
θ
s
2
*
N
S
2
→
θ
S
2
θ
S
1
=
-
N
S
1
N
S
2
(
Equation
1
)
From FIGS. 4A and 4B , a lever can be constructed as shown in FIG. 6 . If C (carrier 50 ) is held and Sun 1 is the input, then R (ring gear 48 ) is the output and the angle ratio of this gearset is:
θ
R
θ
S
1
=
-
N
S
1
N
R
(
Equation
2
)
From FIGS. 5A and 5B , if C is held, Sun 2 and R rotate in the same direction or Sun 2 and R are on the same side of the lever). Also, the tangential velocity of R is less than the tangential velocity of Sun 2 . Thus the lever for the gear set of FIG. 5A is constructed as shown in FIG. 7 .
The angular displacement can be written as follows:
θ R θ S 2 = N S 1 X ( Equation 3 )
From Equations 2 and 3:
Equation 2 Equation 3 = θ S 2 θ S 1 = - X N R ( Equation 4 )
Substitute Equation 4 in Equation 1:
-
X
N
R
=
-
N
S
1
N
S
2
→
X
=
N
R
N
S
1
N
S
2
Finally, from FIGS. 6 and 7 , the lever 60 , which represents the Ravigneaux gearset 34 , is shown in FIG. 8 .
FIG. 9 shows the numerical relationships for a particular transmission application. Since the ring gear 48 is connected to the output shaft 58 , any relative motion within gearset 34 causes the lever 60 to pivot about the output 58 .
The lever diagram of FIG. 10 is helpful in understanding the mechanism by which early application of the final oncoming element negates the torque disturbance due to the torque transfer of the first oncoming element. FIG. 10 shows the geometric relationships for the Ravigneaux gearset 34 .
Since ring gear 48 is connected to the output shaft 58 , any relative motion within gearset 34 causes the lever 60 to pivot about ring gear 48 at point 62 . As indicated in FIG. 2 , clutch CL/B, brake CL/C and sun gear 46 are connected to lever 60 at point 64 . Clutch CL/E and carrier 50 are connected to lever 60 at point 66 . Clutch CL/A and sun gear 47 are connected to lever 60 at point 68 . Clutch CL/B and brake CL/C have significant mechanical advantage about the output 58 compared to either clutch CL/A or brake CL/E.
As FIG. 11 shows, a significant torque disturbance occurs if clutch CL/A gains torque capacity before clutch CL/B. Since clutch CL/E has significant torque capacity, clutch CL/A pulls the transmission back toward the fourth gear. In the figures, DS_TRQ means driveshaft torque and TQT_WO_TQMOD means transmission input torque without torque modulation.
As FIG. 12 shows, clutch CL/B gains torque capacity significantly later than clutch CL/A.
As FIG. 13 shows, clutch CL/A closes rapidly, causing the torque disturbance of FIG. 11 , and clutch CL/B closes shortly after clutch CL/A closes.
The simulation torque trace of FIG. 14 closely matches the vehicle torque trace with clutch CL/B applied early. FIG. 14 illustrates a 6-4-3 shift with early application of clutch CL/B at about 4 psi higher pressure than the stroke pressure of clutch CL/B.
FIG. 15 shows that clutch CL/B gains some torque capacity well before the torque transfer onto clutch CL/A, which closes at low torque capacity as speeds pass through synchronous speed.
FIG. 16 shows the speeds of sun gear 46 , sun gear 47 and carrier 50 near the end of the shift. Torque from clutch CL/B causes the Ravigneaux gearset 34 to move toward the third gear synchronous ratio. In fact, clutch CL/B has closed when the torque transfer onto clutch CL/A begins at approximately 14.75 sec.
FIGS. 16-20 show progressively near the end of a 6-4-3 downshift the variation of element speeds and element torques of the Ravigneaux gearset 34 as it shifts into third gear from fourth gear. As FIGS. 16 and 17 show, at 14.7 sec. after recordation of data begins, the speed of clutch CL/A and sun gear 47 is 1325 rpm, and the speed of clutch CL/B, brake CL/C and sun gear 46 is 2582 rpm, which speeds continue to diverge as shown in FIG. 16 . The net torque on gearset 34 is −39.2 ft-lbs.
Due to its mechanical or lever advantage, the torque on gearset 34 due to torque from clutch CL/B nearly equals the torque carried by clutch CL/E. At this point, torque from clutch CL/A aids clutch CL/B in moving the gearset toward a final ratio (1:1).
As FIGS. 16 and 18 show, at 14.75 sec, clutch CL/B has sufficient torque capacity for the speeds of clutches CL/A and CL/B to converge. The net torque on gearset 34 is +430 ft-lbs.
As FIGS. 16 and 19 show, at 14.8 sec, clutch CL/A closes at low torque capacity as gearset element speeds pass through synchronous speed. The speed of clutch CL/A has not changed from 1240 rpm at 14.75 sec. Torque from clutch CL/B has sufficient capacity to oppose the torque from clutch CL/A, which has now changed to a positive direction. The net torque on gearset 34 is +493.5 ft-lbs.
As FIGS. 16 and 20 show, at 14.85 sec, the downshift is nearly complete. Torque from clutch CL/B has sufficient capacity to oppose the rising torque from clutch CL/A. The net torque on the gearset is +512.4 ft-lbs.
Referring to the logic flow diagram of the control steps of FIG. 21 , at step 70 , a transmission controller issues a command for a sequenced downshift, such as a 6-4-3 downshift.
At step 72 , a check is made to determine whether the commanded downshift requires control of a disturbance of output torque. If the result of test 72 is logically false, control advances to step 74 , where a conventional downshift control is executed.
If the result of test 72 is logically true, at step 76 the commanded downshift begins by disengaging the second element (clutch CL/E) after disengaging the first element (brake CL/C). Actuating pressure in the latter oncoming element of the target third gear (clutch CL/B) is boosted after boosting the actuating pressure in the initial oncoming element of the target third gear (clutch CL/A). Boosting pressure, i.e., stroke pressure, causes the piston of the respective element to move in its servo cylinder toward the clutch discs substantially closing all clearances in the servo but without developing torque transmitting capacity in the element.
At step 78 , the fourth element (clutch CL/B) is brought to low torque capacity after disengaging the second offgoing element (clutch CL/E).
Engagement of the fourth element (clutch CL/B) at torque low capacity begins before engagement of the third element (clutch CL/A), thereby forcing the third element (clutch CL/A) toward the synchronous speed for the target gear prior to full engagement of the third element (clutch CL/A) and fourth element (clutch CL/B).
At step 80 , a check is made to determine whether the vehicle operator has caused a change of mind shift before a downshift to the intermediate gear, i.e., fourth gear has been completed. If the result of test 80 is logically true, control advances to step 82 where clutch CL/A is brought to holding torque capacity and subsequent shifts are cancelled while executing the sequenced downshift control strategy.
If the result of test 80 is logically false, at step 84 the commanded downshift is completed by fully engaging the third element (clutch CL/A) and the fourth element (clutch CL/B) at high capacity, preferably concurrently. Before fully engaging the third element (clutch CL/A) and the fourth element (clutch CL/B) at high capacity, a single torque modulation event is executed by reducing engine output torque to about 50-60 percent of current engine torque for about 100 Msec.
The control strategy for a sequential downshift, such as a 6-4-3 or 5-3-2 downshift, maintains output torque during the gear ratio change and allows for a change of mind shift to the intermediate gear. Should the driver tip-out of the accelerator pedal early enough during the downshift, the first oncoming element is applied and the second shift is cancelled. In addition, the final oncoming control element may be pre-staged to allow a continuous ratio change if the driver tips into a 6-4 or 5-3 downshift while the earlier downshift is in progress.
Early application of the second, oncoming control element (clutch CL/B) increases energy dissipation. The period during which that control element is applied, however, is significantly shorter than it would be during an equivalent downshift using a conventional control strategy.
The solution provides means to calibrate continuous downshifts and to reduce significantly the torque disturbance. Opposing torque from the final oncoming element, clutch CL/B, is used to negate the initial portion of the torque transfer onto the first oncoming element, clutch CL/A. The oncoming element of the second downshift, i.e., clutch CL/B, is boosted and brought to a low torque capacity just before the torque transfer at the end of the first shift. Since the oncoming element of the second shift, clutch CL/B, has low capacity, it only negates the initial portion of the torque transfer. The offgoing element of the second downshift, brake CL/E, must begin the second ratio change before the oncoming element of the first shift, clutch CL/B, gains significantly greater torque capacity than the oncoming element of the second shift.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A method for executing a downshift in a transmission includes starting disengagement of a second control element after starting disengagement of a first element. Disengagement of the second element starts before starting engagement of a fourth element. A third element is forced to synchronous speed by beginning engagement of the fourth element before engaging the third element. Engagement of the third and fourth elements is completed at the end of the downshift.
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TECHNICAL FIELD
This invention relates to an apparatus for increasing access to vehicle storage areas, and more particularly, to a bed slide secured to a vehicle storage area using pre-existing mounting points within the vehicle.
BACKGROUND
Vehicles that are used for transporting equipment, supplies, or other items within enclosed areas can hold more items than are easily accessible. For instance, if a person fills a canopy or toneau covered pickup bed with tools, those tools near the tailgate are more accessible than the tools near the front of the bed (e.g., behind the cab of the truck). Other types of storage areas associated with other vehicles suffer from similar shortcomings.
One solution to the problem of accessing items in a vehicle storage area is the use of a bed slide. The term bed slide is meant to include any extendable platform used in the storage area of a vehicle to facilitate access of otherwise hard to reach locations.
Conventional techniques for mounting bed slides result in undesirable modifications of the storage area by drilling holes in the floor of the vehicle storage area for the insertion of bolts or other fastening devices as shown in FIG. 1 . This method of fastening the bed slide requires additional hardware as well as defaces and possibly damages the integrity of the vehicle storage area. Additionally, the practice of drilling holes from the topside of the vehicle storage area can result in damage to vehicle components that are located directly beneath the vehicle storage area. These important components may include fuel lines and/or spare tires.
FIG. 1 demonstrates how conventional bed slides are fastened to the vehicle storage area. Traditionally, a bed slide base 120 of a bed slide 100 is affixed to the storage area of the vehicle by fasteners 140 . In order to install the fasteners 140 , holes are drilled in the floor of the storage area and the fasteners 140 are installed. The traditional fastener-hole mounting system is also a disadvantage if the bed slide is subsequently removed. The installation procedure leaves holes in the storage area of the vehicle upon removal of the bed slide.
With the advent of the Ultimate Utility Vehicle (UUV), further problems for the conventional method of mounting bed slides are introduced. The term UUV is meant to include any vehicle, such as the Chevrolet® Avalanche® or the Cadillac® Escalade® EXT®, or any other vehicle which enables a user to change the body configuration to allow the bed storage area to be either open or closed to the passenger/cab area. With increased access between the storage area and the passenger/cab area, there is an increased concern of injury resulting from the conventional bed slide entering the passenger compartment in a collision. Conventional bed slide systems do not provide a sufficient momentum stop to prevent the bed slide platform 110 from sliding into the front of the passenger/cab area of the vehicle in the event of a severe collision. FIG. 1 demonstrates that the conventional method for stopping the forward motion of a bed slide is either a pin 130 from a latch mechanism or a bolt (not shown). In the event of a head on collision, the pin 130 or bolt is easily bent or sheared thereby allowing the bed slide platform 110 to continue forward into the passenger/cab area of the vehicle.
SUMMARY
In accordance with one embodiment of the present invention, a bed slide and techniques for attaching a bed slide to the storage area of a vehicle are presented. In accordance with one embodiment, an apparatus is presented comprising a mounting bracket with a protrusion that accommodates being connected to the storage area of the vehicle using the vehicle's pre-existing hardware.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by way of example, and not by way of limitation. Like reference numerals refer to similar elements in the figures of the accompanying drawings.
FIG. 1 is a perspective view of a prior art bed slide.
FIG. 2 is a perspective view of one embodiment of the bed slide-securing bracket.
FIG. 3 is a perspective view of one embodiment of the bed slide-securing bracket.
FIG. 4 is a perspective view of one embodiment of the bed slide-securing bracket in association with an embodiment of pre-existing vehicle hardware,
FIG. 5 is a perspective view of one embodiment of the bed slide-securing bracket.
FIG. 6 is a perspective view of one embodiment of the bed slide-securing bracket assembled and affixed to a bed slide in a vehicle storage space.
FIG. 7 is a perspective view of one embodiment of a bed slide-securing bracket assembled to an embodiment of a bed slide and affixed to the cargo area of a UUV.
FIG. 8 is a perspective view of one embodiment of a bed slide base.
FIG. 9 is an exploded view of one embodiment of a bed slide platform.
FIG. 10 is a perspective view of an assembled bed slide platform and base.
DETAILED DESCRIPTION
Embodiments of the invention are generally drawn to a bed slide as well as apparatuses for securing a bed slide to the storage area of a vehicle using pre-existing vehicle mounting points. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details.
Example Overall Structure
FIG. 2 is a perspective view of one embodiment of an example bed slide-securing bracket. In accordance with the example of FIG. 2 , the bed slide-securing bracket includes a main body 200 with an upper 210 and a lower 240 portion. The lower portion 240 of the body 200 further comprises a hole 250 sufficiently large to facilitate connection to a fastener to secure the bed slide base 400 to the main body 200 of the bracket. The illustrated example also depicts a protruding portion 220 extending from the distal end 270 of the body 200 . The protrusion portion 220 of the bracket forms an approximately 90-degree elbow that terminates with a substantially flat piece. The substantially flat piece contains an orifice 230 sufficiently sized to receive the pre-existing hardware of a vehicle storage area tie-down.
The illustrated embodiment of the bed slide-securing bracket shown in FIG. 2 may be comprised of metal, polymer, a composite, or other similar materials or combinations of materials that are structurally adequate to support a bed slide
FIG. 3 is a perspective view of an alternative embodiment of an example bed slide-securing bracket. FIG. 3 illustrates alternative embodiments for providing holes 255 sufficiently large to facilitate connection to a fastener. In FIG. 3 , there are two horizontal holes 255 located in the lower portion 245 of the body 205 . Additionally, FIG. 3 demonstrates that a number of different methods may be used to attach the protrusion 225 to the distal end 275 of the body 205 . The protrusion 225 may be welded to the body 205 as demonstrated in FIG. 3 , it may form an integral part of the body 205 as illustrated in FIG. 2 , or the protrusion 225 may be connected to the body 205 by any number of fasteners.
Additionally, FIG. 3 also illustrates an alternative embodiment for providing an orifice 235 sufficiently sized to receive the pre-existing hardware of a vehicle storage area tie-down. As demonstrated in FIG. 3 , the orifice 235 may be completely contained by the material making up the protrusion 225 .
FIG. 4 is a perspective view of one embodiment of an example bed slide-securing bracket in association with an example of pre-existing hardware from the storage area of a vehicle. The demonstrated example of the pre-existing hardware comprises a fastening device 310 , a washer 320 , a tie-down loop 350 , and a tie-down flange 330 with a hole 340 in the center. The bed slide-securing bracket is designed to work with any storage area hardware that includes a fastening device 310 .
FIG. 5 demonstrates an additional embodiment of an example bed slide-securing bracket. The embodiment demonstrated in FIG. 5 also comprises a body 500 with an upper 510 and lower portion 540 . However, the lower portion 540 is substantially smaller than that demonstrated in FIG. 2 to allow for only a single fastener. The reduced size of the lower portion 540 also allows the bed slide-securing bracket to be secured to the side of the bed slide frame 400 rather than the front. This embodiment adds the ability to secure the bed slide frame 400 to a number of additional mounting points such as the rear of a UUV bed near the tailgate. Additionally, those of skill in the art will recognize that any number of fasteners may be used without varying from the teachings of the present invention.
FIG. 8 demonstrates an embodiment of a bed slide base 800 that is possible with the above-mentioned bed slide-securing bracket. The demonstrated embodiment includes two bottom rails 860 positioned substantially parallel to each other. Joining the bottom rails is a number of cross supports 880 . The cross supports 880 strengthen the bottom rails 860 and keep the bed slide base 800 substantially square. On the side of each bottom rail 860 located beneath the top securing rail 840 is attached a number of bearings 820 .
FIG. 9 is an exploded view of the top section of a bed slide. As shown in FIG. 9 , the top section is preferably composed of a platform 910 which sits upon and is fastened to a platform base 940 . On each side of the platform base 940 is located a slide rail 930 which when assembled is allowed to slide on the bearings 820 of the bed slide base 800 . Covering the slide rail 930 and fitting under the outer edge of the platform 910 is the side guards 920 . The side guards 920 protect any cargo that is placed on the platform 910 from rubbing or catching on the top securing rail 840 .
Example Implementation and Operation
FIG. 6 is a perspective view of one embodiment of a bed slide-securing bracket implemented in connection with pre-existing vehicle hardware. In accordance with the illustrated example implementation of FIG. 6 , the bracket is assembled and affixed to a bed slide base 400 in a vehicle storage space. For ease of explanation only, the description will be developed within the context of installing a bed slide 100 into a Chevrolet® Avalanche® or similar vehicle.
As demonstrated in FIG. 6 , one embodiment of the bed slide-securing bracket utilizes the pre-existing vehicle hardware to attach the bracket and bed slide to the vehicle. In order to facilitate the attachment, the tie-down screw(s) 310 (or other vehicle hardware) is loosened from the side of the vehicle storage area. For an embodiment of the open ended bracket displayed in FIG. 2 , the tie-down screw(s) 310 need only be loosened enough to slide the protrusion 220 under the tie-down screw(s) 310 . For an embodiment of the closed ended bracket, the entire tie-down screw(s) 310 must be removed.
With the tie-down screw(s) 310 loosened, the open-ended protrusion 220 is slid under the washer 320 and under the tie-down screw 310 . Alternatively, if the closed ended embodiment of the bed slide-securing bracket is used, the removed tie-down screw 310 and washer 320 are inserted into the protrusion hole 230 .
Once the protrusion 220 of the bracket is in contact with the tie-down screw 310 , the tie-down screw 310 is lightly tightened to the pre-existing mounting point. This allows the bracket to be lightly secured to the bed or storage area of the vehicle while still allowing for some movement of the body of the bracket 200 .
With the bracket lightly secured to the vehicle storage area, the holes (not shown) in the front of the bed slide base 400 can be aligned with the hole(s) 250 in the lower body 240 of the bracket. The bed slide base 400 can be attached to the bed slide-securing bracket by inserting a fastening device 410 through the hole(s) 250 and securing it with a securing device 420 , 430 . To complete the installation, the tie-down screw 310 is then tightened.
Due to the shape of the bracket, a barrier is formed preventing the bed slide from extending forward into the cab/passenger area of the vehicle. The distance between the hole(s) 250 in the lower portion 240 of the body 200 and the top portion 210 of the body 200 is greater than the distance from the holes (not shown) in the bed slide base 400 and the bottom of the bottom rail 460 . The inequality in height creates a stop(s) 450 at the end of the bed slide base 400 . In the event of a collision, the bed slide will only slide forward on the base 400 until it comes in contact with the stop(s) 450 thus increasing safety.
FIG. 7 is a perspective view of one embodiment of a bed slide-securing bracket assembled to an embodiment of a bed slide and affixed to the cargo area of a UUV. As demonstrated in FIG. 7 , the bed slide base 400 may be secured at the factory-installed tie-down 300 . FIG. 7 also demonstrates how an alternative embodiment of the bed slide-securing bracket can be installed on the side of the bed slide base 400 near the rear of the vehicle storage area. Once installed, there are only original holes in the storage area of the vehicle since the only securing devices attached to the bed slide base were subsequently attached to the pre-existing hardware at the factory mounting points rather than through the floor of the vehicle storage area.
FIG. 7 also demonstrates an additional advantage of one embodiment of a bed slide-securing bracket. As demonstrated in FIG. 7 , with the bed slide securely fastened to the storage area of the vehicle, the factory-installed tie-down 300 is still useable. By only utilizing the tie-down screw 310 to attach the bracket, there is little or no limitation on the motion of the factory-installed tie-down 300 .
FIG. 10 illustrates a modified bed slide attached to a UUV by a bed slide-securing bracket 550 . As shown in FIG. 10 , the bottom rail 860 of the bed slide base 800 is fastened to the bed of a UUV using only a bed slide-securing bracket 550 and the pre-existing hardware. With the base 800 securely attached to the UUV, the top of the bed slide may be inserted. The slide rail 930 is slid between the top of the bearings 820 and the bottom of the top-securing rail 840 . As demonstrated in FIG. 10 , the side guards 920 extend above and around the top-securing rail 840 thereby protecting anything that may be on the platform 910 from being damaged.
The unique method of mounting the bed slide base 800 to the UUV using only pre-existing hardware allows the bottom of the platform base 940 , and consequently the platform 910 to extend further down towards the bottom of the bed. This configuration is advantageous because it allows for additional space between the platform 910 and a toneau cover. This added space allows the user to store objects that have a higher profile than those objects allowed by conventional bed slides.
ALTERNATIVE EMBODIMENTS
According to one embodiment of the bed slide bracket, the bed slide bracket forms an integral part of the bed slide base 400 . This embodiment eliminates the need for additional securing devices 410 to join the bracket to the bed slide base 400 . This embodiment also allows for securing a bed slide base 400 using only the vehicle hardware located at pre-existing mounting points, thereby avoiding the previously mentioned shortcomings of conventional installation methods.
In an additional embodiment of the modified bed slide, a bearing may be attached to the upper portion of the slide rail 930 . This additional bearing will act as a leveler for the platform 910 by providing a force opposite that caused by any load on the platform 910 .
Attached as an appendix are detailed illustrations of one embodiment of a bedslide as described herein. Other embodiments can also be provided without deviating from the scope of the invention as claimed below.
Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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A securing bracket for mounting a bed slide in a vehicle storage area is disclosed. The bed slide-mounting bracket is characterized by a body with a protrusion. The protrusion is formed comprising a cavity sufficient to affix the bed slide-mounting bracket to the vehicle storage area using pre-existing vehicle hardware.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to solar panel structure, and more particularly pertains to a new and improved solar cooking panel apparatus wherein the same is arranged to direct reflected heat and light to a central cooking chamber.
2. Description of the Prior Art
The instant invention attempts to overcome deficiencies of the prior art by providing for a panel member arranged for disassembly and permitting pivoting of the panels relative to one another to provide for deformation of the panel in an assembled configuration to reflect heat relative to a focal position of a cooking pot and the like.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of solar panel apparatus now present in the prior art, the present invention provides a solar cooking panel apparatus wherein the same is arranged to include a matrix of individual reflective plates to focus light to a central position upon positioning the reflector structure in a concave configuration. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved solar cooking panel apparatus which has all the advantages of the prior art solar panel apparatus and none of the disadvantages.
To attain this, the present invention provides a cooking panel member formed of a plurality of individual panel reflector pates, including first and second inner rows of individual panel plates hingedly mounted together, with first and second outer rows of panel plates interconnected to the inner rows of plates to provide a completed arcuate member having a concave surface to reflect heat to a cooking vessel.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved solar cooking panel apparatus which has all the advantages of the prior art solar panel apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved solar cooking panel apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved solar cooking panel apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved solar cooking panel apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such solar cooking panel apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved solar cooking panel apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the invention.
FIG. 2 is an enlarged isometric illustration of section 2 as set forth in FIG. 1.
FIG. 3 is an isometric illustration of the invention arranged for mounting upon a support structure.
FIG. 4 is an enlarged isometric illustration of section 4, partially in section, as set forth in FIG. 3.
FIG. 5 is an isometric illustration of a modified panel structure, as indicated by the invention.
FIG. 6 is an enlarged orthographic view, partially in section, of section 6 as set forth in FIG. 5.
FIG. 7 is an orthographic side view of the modified panel structure arranged for mounting upon an associated support structure.
FIG. 8 is an enlarged orthographic view of section 8 as set forth in FIG. 7.
FIG. 9 is an orthographic top view of the solar panel structure having hinged mounting of the various panels together.
FIG. 10 is an enlarged orthographic view of section 10 as set forth in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 10 thereof, a new and improved solar cooking panel apparatus embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the solar cooking panel apparatus 10 of the instant invention essentially comprises a matrix of reflector plates 15, each of a generally square configuration, having plate facing walls 17 that are arranged to face an adjacent one of the reflector plates 15, as indicated in FIG. 2. First and second facing inner rows of plates 11 and 12 are optionally joined together by a central hinge 16, or alternatively may employ the use of connector plugs 18 that are received within facing wall apertures 19 of facing wall portions 17, as indicated in FIG. 2. First and second outer rows of the reflector plates 13 and 14 are mounted by the use of the plug members to the respective first and second inner rows of reflector plates 11 and 12.
In use, and in this manner, the outer rows may be separably mounted relative to the inner rows, with the inner rows arranged for folding relative to one another for compact storage of the construction. As noted, the first and second inner rows 11 and 12 may also be interconnected by the use of facing wall apertures 19 having an individual connecting plug 18 into a pair of facing wall apertures 19.
The FIG. 3 indicates the use of a rectilinear support frame 20 arranged to receive the panel 10 thereon, with the support frame 20 having a central support axle 21 pivotally and orthogonally mounted medially of the support frame 20 that is received within a central hub 22, that in turn has support legs 23 to permit rotation of pivoting as well as positioning of the support frame structure and the associated panel 10.
The FIG. 5 indicates the use of a modified panel apparatus 10a, wherein each of the reflector plates 15, and more specifically the facing wall portion 17, include at least one flexible tubular connecting member 24 extending therebetween. Each of the tubular connecting members 24 (see FIG. 6) includes a spring 25 directed coextensively between the facing wall 17 of adjacent reflector plates 15. Further, each of the tubular connector members 24 themselves include a plug portion 18a that is received within an associated facing wall aperture 19 to mount the individual connector members 24 between the individual reflector plates 15, as illustrated.
A support framework for the modified panel apparatus 10a includes the use of a central hub 22 (see FIG. 7) mounted pivotally to a lower hub 22a that in turn includes support legs 23 fixedly secured thereto. The pivotal mounting of the central hub 22 to the lower hub 22a about connector 40 permits at least 90 degree tilting of the support frame. This includes 45 degree tilting to either side of the lower hub 22a to accommodate movement of the sun and reorienting of the solar panel structure to that movement. A telescoping hub portion 26 extends from the central hub 22 utilizing a latch rod 27 to secure adjustably the telescoping hub 26 relative to the central hub 22. The support frame mounted orthogonally relative to the telescoping hub 26 includes a central hub 34 medially and orthogonally mounted relative to the support frame 20, wherein the central hub 34 includes a hook member 35 mounted onto a hook member rod 36 that in turn is threadedly received within the central hub 34. The hook member 35 is arranged to receive one of the tubular connecting members 24 medially of the panel 10a, wherein each corner portion of the support frame 20 incudes a corner support tube 29 having an internally threaded socket 30 that receives an adjuster rod 31 threadedly therewithin. The adjuster rod 31 includes an adjuster rod head 32 pivotally mounted to an upper distal end of the adjuster rod 31, with each adjuster rod head 32 including a top wall notch 33 to receive a further one of the connector members 24. In this manner, vertical adjusting of the hook member, as well as the adjuster rod head 32 or each adjuster rod structure, permits bowing of the organization, in a manner as indicated in FIG. 7, to permit adjusting of the curvature of the panel apparatus.
The FIGS. 9 and 10 indicate use of hinge structure interconnecting the individual reflector plates 15 to accommodate various movement and conformation of the panel apparatus 10b. Further it should be noted that there are hinge members mounted between adjacent vertical rows of the plates 15 to permit over-folding of the outer rows relative to the central rows to permit the panels to be over-folded during storage and the like. The hinges may be employed in addition to the connector structure, as indicated in the FIG. 6 for example, such as in hinge pins 51 relative to each of the hinges permitting separation of the various panel plates to this end.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A cooking panel member formed of a plurality of individual panel reflector plates includes first and second inner rows of individual panel plates hingedly mounted together, with first and second outer rows of panel plates interconnected to the inner rows of plates to provide a completed arcuate member having a concave surface to reflect heat to a cooking vessel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 13/274,947, filed on Oct. 17, 2011, which is a non-provisional of U.S. Provisional Application No. 61/500,914, filed on Jun. 24, 2011, both of which is hereby incorporated herein by reference in its entirety for all purposes.
BACKGROUND
Offshore oil and gas operations often utilize a wellhead housing supported on the ocean floor and a blowout preventer stack secured to the wellhead housing's upper end. A blowout preventer stack is an assemblage of blowout preventers and valves used to control well bore pressure. The upper end of the blowout preventer stack has an end connection or riser adapter (often referred to as a lower marine riser packer or LMRP) that allows the blowout preventer stack to be connected to a series of pipes, known as riser, riser string, or riser pipe. Each segment of the riser string is connected in end-to-end relationship, allowing the riser string to extend upwardly to the drilling rig or drilling platform positioned over the wellhead housing.
The riser string is supported at the ocean surface by the drilling rig. This support takes the form of a hydraulic tensioning system and telescoping (slip) joint that connect to the upper end of the riser string and maintain tension on the riser string. The telescoping joint is composed of a pair of concentric pipes, known as an inner and outer barrel, that are axially telescoping within each other. The lower end of the outer barrel connects to the upper end of the aforementioned riser string. The hydraulic tensioning system connects to a tension ring secured on the exterior of the outer barrel of the telescoping joint and thereby applies tension to the riser string. The upper end of the inner barrel of the telescoping joint is connected to the drilling platform. The axial telescoping of the inner barrel within the outer barrel of the telescoping joint compensates for relative elevation changes between the rig and wellhead housing as the rig moves up or down in response to the ocean waves.
According to conventional practice, various auxiliary fluid lines are coupled to the exterior of the riser tube. Exemplary auxiliary fluid lines include choke, kill, booster, and hydraulic fluid lines. Choke and kill lines typically extend from the drilling rig to the wellhead to provide fluid communication for well control and circulation. The choke line is in fluid communication with the borehole at the wellhead and may bypass the riser to vent gases or other formation fluids directly to the surface. According to conventional practice, a surface-mounted choke valve is connected to the terminal end of the choke conduit line. The downhole back pressure can be maintained substantially in equilibrium with the hydrostatic pressure of the column of drilling fluid in the riser annulus by adjusting the discharge rate through the choke valve.
The kill line is primarily used to control the density of the drilling mud. One method of controlling the density of the drilling mud is by the injection of relatively lighter drilling fluid through the kill line into the bottom of the riser to decrease the density of the drilling mud in the riser. On the other hand, if it is desired to increase mud density in the riser, a heavier drilling mud is injected through the kill line.
The booster line allows additional mud to be pumped to a desired location so as to increase fluid velocity above that point and thereby improve the conveyance of drill cuttings to the surface. The booster line can also be used to modify the density of the mud in the annulus. By pumping lighter or heavier mud through the booster line, the average mud density above the booster connection point can be varied. While the auxiliary lines provide pressure control means to supplement the hydrostatic control resulting from the fluid column in the riser, the riser tube itself provides the primary fluid conduit to the surface.
A hose or other fluid line connection to each auxiliary fluid line coupled to the exterior of the riser tube is provided at the telescoping joint via a pipe or equivalent fluid channel. The pipe is often curved or U-shaped, and is accordingly termed a “gooseneck” conduit. In the course of drilling operations, a gooseneck conduit may be detached from the riser, for example, for maintenance or to permit the raising of the riser through the drilling floor, and reattached to the riser to provide access to the auxiliary fluid lines. The gooseneck conduits are typically coupled to the auxiliary fluid lines via threaded connections.
SUMMARY
A gooseneck conduit system for use with a telescoping joint of a subsea riser is disclosed herein. In one embodiment, a riser telescoping joint includes a tube and a gooseneck conduit assembly affixed to the tube. The gooseneck conduit assembly includes a gooseneck conduit extending radially from the tube, and a tenon projecting from a rear face of the gooseneck conduit. The width of the tenon increases with distance from the rear face. The riser telescoping joint also includes a mortise channel extending lengthwise along the tube. The mortise channel interlocks with the tenon to laterally secure the gooseneck conduit assembly to the tube.
In another embodiment, a gooseneck conduit unit includes a plate, a gooseneck conduit, and a bumper. The gooseneck conduit is removably mounted to the plate. The bumper is coupled to a rear face of the gooseneck conduit. The bumper includes a tenon that guides the gooseneck conduit unit into position on a telescoping joint.
In a further embodiment, a system includes a telescoping joint. The telescoping joint includes an alignment ring and a gooseneck conduit assembly. The alignment ring is circumferentially coupled to a tube of the telescoping joint. The alignment ring includes a longitudinal mortise channel. The gooseneck conduit assembly is coupled to the alignment ring. The gooseneck conduit assembly includes a gooseneck conduit and a tenon. The tenon slidingly engages sides of the mortise channel to secure the gooseneck conduit assembly to the alignment ring.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of exemplary embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIGS. 1A-1B show a drilling system including a gooseneck conduit system in accordance with various embodiments;
FIG. 2 shows a telescoping joint in accordance with various embodiments;
FIG. 3 shows a top view of a plurality of gooseneck conduit assemblies in accordance with various embodiments;
FIG. 4 shows an elevation view of a support collar and gooseneck conduit assemblies in accordance with various embodiments;
FIG. 5 shows a perspective view of a support collar and gooseneck conduit assemblies in accordance with various embodiments; and
FIG. 6 shows a cross sectional view of a support collar and gooseneck assemblies in accordance with various embodiments.
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, 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 . . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.
DETAILED DESCRIPTION
The following discussion is directed to various embodiments of the invention. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. 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, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. 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, including the claims, is limited to that embodiment.
The size and weight of the gooseneck conduits, and the location of the attachment points of the conduits to the telescoping joint and the auxiliary fluid lines, makes installation and/or retrieval of the conduits a labor-intensive process. Consequently, gooseneck conduit handling operations can be time consuming and costly. Embodiments of the present disclosure include a gooseneck conduit system that reduces handling time and enhances operational safety. Embodiments of the conduit system disclosed herein can provide simultaneous connection of gooseneck conduits to a plurality of auxiliary fluid lines with no requirement for manual handling or connection operations. Embodiments include hydraulically and/or mechanically operated locking mechanisms that secure the conduit system to the telescoping joint and the auxiliary fluid lines. The conduit system may be hoisted into position on the telescoping joint, and attached to the telescoping joint and the auxiliary fluid lines via the provided locking mechanisms. Thus, embodiments allow gooseneck conduits to be quickly and safely attached to and/or removed from the telescoping joint.
FIGS. 1A-1B show a drilling system 100 in accordance with various embodiments. The drilling system 100 includes a drilling rig 126 with a riser string 122 and blowout preventer stack 112 used in oil and gas drilling operations connected to a wellhead housing 110 . The wellhead housing 110 is disposed on the ocean floor with blowout preventer stack 112 connected thereto by hydraulic connector 114 . The blowout preventer stack 112 includes multiple blowout preventers 116 and kill and choke valves 118 in a vertical arrangement to control well bore pressure in a manner known to those of skill in the art. Disposed on the upper end of blowout preventer stack 112 is riser adapter 120 to allow connection of the riser string 122 to the blowout preventer stack 112 . The riser string 122 is composed of multiple sections of pipe or riser joints 124 connected end to end and extending upwardly to drilling rig 126 .
Drilling rig 126 further includes moon pool 128 having telescoping joint 130 disposed therein. Telescoping joint 130 includes inner barrel 132 which telescopes inside outer barrel 134 to allow relative motion between drilling rig 126 and wellhead housing 110 . Dual packer 135 is disposed at the upper end of outer barrel 134 and seals against the exterior of inner barrel 132 . Landing tool adapter joint 136 is connected between the upper end of riser string 122 and outer barrel 134 of telescoping joint 130 . Tension ring 138 is secured on the exterior of outer barrel 134 and connected by tension lines 140 to a hydraulic tensioning system as known to those skilled in the art. This arrangement allows tension to be applied by the hydraulic tensioning system to tension ring 138 and telescoping joint 130 . The tension is transmitted through landing tool adapter joint 136 to riser string 122 to support the riser string 122 . The upper end of inner barrel 132 is terminated by flex joint 142 and diverter 144 connecting to gimbal 146 and rotary table spider 148 .
A support collar 150 is coupled to the telescoping joint 130 , and the auxiliary fluid lines 152 are terminated at seal subs retained by the support collar 150 . One or more gooseneck conduit assemblies 154 are coupled to the support collar 150 and to the auxiliary fluid lines 152 via the seal subs retained by the support collar 150 . Each conduit assembly 154 is a conduit unit that includes one or more gooseneck conduits 156 . A hose 158 or other fluid line is connected to each gooseneck conduit 156 for transfer of fluid between the gooseneck conduit 156 and the drilling rig 126 . In some embodiments, the connections between the hoses 158 and/or other rig fluid lines and the gooseneck conduits 156 are made on the rig floor, and thereafter the gooseneck conduit assembly 154 is lowered onto the telescoping joint 130 .
The gooseneck conduit assembly 154 includes locking mechanisms that secure the conduit assembly 154 to the telescoping joint 130 . The conduit assembly 154 can be lowered onto the support collar 150 using a crane or hoist. In some embodiments, the conduit assembly 154 can be connected to hydraulic lines that actuate the locking mechanisms. Thus, embodiments allow the gooseneck conduits 156 to be quickly and safely fixed to and/or removed from the telescoping joint 130 while reducing the manual effort required to install and/or remove the gooseneck conduits 156 .
FIG. 2 shows the telescoping joint 130 in accordance with various embodiments. The auxiliary fluid lines 152 are secured to the telescoping joint 130 . The uphole end of each auxiliary fluid line 152 is coupled to a seal sub 206 at the support collar 150 . The support collar 150 is coupled to and radially extends from the telescoping joint 130 . In some embodiments, the support collar 150 includes multiple connected sections (e.g., connected by bolts) that join to encircle the telescoping joint 130 .
The gooseneck conduit assembly 154 includes one or more locking mechanisms, and a plurality of gooseneck conduits 156 . As the gooseneck conduit assembly 154 is positioned on the support collar 150 , each gooseneck conduit 156 engages a seal sub 206 and is coupled to an auxiliary fluid line 152 . The locking mechanisms secure the gooseneck conduit assembly 154 to the support collar 150 , and secure each gooseneck conduit 156 to a corresponding auxiliary fluid line 152 . In some embodiments, the locking mechanisms are hydraulically operated. In other embodiments, the locking mechanisms are mechanically operated. The locking mechanisms may be either hydraulically or mechanically operated in some embodiments. The gooseneck conduits 156 may include swivel flanges 208 for connecting the conduits 156 to fluid lines 158 .
FIG. 3 shows a top view of a plurality of gooseneck conduit assemblies 154 in accordance with various embodiments. Each gooseneck conduit assembly 154 includes one or more gooseneck conduits 156 . Each gooseneck conduit assembly 154 includes a top plate 302 and fasteners 312 that connect the top plate 302 to underlying structures explained below. The gooseneck conduit assembly 154 includes a projection or tenon 306 for aligning and locking the gooseneck conduit assembly 154 to the telescoping joint 130 . Some embodiments of the gooseneck conduit assembly 154 include a tenon 306 coupled to each gooseneck conduit 156 . In some embodiments, the tenon 306 may be trapezoidal, or fan-shaped to form a dove-tail tenon. Other embodiments may include a differently shaped tenon 306 . The tenon 306 may be formed by a bumper attached to the rear face 318 of the gooseneck conduit 156 , with the bumper, and thus the tenon 306 , extending along the length of the rear face 318 . In some embodiments, the tenon 306 may be made of bronze or another suitable material. In some embodiments, the tenon 306 may be part of the gooseneck conduit 156 .
An alignment guidance ring 316 is circumferentially attached to the telescoping joint 130 . The alignment guidance ring 316 includes channel mortises 304 that receive, guide the gooseneck conduits 156 into alignment with the seal subs 206 , and retain the tenons 306 as the gooseneck conduit assembly 154 is lowered onto the telescoping joint 130 . Consequently, the mortises 304 are shaped to mate with and slidingly engage the tenons 306 (i.e., a trapezoids, dove-tails, etc). The channel mortises 304 may narrow with proximity to the support collar 150 (with proximity to the bottom of the alignment ring 316 ). Similarly, the tenons 306 may narrow with distance from the top plate 302 (with proximity to the bottom of the rear face 318 of the gooseneck conduit 156 ). The tenons 306 and mortises 304 are dimensioned to securely interlock.
The gooseneck conduit assembly 154 includes locking mechanisms that secure the gooseneck conduit assembly 154 to the telescoping joint 130 . Embodiments may include one or more locking mechanisms that are mechanically or hydraulically actuated. For example, embodiments may include a primary and a secondary locking mechanism. Hydraulic secondary backup locks 308 are included on some embodiments of the gooseneck conduit assembly 154 . The hydraulic secondary locks include a hydraulic cylinder that operates the lock. Other embodiments include mechanical secondary backup locks 310 . In some embodiments, the secondary backup locks secure the primary locking mechanisms into position. Lock state indicators 314 show the state of conduit assembly locks. For example, extended indicators 314 indicate a locked state, and retracted indicators 314 indicate an unlocked state.
FIG. 4 shows an elevation view of the support collar 150 and gooseneck conduit assemblies 154 in accordance with various embodiments. The gooseneck conduit assembly 154 A includes two gooseneck conduits 156 , and is unlocked and separated from the telescoping joint 130 , and positioned above the support collar 150 . The gooseneck conduit assembly 154 B includes three gooseneck conduits 156 , and is secured to the telescoping joint 130 and associated seal subs 206 . Each gooseneck conduit 156 is replaceably fastened to a lower support plate 404 by bolts or other attachment devices. The upper support plate 302 is attached to the lower support plate 404 . The support collar 150 retains the seal subs 206 via clamps 412 attached to the support collar 150 by bolts or other fastening devices.
The alignment and guidance ring 316 is secured to the telescoping joint 130 . The alignment and guidance ring 316 may be formed from a plurality of ring sections joined by bolts or other fastening devices. The alignment and guidance ring 316 includes a locking channel 406 . The gooseneck conduit assembly 154 B rests on surface 502 ( FIG. 5 ) of the alignment and guidance ring 316 , and as discussed above, the tenons 306 interlock with the mortises 304 to laterally secure the gooseneck conduit assembly 154 B. The locking member 408 extends from the gooseneck conduit assembly 154 B into the locking channel 406 to prevent movement of the gooseneck conduit assembly 154 B upward along the telescoping joint 130 .
FIG. 5 shows a perspective view of the support collar 150 and the gooseneck conduit assemblies 154 as arranged in FIG. 4 .
FIG. 6 shows a cross-sectional view of the support collar 150 and gooseneck conduit assemblies 154 as arranged in FIG. 4 . Embodiments of the gooseneck conduits assemblies 154 may include any combination of hydraulic and mechanical primary and secondary locks. The gooseneck conduit assembly 154 B includes a hydraulic primary lock 618 and a hydraulic secondary lock 308 . The components of the hydraulic primary lock 618 are disposed between the upper and lower support plates 302 and 404 . The hydraulic primary lock 618 includes a hydraulic cylinder 612 coupled to the locking member 408 for extension and retraction of the locking member 408 .
The components of the hydraulic secondary lock 308 are secured to the upper plate 302 by hydraulic cylinder support plate 606 . The hydraulic secondary lock 308 includes a hydraulic cylinder 602 coupled to a locking pin 604 for extension and retraction of the locking pin 604 . When the locking member 408 has been extended, extension of the locking pin 604 secures the locking member 408 in the extended position. In some embodiments, the locking member 408 includes a passage 608 . The locking pin 604 extends into the passage 608 to secure the locking member 408 in the extended position.
The gooseneck conduit assembly 154 A includes a hydraulic primary lock 618 and a mechanical secondary lock 310 . As described above, the components of the hydraulic primary lock 618 , including the hydraulic cylinder 612 , and the locking member 408 , are disposed between the upper and lower support plates 302 and 404 . In some embodiments, the locking member 408 may be retracted by mechanical rather than hydraulic means. For example, force may be applied to the state indicator 314 to retract the locking member 408 from the locking channel 406 . The mechanical secondary lock 310 comprises an opening 624 that allows a bolt or retention pin to be inserted into the passage 608 of the locking member 408 when the locking member 408 is extended.
An upper split retainer 626 and a lower split retainer 622 are attached to the support collar 150 to reduce support collar 150 radial loading. The upper split retainer 626 is bolted to the upper side of the support collar 150 , and the lower split retainer 622 is bolted to the lower side of the support collar 150 . Each split retainer 626 , 622 comprises two sections. The two sections of each retainer 626 , 622 abut at a position 90° from the location where the support collar sections are joined. The upper split retainer 626 includes a tapered surface 628 on the inside diameter that retains and positions the support collar 150 on the telescoping joint 130 . The support collar 150 also includes a key structure (not shown) for aligning the support collar 150 with a keying structure of the telescoping joint and preventing rotation of the support collar 150 about the telescoping joint 130 .
Each gooseneck conduit 156 includes an arcing passage 614 extending through the gooseneck conduit 156 for passing fluid between the auxiliary fluid line 152 and the hose 158 . The gooseneck conduit assembly 156 may be formed by a casting process, and the thickness of material between the passage 614 and the exterior surface of the gooseneck conduit 156 may exceed the diameter of the passage 614 (by 2-3 or more times in some embodiments) thereby enhancing the strength and service life of the gooseneck conduit 156 . The gooseneck conduit 156 includes a socket 630 that sealingly mates with the seal sub 206 to couple the gooseneck conduit 156 to the auxiliary fluid line 152 . The socket 630 includes grooves 616 for holding a sealing device, such as an O-ring, that seals the connection between the gooseneck conduit 156 and the sealing sub 206 .
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. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A gooseneck conduit system for use with a telescoping joint of a subsea riser. In one embodiment, a riser telescoping joint includes a tube and a gooseneck conduit assembly affixed to the tube. The gooseneck conduit assembly includes a gooseneck conduit extending radially from the tube, and a tenon projecting from a rear face of the gooseneck conduit. The width of the tenon increases with distance from the rear face. The riser telescoping joint also includes a mortise channel extending along the length of the tube. The mortise channel is interlocks with the tenon and laterally secures the gooseneck conduit assembly to the tube.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2008/051834, filed Feb. 15, 2008 and claims the benefit thereof. The International Application claims the benefits of European Patent Office application No. 07003922.7 EP filed Feb. 26, 2007, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method for operating a multi-stage steam turbine and to a steam power plant comprising a multi-stage steam turbine, a boiler and a cooling medium supply.
BACKGROUND OF INVENTION
[0003] For thermodynamic reasons, it is necessary to increase the fresh steam temperatures in order to increase the efficiency of modern steam turbine plants. At present, steam turbines are designed and produced for fresh steam temperatures of approximately 630° C. and fresh steam pressures of approximately 300 bar. The selection of the materials for the rotor and for the housing plays a significant role. It would appear to be possible to use nickel-based alloys as high-temperature materials for planned fresh steam temperatures of 700° C. The rotor and the housing of a steam turbine suitable for 700° C. could therefore be produced from a nickel-based alloy, though this would be a very expensive solution.
[0004] In high-pressure turbine sections, the materials in the vicinity of the inflow region are subjected to extreme thermal loading. In the exhaust steam region of the high-pressure turbine section, the temperature and the pressure of the fresh steam is low in relation to the temperature and the pressure of the fresh steam. It is therefore not imperatively necessary to use the expensive nickel-based alloy in the exhaust steam region.
[0005] It is therefore conventional to produce high-pressure turbine sections from different materials. It would thus be possible, for example, for the rotor to be formed as a welded structure, with a nickel-based alloy being used in the fresh steam region and a conventional material being used in the exhaust steam region. This would lead to lower overall production costs. A high-pressure turbine section produced in this way would withstand the loadings which occur in operation. However, the steam temperatures in the exhaust steam region of the high-pressure turbine section are comparatively high during a period of idle operation or low-load operation, as a result of which the conventional material is subjected to too great a thermal loading. This problem occurs in particular during a hot start, since the fresh steam temperatures cannot be arbitrarily reduced in order to limit the thermal loading of the incoming flow.
[0006] DD 148 367 describes a method for lowering the work capacity of the steam during a load-shedding process, wherein the solution consists in admixing water to the fresh steam via injection nozzles, thereby reducing the temperature of the steam.
SUMMARY OF INVENTION
[0007] What would be desirable is a high-pressure turbine section which is formed from different materials and which is suitable for different load conditions, such as for example low load or high load.
[0008] The invention addresses this; it is the object of the invention to specify a method for operating a steam turbine and a steam power plant, with it being possible for the steam turbine to be produced in a cost-effective manner.
[0009] The object on which the invention is based is achieved by means of a method for operating a multi-stage steam turbine, with the steam turbine being supplied with fresh steam and, downstream of an intermediate stage, a cooling medium.
[0010] The invention is based on the aspect that a high-pressure turbine section can be produced from a conventional material in the exhaust steam region if the exhaust steam region is provided with suitable cooling under idle or low-load operation. This takes place according to the invention by virtue of a cooling medium being supplied downstream of the intermediate stage in the steam turbine. That region of the steam turbine which is situated downstream of said intermediate stage is thereby cooled. That region of the steam turbine which is situated upstream of said intermediate stage may be formed from a nickel-based alloy, with it being possible for the material used in the exhaust steam region to be formed from a conventional material, since the temperatures in the exhaust steam region can now be reduced in a targeted fashion.
[0011] Therefore, in contrast to DD 148 367, not all of the fresh steam is cooled by means of the injection of water, but rather only steam which has already cooled and expanded in the steam turbine is cooled further by the cooling medium, as a result of which an abrupt reduction in the temperature of the steam situated in the steam turbine takes place.
[0012] The cooling medium is preferably formed from a mixture of propellant steam and water.
[0013] This is a comparatively fast and expedient solution for providing a suitable cooling medium since, as a result of the high vaporization heat of the water, the enclosed steam quantity undergoes a significant temperature reduction and therefore also pressure reduction.
[0014] The propellant steam is preferably extracted from a boiler. In this way, it is easily possible for the boiler, also referred to as a steam generator, to be retrofitted in an existing steam power plant in order to provide propellant steam.
[0015] Alternatively, in a further preferred embodiment, the propellant steam may be branched off from the fresh steam supply via a bypass line. In addition to the branching directly from the boiler, this would be a further simple and cost-effective option for providing suitable propellant steam which, by means of the admixture of water, may be used as cooling medium in the steam turbine.
[0016] In one preferred embodiment, the cooling medium is supplied in idle operation or in low-load operation.
[0017] The cooling medium is preferably supplied in particular at the commencement of a hot start. During a hot start, the temperature of the materials of the high-pressure turbine section is comparatively high, such that during a hot start, the fresh steam thermally loads the entire high-pressure turbine section. In particular, since the steam turbine is operated at low load during starting and the steam in the outflow region is at a comparatively high temperature, the high-pressure turbine section is subjected to particularly high thermal loading during a hot start.
[0018] The cooling medium is preferably supplied during a starting process until a synchronization has taken place and/or a minimum power has been attained. This has the advantage that the high-pressure steam temperature can be kept constant by regulating the cooling medium mass flow.
[0019] In a further advantageous refinement, the steam turbine is refined such that an additional cooling medium is additionally supplied downstream of a second stage.
[0020] This has the advantage that the outflow region of the high-pressure turbine section is cooled further, as a result of which suitable conventional materials can be used in the outflow region.
[0021] Here, the additional cooling medium is preferably branched off from the cooling medium, which is a cost-effective option for retrofitting an existing steam power plant.
[0022] In one advantageous embodiment, the additional cooling medium is emitted from a duct formed in a guide blade. In this way, it is possible for additional cooling medium to flow quickly and over a large area, so to speak, into the flow duct of the turbo-machine. Here, the mixture of the additional cooling medium with the flow medium is comparatively thorough, such that an abrupt reduction in temperature takes place.
[0023] The object aimed at the steam power plant is achieved by means of a steam power plant, comprising a multi-stage steam turbine, a boiler and a cooling medium supply, wherein the cooling medium supply opens out into the steam turbine downstream of an intermediate stage. The advantages substantially correspond to those mentioned with regard to the method.
[0024] The cooling medium supply is preferably flow-connected to the duct and to a water reservoir.
[0025] In a further preferred embodiment, the cooling medium supply is flow-connected to a bypass line from a fresh steam supply line and to a water reservoir.
[0026] The steam turbine preferably has a second stage which is flow-connected to an additional cooling medium supply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will be explained in more detail on the basis of exemplary embodiments which are illustrated in the figures, in which:
[0028] FIG. 1 shows an illustration of a steam power plant,
[0029] FIG. 2 shows a sectional illustration of a high-pressure turbine section,
[0030] FIG. 3 shows temperature profiles within the high-pressure turbine section.
DETAILED DESCRIPTION OF INVENTION
[0031] FIG. 1 shows a steam power plant 1 . The steam power plant 1 comprises a steam generator 2 . The steam generator 2 may also be referred to as a boiler 2 . The steam generator 2 comprises a collecting tank 3 in which the steam can be collected. The steam power plant 1 also comprises a high-pressure turbine section 4 , a medium-pressure turbine section 5 and a low-pressure turbine section 6 . Among experts, the classification of high-pressure, medium-pressure and low-pressure turbine sections is not defined consistently. There is a DIN standard which defines a high-pressure turbine section 4 as being one in which the steam emerging from the high-pressure turbine section 4 is heated in an intermediate superheater 7 and subsequently flows into a medium-pressure turbine section 5 .
[0032] In the steam generator 2 , fresh steam is generated which is supplied via a line 8 to the high-pressure turbine section 4 . The high-pressure turbine section 4 , as an embodiment of a steam turbine, comprises a plurality of stages. At the outflow pipe 9 , steam flows to the intermediate superheater 7 , is heated there and is subsequently conducted to the inflow pipe 10 of the medium-pressure turbine section 5 . The steam is expanded further in the medium-pressure turbine section 5 , with said steam flowing into the low-pressure turbine section 6 after emerging from the medium-pressure turbine section 5 . Downstream of the low-pressure turbine section 6 , the steam flows into a condenser 11 , where it is condensed to form water.
[0033] The condensed water is conducted by means of a pump 12 via a further line 13 to the steam generator 2 .
[0034] The high-pressure turbine section 4 is operated in such a way that a cooling medium is supplied downstream of an intermediate stage 14 . For this purpose, the steam power plant 1 has a cooling medium supply 15 which opens out into the high-pressure turbine section 4 downstream of the intermediate stage 14 .
[0035] The cooling medium is formed from a mixture of propellant steam and water. The water is extracted from a water reservoir 16 , which water may be admixed to the propellant steam by means of a valve 17 . The propellant steam is extracted from a branch line 18 which opens out in the collecting tank 3 of the steam generator 2 . Fresh steam from the steam generator 2 therefore passes via the branch line 18 and a valve 19 and is mixed with the water from the water reservoir 16 at the junction 20 , and is conducted into the high-pressure turbine section 4 downstream of the intermediate stage 14 via the cooling medium supply 15 .
[0036] In an alternative embodiment, the branch line 18 and the valve 19 may be dispensed with, with the propellant steam from the line 8 being supplied, at the branch junction 21 , to the junction 20 via a bypass line 22 and a valve 23 .
[0037] The mass flow of the propellant steam and of the water may be adjusted by means of throttles (not illustrated in any more detail) and the valves 17 , 19 , 23 . The throttles and/or the valves 17 , 19 , 23 may be coupled to a control system which regulates the throughflow rate. Here, the regulation may be carried out in such a way that, with progressive time after a minimum load is attained, the throughflow rate is successively reduced and finally completely shut off.
[0038] Here, the steam turbine 4 is operated in such a way that the cooling medium is supplied to the high-pressure turbine section 4 in idle operation or in low-load operation.
[0039] The cooling medium is supplied during a starting process until a synchronization has taken place and/or a minimum power has been attained. A synchronization is to be understood to mean the synchronization with the mains frequency. A minimum power is to be understood to mean a power at which the high-pressure turbine outputs a sufficient level of power and thus has low exhaust-steam temperatures.
[0040] FIG. 2 shows a cross-sectional view of the high-pressure turbine section 4 . The high-pressure turbine section 4 comprises an outer housing 24 and an inner housing 25 . A plurality of guide blades 26 are arranged on the inner housing 25 , wherein for clarity, only one guide blade has been provided with the reference numeral 26 . A rotor 27 is rotatably mounted within the inner housing 25 . The rotor 27 comprises a plurality of rotor blades 28 , wherein for clarity, only one rotor blade has been provided with the reference numeral 28 . The high-pressure turbine section 4 has a flow inlet 29 into which is supplied the fresh steam from the steam generator 2 . The fresh steam which is supplied in this way is conducted through the guide blades 26 and rotor blades 28 , with the fresh steam being expanded and the temperature falling. A flow duct 30 is formed between the rotor 27 and the inner surface of the inner housing 25 , which flow duct 30 ends in an outflow pipe 31 .
[0041] The high-pressure turbine section 4 is designed in such a way that a cooling medium supply 15 is arranged such that the cooling medium can be conducted into the flow duct 30 downstream of the intermediate stage 14 . The region up to the intermediate stage 14 , in particular the region around the flow inlet 29 , is subjected to particularly high thermal loading and should therefore be formed from a nickel-based alloy. Cooling of the flow medium in the flow duct 30 takes place as a result of the inflow of the cooling medium via the cooling medium supply 15 downstream of the intermediate stage 14 , which cooling causes the temperature to be reduced in the outflow region 32 and therefore makes it possible to use a cheaper material than the nickel-based alloy. The rotor 27 may therefore be produced from two components, wherein the first component 33 may be formed from the nickel-based alloy and the second component 34 may be formed from a cheaper material. The first component 33 and the second component 34 are connected to one another by means of a welded connection 35 .
[0042] The steam power plant 1 may be provided with additional cooling by means of the supply of an additional cooling medium downstream of a second stage. The second stage is not illustrated in any more detail in FIG. 2 , but is situated downstream of the intermediate stage 14 as viewed in the flow direction. The additional cooling medium is branched off from the cooling medium.
[0043] Here, the high-pressure turbine section 4 is designed such that the guide blades 26 of the second stage have ducts.
[0044] Said guide blades 26 of the second stage are accordingly formed so as to be hollow to a greater or lesser extent, with it being possible for the cavity to be filled with the additional cooling medium. The additional cooling medium flows out of said ducts, out of the guide blades 26 of the second stage, and mixes with the flow medium situated in the flow duct 30 . This means that, beyond said point, further cooling of the flow medium takes place downstream of the second stage, and the thermal loading is reduced beyond said point.
[0045] High-pressure turbine sections 4 are, in some embodiments, formed with a steam tap pipe. Said steam tap pipes are used as a tap in normal load operation of the high-pressure turbine section 4 , with steam being discharged from the flow duct 30 via the steam tap pipe. In idle operation or low-load operation, said steam tap pipe is, in a sense, converted into the cooling medium supply, with the cooling medium passing into the high-pressure turbine section 4 via said steam tap pipe. The steam tap pipe therefore performs a dual function: firstly for discharging steam out of the flow duct 30 in load operation, and secondly for supplying cooling medium during low-load operation or idle operation.
[0046] The high-pressure turbine section 4 comprises the second stage, which is flow-connected to an additional cooling medium supply. The additional cooling medium supply is flow-connected to the steam generator 2 and to the water reservoir 16 , which is not illustrated in any more detail in FIG. 1 .
[0047] FIG. 3 illustrates the temperature profile within the high-pressure turbine section 4 as a function of the number of stages N (n 1 -n 7 ). The stages n 1 , n 2 , . . . n 7 represent positive integers which correspond to the number of stages. The exact number of stages is not necessary for precise understanding of the invention, for which reason the number of stages has been replaced by the indices 1 to 7 . The curve 36 shows the temperature profile as a function of the stages in normal operation. It can be clearly seen that the temperature drops from approximately 700° C. to approximately 420° C. downstream of the stage n 6 . This takes place as a result of thermodynamic transformations, with the fresh steam being expanded and the temperature being reduced.
[0048] The second curve 37 shows the profile of the temperature as a function of the stages N in idle operation or low-load operation if no measures according to the invention are implemented. It can be clearly seen that the temperature barely falls upstream of the stage n 4 and even rises again downstream of the stage n 4 . This means that the stages beyond approximately n 3 in the outflow region are subjected to thermal loading since the temperatures there are constantly higher than 600° C. The third curve 38 shows the profile of the temperature T as a function of the stages N in low-load operation or idle operation if the cooling medium is supplied to the high-pressure turbine section 4 downstream of the stage n 4 , which is to be understood to be the intermediate stage 14 . At the vertical dashed line, it is possible to clearly see that the temperature at that point has dropped significantly from approximately 630° C. to 470° C. This means that, beyond said point, the high-pressure turbine section 4 is subjected to a lesser thermal loading since the temperatures in said region do not exceed 500° C.
[0049] The fourth curve 41 shows the temperature profile T as a function of the stages N if the intermediate stage 14 is instead provided at the point n 3 and the additional cooling medium is additionally supplied at the point n 4 , downstream of the second stage. It can be very clearly seen that, downstream of the intermediate stage 14 , that is to say a short distance after the stage n 3 in the illustration of FIG. 3 , the temperature drops abruptly from approximately 640° C. to 540° C., and the temperature subsequently falls from approximately 530° C. to 490° C. downstream of the further supply of additional cooling medium.
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A method for operating a multi-step steam turbine operating in high temperature conditions is provided. The rotor is embodied as a welded construction including a first component and a second component. A coolant is supplied to the steam turbine after an intermediate state when the steam turbine is in the light-load or no-load phase. As a result, the thermal loads in the outflow area of the steam turbine are reduced.
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BACKGROUND OF INVENTION
This invention generally relates to an embedded dynamic random access memory (embedded DRAM), and more particularly, to a high-performance DRAM architecture utilizing gain cells.
Memory arrays constructed of six transistor static memory cells (6T SRAMs) are generally known to have faster access time and cycle time when compared to single-ended dynamic cells.
FIG. 1A shows a transistor level schematic of a conventional 6T SRAM cell 10 consisting of four NMOS transistors 1 , 2 , 5 , and 6 , and two PMOS transistors 3 and 4 . PMOS 3 and 4 and NMOS 5 and 6 form a CMOS cross-coupled latch, which maintains a data bit as a storage element. NMOS transistors 1 and 2 couple nodes 7 and 8 to biltlines BL 1 and BL 2 when activated by wordline WL, allowing the data bit to read to or written from BL 1 and BL 2 . On the other hand, single-ended dynamic cells are known to be smaller and benefit from significantly reduced soft-error-rate at small geometries.
FIG. 2A is a transistor level schematic of a conventional single-ended dynamic cell 20 . It consists of one NMOS transistor 21 and capacitor 22 (1T DRAM cell). When the wordline WL is activated, NMOS 21 couples capacitor 22 to the bitline BL, allowing the data bit stored in capacitor 22 to be read to or written from BL.
Several reasons exist to explain the difference in performance. From a functional standpoint, the SRAM cell 10 shown in FIG. 1B can be described as one having three signal connections attached to each cell consisting of one storage element and two switches 11 and 12 . These are: wordline (WL) and bitlines 1 (BL 1 ) and 2 (BL 2 ). Cells are arranged in a matrix formation with a wordline connecting a plurality of cells in one direction and bitlines in an orthogonal arrangement. Switches 11 and 12 are controlled by wordline WL such that storage element 15 can be accessed by bitlines BL 1 and BL 2 . Data is preserved in the SRAM cell for many cycles as long as power is maintained, and as long as the wordline servicing the cells is not activated. In a non-activated condition, because switches 11 and 12 are opened, the SRAM cell presents a high impedance to the BL 1 and BL 2 connections. When the wordline is activated, switches 11 and 12 couple storage element 15 to bitlines BL 1 and BL 2 . As a result, the SRAM cell displays a different impedance to bitlines BL 1 and BL 2 depending upon the state of the memory cell. For a cell storing a logic ‘1’, BL 1 displays a lower impedance than BL 2 at an impedance value that is slightly less than that in the non-activated case. A logic “1” represents the condition necessary for the CMOS cross-coupled latch in FIG. 1A to maintain a “0” and “1” at nodes 7 and 8 , respectively.
Assuming that BL 1 and BL 2 are precharged to VDD, the impedance of NMOS switch 1 in FIG. 1A is lower than that of NMOS switch 2 . For a cell storing a ‘0’, bitline_ 2 port will have a lower impedance than the bitline_ 1 port which, in turn, will display an impedance that is slightly less than the non-activated case. Thus, a “0” is the state wherein the CMOS cross-coupled latch maintains a 1 and 0 at nodes 7 and 8 , respectively. Assuming having BL 1 and BL 2 precharged to VDD, then, NMOS switch 2 impedance is lower than the impedance of NMOS switch 1 . This difference in impedances can be used to sense the state of the memory cell using one of several existing techniques. The state of the static memory cell is not disturbed by reading it; hence it is known to have a non-destructive read-out (NDRO). The cell is written by asserting the wordline while forcing a reference voltage on bitline_ 1 to write one state, or by forcing a reference voltage on bitline_ 2 to write the other state. If no bitline is forced (or if both are forced to the same direction), the cell will not be written, but instead will maintain its previous state. This is known as a non-destructive write (NDW).
The aforementioned characteristics are used to enhance performance using the following techniques since the read-out operation is nondestructive and the bitlines may be precharged back to their ‘ready’ state while the wordline is still activate. This characteristic makes it possible to reduce the time of a random access cycle. When a read-out is nondestructive, it is possible to multiplex several bitlines into a single sense amplifier, allowing the use of a larger area for each sense amplifier, and hence more complex, higher performance circuits. Moreover, since bitlines produce differential signals from each cell, the bitline signal is ‘self-referenced’, essentially reducing noise, improving the signal/noise ratio, and allowing a faster amplification of the signal. Furthermore, since the SRAM cell develops an impedance difference when read, it is possible to use current sensing techniques to sense the signal. These are known to be faster than voltage sensing techniques (traditionally used to sense dynamic cells) particularly for arrays having many bits per bitline. Since the SRAM cell can be read nondestructively (NDRO), the cell need not be written-back after it is read-out (as compared to traditional dynamic cells). Also, because the SRAM cell enables a nondestructive write (NDW), it is possible to perform a write operation only for selected cells even if more cells are activated by the corresponding wordline. Unselected data bits are typically maintained by floating bitlines (or by forcing both bitlines to high). Accordingly, the non-destructive read (NDRO) and non-destructive write (NDW) features have the most significant impact on the cycle time of a conventional DRAM cell array when compared to an SRAM cell.
From a functional standpoint, the single ended dynamic cell 20 can be described as one having two signal connections attached to each cell including one storage element 22 and one switch 21 (FIG. 2 B). The connections are: wordline (WL) and bitline (BL). Because of the nature of the dynamic cell, when WL is activated, data in the storage element is destroyed (destructive read). The destroyed data needs then to be written back into the storage element increasing the read cycle time. Because of the write back requirement, DRAMs typically use a CMOS cross-coupled sense amplifier SA. Additionally, the write cycle time is equal or slower than the read cycle time, unless all the bits coupled to the wordline are simultaneously written. This may be explained by the fact that unselected cells for the write operation are destroyed in a manner similar to the destructive read operation, requiring a sensing and write back operation (read modified write), necessitating a longer write cycle time.
Accordingly, it is important to solve these two problems to enable the SRAM like cycle time. Techniques are known to utilize a destructive read/destructive write 1T1C DRAM cell in combination with a write-back buffer array to realize a dynamic memory with cycle time that approaches that of an SRAM. One known technique is a memory architecture in which the read-out of one DRAM array occurs simultaneously with the write-back operation in a separate DRAM array of the same memory. A buffer array is used to resolve data conflicts. Data management techniques inherent to this solution, however, tend to increase the access time. Hence it is difficult to use such a technique to achieve an SRAM-like access time.
FIG. 3A shows a prior art single-ended multi-port destructive write memory cell 30 consisting of a storage element 33 and two switches ( 31 and 32 ). The single ended multi port destructive write memory cell is characterized by having four wires connected to each cell:
a read bitline (RBL) traversing the array in one direction,
a write bitline (WBL) traversing the array in a direction parallel to the read bitline;
a read wordline (RWL) traversing the array of cells in a direction orthogonal to the bitlines;
and a write wordline (WWL) traversing the array of cells in a direction parallel to the read wordline.
Data is stored in the cell for as many cycles as necessary as long as the read wordline and write wordline are not activated. The cell displays high impedance at its read bitline port as long as the read wordline is not activated. When the read wordline RWL is activated, the switch 30 couples storage element 33 to read bitline RBL. This enables the nondestructive read cell to provide an impedance to the read bitline (RBL) which depends on the logic value stored in a cell similar to the 6T SRAM cell. This occurs in the class of single-ended multi-port cells which have nondestructive read-out.
FIGS. 3B-3C show conventional nondestructive read and destructive write memory cells comprising three transistors (3T cell) and two transistors (2T cell), respectively, or a destructive read cell such as one having a single capacitor, wherein the storage element shares the charge that it is stored in the capacitor in the read bitline (RBL). This occurs in the class of single-ended multi-port cells which have destructive read-out.
FIG. 3D shows a prior art destructive read and destructive write memory cell consisting of two transistors and one capacitor (2T 1C cell).
Regardless whether a 3T, 2T, or 2T 1C cells are used, when a write wordline is activated, the cell takes on the logic state that is forced onto the write bitline by opening switch 32 (FIG. 3 A), coupling it to the write BL (WBL). Every cell which is connected by a write wordline being activated is written into. There is no option for activating a wordline and having the cell maintain its previous state because of a destructive write. Therefore, it is required to write all the bits coupling to the activated WWL simultaneously. Otherwise, the write cycle time is limited by the read modify write back operation similar to the DRAM. However, writing all the bits along the wordline concurrently requires rearranging the data lines and associated drivers with the same periodicity as the memory cells. Such a solution requires significant area and hence is expensive. Also, the number of cells coupled to a wordline must be equal or less than the number of the write data bits. This requirement is not practical for a “narrow” I/O organization, such as x 16, or even for x 32 or x 64. Using a single-ended multi-port non-destructive write memory cell may overcome the problem. However, it requires at least an equal number, or preferably, more transistors than the conventional 6T SRAM cell and is, therefore, undesirable for being expensive.
In a typical destructive read array, the read cycle consists of a read-out, a write-back and a precharged phase. In the conventional destructive write array, all the data bits coupled to a wordline are simultaneously written. Otherwise, the write cycle consists of a read-out, a modify-write-back and a precharged phase (read modified write). Hence the typical operation of a single-ended destructive write multi-port memory cell ends up having a longer cycle than that of a nondestructive read /write 6T SRAM.
SUMMARY OF INVENTION
It is an object of the invention to provide a memory formed with single-ended multi-port destructive write memory cells.
It is another object to provide a memory architecture that makes it possible to have a write-back phase from one cycle to occur simultaneously with the read-out phase of another cycle.
The foregoing and other objects of the invention are realized by a circuit and an architecture that utilize single-ended dual-port destructive write memory cells and a local write-back buffer. Each cell has separate read and write ports that make it possible to read-out data from cells along one wordline in the array, and immediately thereafter write-back data to the same cell while simultaneously cells on another wordline in the array are being read-out. Thus, by implementing an array of sense amplifiers such that one amplifier is coupled to each read bitline, and a latch receiving the result of the sensed data and delivering this data to the write bitlines, it is possible to ‘pipeline’ the read-out and write-back phases of the read cycle. This allows for a write-back phase from one cycle to occur simultaneously with the read-out phase of another cycle.
By extending the operation of the latch to accept data either from the sense amplifier, or from the memory data inputs, modified by the column address and masking bits, it is also possible to pipeline the read-out and the modify write-back phases, allowing them to occur simultaneously for different wordlines. The architecture preferably employs a nondestructive read memory cell such as 2T or 3T gain cells, achieving an SRAM-like cycle and access times with a smaller and more SER immune memory cell.
Alternatively, the architecture is provided with a destructive read memory cell such as a 2T 1C cell, which achieves the same performance with a destructive read architecture employed in other, known destructive read architectures, but with a simpler destructive read scheduling.
In a first aspect of the invention, there is provided an array of memory cells, respectively coupled to read and write bitlines, each read bit line being attached to a read sensing circuits, and each write bitlline connected to a write drivers, a latch and a multiplexer, as described above. A series of write wordlines connect the write activation ports on many cells in a manner that is orthogonal to the read and write bitlines. Similarly a series of read wordlines connects the read activation port on many cells in an orthogonal arrangement to the read and write bitlines. Read and write wordlines are asserted by a wordline decoder and driver circuits in such a manner so that one read wordline and one write wordline can be asserted simultaneously.
In a second aspect of the invention, the row decoder circuit is augmented by a latch located at each decoder output. Using this latch, the row decoder can first select a read wordline for activation. The wordline selection is stored in the latch so that the decoder is free to select the next read wordline while the last latched wordline selection is used to activate the write wordline.
The sequence of events to perform a read operation of the above array of memory cells is as follows: i) row address decoding; ii) read wordline assertion; iii) read data transfer from the selected memory cells to the read bitlines; iv) detection of the data on the read bitlines by the read sense circuits; v) transfer of the digital data from the read sense circuits both to the readout port of the memory array and to the latch associated with the read bitline; and vi)de-assertion of the read wordline.
The sequence of events to perform a write operation in the above array of memory cells is as follows: i) row address decoding; ii)read wordline assertion; iii) read data transfer from the selected memory cells to the read bitlines; iv) detection of the data on the read bitlines by the read sense circuits; v) transfer of the digital data from the read sense circuits to the latch associated with the read bitline; vi) de-assertion of the read wordline and transfer of the wordline selection to the write wordline latch; vii) logical combination of data in the read bitline latch with input signals such as column addresses, mask bit and data bits to form the appropriate state presented to the write bitline driver; viii) write wordline assertion using the wordline indicated in the wordline selection latch; ix) driving the write bitlines with the calculated write bits; x) modification of the memory cell based on the data on the cells write port; and xi) de-assertion of the write wordline and clearing of the wordline selection latches.
A “pipeline” operation of the memory array is such that some or all of the operations vii) to xi) of the write cycle operating at one wordline address may overlap, i.e., they occur concurrently with operations i) to vi) of the write cycle, or operations i) to vi) of the read cycle at a different wordline address.
The aforementioned memory array may also operate in a mode where the memory cells are read-out destructively. In this case, a read or a refresh cycle includes the same operation steps as the write cycle previously described, except for operation vii) which does not accept signals from outside the array, such that data from the read sense circuits is not modified before being delivered to the write driver. Additionally, some or all of operations vii) to xi) of the write cycle operating and one wordline address may overlap in time with operations i) to vi) of the refresh or read cycle. Also some or all of operations vii) to xi) of the refresh cycle may overlap with operations i) to vi) of the refresh cycle, and operations i) to vi) of a write cycle or operations i) to iv) of the read cycle.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and which constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given hereinafter serve to explain the principles of the invention.
FIG. 1A is a transistor level schematic showing a prior art 6T SRAM cell.
FIG. 1B is a functional representation of the prior art SRAM cell shown in FIG. 1A consisting of one storage element and two switches.
FIGS. 2A and 2B are, respectively, a transistor level schematic and a functional representation of a prior art single-ended DRAM cell.
FIG. 3A is a schematic diagram of a prior art single-ended multi-port destructive write memory cell consisting of a storage element and two switches.
FIGS. 3B and 3C respectively show typical prior art nondestructive read and destructive write memory cells consisting of 3 transistors (3T cell) and 2 transistors (2T cell).
FIG. 4 shows a single ended destructive write multi-port memory array architecture consisting of a plurality of a single ended destructive write multi-port memory cells, each including a read port, a write port and a storage element, according to the present invention.
FIG. 5 shows how the concepts of the present invention apply to a prior art 2-port 3T gain cell by enabling a non-destructive read and a destructive write operation.
FIG. 6A is a transistor level schematic of a column shown in FIG. 4 , with each column consisting of a plurality of 3T memory cells coupled to a plurality of RWL and WRL pairs, and one RBL and WBL pair, according to the invention.
FIG. 6B shows the internal timing diagram for several commands, i.e., write 0 for memory cell i (W 0 i), write command 1 for the memory cell j (W 1 j), read memory cell i (Ri) and read memory cell j (Rj).
FIG. 7 shows a block diagram consisting of an address match detection circuit, a write bit register and a multiplexer.
DETAILED DESCRIPTION
FIG. 4 shows a single-ended destructive write multi-port memory array architecture, according to the present invention. The memory architecture 40 includes a plurality of single-ended destructive write multi-port memory cells 30 , each consisting of a read port 31 , a write port 32 , and a storage element 33 . The cells are organized in a matrix formation by way of a plurality of rows, each coupled to the read wordline RWL and write wordline WWL, and a plurality of columns, each coupled to read bitline RBL and to write bitline WBL. Each RWL and WWL is supported by a common row decoder 41 , a read wordline driver 42 , and write wordline latch and driver 43 . Alternatively, each read and write wordline drivers 42 and 43 have an independent row decoder 41 . Each read bitline RBL is supported by a read sense amplifier 44 and a precharged device or resistor 49 , and each write bitline WBL, by bitline write circuit 45 . A common column decoder 46 services a read column select driver 47 and a write column select driver 48 . Alternatively, each read and write column select drivers 46 and 47 are provided with an independent column decoder 46 .
The discussion following hereinafter assumes a synchronous pseudo-SRAM interface, which supports read, write, and refresh operations at each clock cycle.
Read Mode:
When a read command is given at which time the system clock CLK switches to high, the row decoders 41 and column decoders 46 enable, respectively, the corresponding read wordline driver 42 and read column select driver 47 . The respective RWL thus switches to high, and opens read ports 31 of the corresponding memory cells 30 . As a result, data bits in the appropriate memory cells 30 are read out to the corresponding RBLs. Concurrently, signal read column select RCSL switches to high, opening read column switch 31 , allowing the corresponding read sense amplifier 45 to couple to the local read data line LRDL. Read BL precharged device 49 is preferably kept on for current sensing of the non-destructive memory cell. However, it may be turned off during RWL activation to conserve power. Alternatively, it may be turned off prior to activating RWL for a destructive read memory cell. Regardless whether a non-destructive read memory cell or a destructive read cell, a current mode sense amplifier 44 is preferably used, although the present invention is not limited to only this configuration.
Sense amplifier 44 senses the data bit generated in each RBL, which is then automatically transferred to LRDL and PRDL, allowing an SRAM-like access behavior, particularly, if a non-destructive read cell is used.
For a destructive read memory cell, the destructive read operation is preferably used for creating a preconditioned write by choosing a proper BL precharged voltage, such as VDD or ½VDD. For a write-back operation following the read-out, the sensed data bits are transferred to write buffer 45 , which occurs when delayed clock CLKI switches to high. When this occurs, the write wordline latch and driver 43 activates the corresponding WWL. When a transition to high takes place, WWL opens the corresponding write ports 32 of memory cells 30 . Concurrently, write bitline driver 45 drives the read data bits to WBL, allowing the read data bit to be transferred from read port 31 of memory cell 30 to be written back to write port 32 of the memory cell through RBL and WBL, and within two cycles. As long as each read and write cycle is equal or less than the clock cycle, the next read command will be accepted as a “pipeline” allowing a single cycle read access time. Alternatively, for a non-destructive read array, the write back cycle may be disabled to save power.
Write mode:
When a write command is given at which time the system clock CLK switches to high, row decoders 41 and column decoders 46 enable the appropriate read wordline driver 42 . The corresponding RWL thus switches to high, and opens read ports 31 of the corresponding memory cells 30 . As a result, data bits in the matching memory cells 30 are read out to the corresponding RBLs. The read BL precharged device 49 may be kept on, preferably, for current sensing of the nondestructive memory cell. However, it may be turned off during the activation of RWL to conserve power. Alternatively, one may turn it off prior to activating RWL, i.e., in an instance of a destructive read memory cell. Regardless whether a destructive read memory cell or non-destructive read cell, current mode sense amplifier 44 senses the data bit developed on each RBL. The read-out data is transferred to the write data latch 45 .
Concurrently, write data bits are driven to the primary write data line (PWDL) and local write data line. At the same time, the CLKI enables a write column select driver 48 , activating the signal WCSL. The activation of the WCSL transfers the write data bit from the LWDL to the selected write bitline circuit 45 , overriding the data from the read sense amplifier. When the CLKI switches to high, the write wordline driver 43 asserts the corresponding WWL. Switching WWL to high opens the corresponding write ports 32 of the memory cells 30 enabling a simultaneous write back to cells on un-selected columns and write to cells on the selected columns.
Optionally, by integrating the disable function of the WCSL with a mask bit control, the write bits end up also masked. This is well known in the art and, consequently, will not be discussed further. The foregoing allows the write data bit driven from WPDL to be written to a write port of the same memory cell, keeping the destructive write memory cell deselected by transferring the data bits form the read port of the memory cell to the write port of the same memory cell via RBL and WBL over two cycles. As long as each read or each write cycle is equal or less than the clock cycle, the next read command can be accepted as a “pipeline”, to allow a single write access cycle.
Refresh Mode:
When a refresh command is given at which time a system clock CLK switches to high, row decodes 41 enables the corresponding read wordline driver 42 . The corresponding RWL switches to high, opening read ports 31 of the corresponding memory cells 30 . As a result, data bits in the corresponding memory cells 30 are read out to the corresponding RBLs. The read BL precharged device 49 may preferably be kept on for current sensing of a non-destructive memory cell. However, it may be turned off during RWL activation to conserve power. Alternatively, it may be turned off prior to activating RWL for a destructive read memory cell. Regardless whether a destructive read memory cell or a non-destructive read cell are used, a current mode sense amplifier 44 may be utilized, although the invention is not limited in this configuration.
The current mode sense amplifier 44 senses the data bit generated on RBL. This makes it possible to achieve an SRAM-like access performance, particularly, if a non-destructive read cell is employed. For a destructive read memory cell, a destructive read operation is preferably used for creating a preconditioned write by selecting the appropriate BL precharged voltage, such as VDD or ½VDD. For the write back operation following the read-out mode, the sensed data bits are transferred to the write buffer 45 when the delayed clock CLKI switches to high. When CLKI switches to high, write wordline driver 43 activates the corresponding WWL. Switching WWL to high opens the corresponding write ports 32 of the memory cells 30 . Simultaneously, write bitline driver 45 drives the read data bits to WBL. This allows the read data bit that was transferred from the read port of the memory cell to be written back to the write port of the same memory cell through the RBL and the WBL within two cycles. As long as each read or write cycle is equal less than the clock cycle, the next read command can be accepted as a pipeline allowing a single cycle refresh access cycle time.
The concepts discussed above will now be more clearly understood by way of the following preferred embodiment applicable to a prior art 3T gain cell.
FIG. 5 shows a conventional 2-port 3T gain cell that enables a non-destructive read and a destructive write operation. The 3T gain cell 50 consists of three NMOS transistors 51 , 52 and 53 A. A data bit is maintained by gate capacitor 53 A as a storage element. Optionally, an additional capacitor 53 B may be integrated to improve the data retention time. The data bit at the node S can be read-out to the read bitline RBL when the read wordline RWL coupled to the gate of NMOS31 switches to high. Maintaining node S to high discharges RBL. If node S is at low, RBL remains in a high state. When write wordline WWL switches to high, the source node S becomes coupled to write bitline WBL. Thus, the data bits at the node S can be changed by WBL.
FIG. 6A is a transistor level schematic diagram of the column shown in FIG. 4 . Each column 60 consists of a plurality of 3T memory cells 30 i and 30 j ( FIG. 3 ) coupled to a plurality of RWL-WWL pairs and one RBL-WBL pair (FIG. 4 ). A read bitline RBL is precharged to VDD by PMOS 49 . When RWL switches to high, RBL remains at high if node S is at 0, or it may discharge a few hundred millivolts from VDD. The RBL voltage level is determined by the conductance ratio between PMOS 49 and the 3T cell memory cell. A current mirror sense amplifier 44 ( FIG. 4 ) compares RBL to a reference voltage VREF, which is set at a level half-way between VDD and the voltage to which RBL discharges to. If the voltage at RBL is higher than VREF, nodes SO and bSO are then, respectively kept at 0 and 1. If the RBL is lower than VREF, nodes SO and bSO will switch to 1 and 0, respectively. The current mirror sense amplifier 44 is enabled when signal ENABLE switches to high. A signal RCSL activates read column switch 66 to transfer the data bit from the current mirror sense amplifier 44 to the local read data line LRDL. It is preferably driven in order to transfer a signal to the primarily read data line PRDL. The signal transfer to the PRDL occurs immediately following RWL being activated. This allows an SRAM like read access performance. Bitline write circuit 61 includes a simple CMOS latch which is driven either by the current mirror sense amplifier 44 when both write column switches 62 and 63 are closed, or by the data on the LWDL line when the write column switch 64 closes. In a read or data refresh modes, write column select signal WCSL and bWCSL remain, respectively, at low and high. When the delayed clock CLKI switches to high, the node bSO at sense amplifier 44 drives CMOS latch 61 , allowing the sensed result to be transferred to WBL. CLKI is preferably generated by sensing the state of cells in a dummy column in the array which is identical to a regular column in every what except the cells are pre-conditioned so that they will always store a “1” data state. The RBL in the dummy column, therefore, discharges when the RWL switches to high, which generates signal CLKI and guarantees the data bits to be ready for the write back operation to all cells on the wordline.
Two situations exist for a write cycle. For the selected columns, WCSL switches to high, allowing write BL circuit 61 to be driven by LWDL. Note that the write path from the current mirror sense amplifier 44 is disabled by bWCSL. For the unselected columns, write BL circuit 44 is driven by the corresponding current mirror sense amplifier 44 , allowing the sensed data bits to be written back to the corresponding memory cells. Optionally, the data mask function may be integrated by disabling the WCSL selection. This is well known in the art, and will not be discussed further.
FIG. 6B shows the internal timing diagram for the given commands write 0 for memory cell i (W 0 i), write command 1 for the memory cell j (W 1 j), read memory cell i (Ri) and read memory cell j (Rj). It is assumed that memory cells 0 and 1 originally store 1 and 0, respectively.
The “pipelined” write followed by read architecture described above works well if the consecutive addresses are different. In view of the non-destructive read nature, two consecutive read commands (or read and write) for the same row address can also be serviced because the memory cells are forced by the same data bits read out from the same cell. For two consecutive write commands for the same row address, the BL write circuit should only be updated by the write command by forcing bWCSL while enabling WCSL. A write followed by a read for the same row address requires special data handling. Since the read-out and modify-write-back operations associated with the write cycle are pipelined, the bits written are not yet stored in the memory cell when the next read command is issued. Note that this is the only concern for the updated write bits, whereas other unselected write bits provide the same operation as a read mode. Consequently, a problem occurs only when the row and column addresses are exactly the same as for the previous write command.
FIG. 7 is a block diagram of an address match detection circuit, write bit register and multiplexer. The address match detection compares the address input with the previous address, and generates a signal REGOUT that remains at 0 if no match occurs, allowing the read data bits to be read from the memory array. If a match occurs, the signal REGOUT switches to high, allowing the data bits to be read out from the register which has been loaded by the write data of the last command.
For the destructive read and destructive write multi-port memory cell shown in FIG. 3D , VDD or ½VDD BL precharged voltage is preferably chosen. This allows a destructive read operation to be a preconditioning write operation at VDD or ½VDD. It also results in a faster write operation for the following write operation, further improving the write cycle time.
While the invention has been described in terms of a preferred embodiment, various alternative and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives which fall within the scope of the appended claims.
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A memory architecture that utilizes single-ended dual-port destructive write memory cells and a local write-back buffer is described. Each cell has separate read and write ports that make it possible to read-out data from cells on one wordline in the array, and subsequently write-back to those cells while simultaneously reading-out the cell on another wordline in the array. By implementing an array of sense amplifiers such that one amplifier is coupled to each read bitline, and a latch receiving the result of the sensed data and delivering this data to the write data lines, it is possible to ‘pipeline’ the read-out and write-back phases of the read cycle. This allows for a write-back phase from one cycle to occur simultaneously with the read-out phase of another cycle. By extending the operation of the latch to accept data either from the sense amplifier, or from the memory data inputs, modified by the column address and masking bits, it is also possible to pipeline the read-out and the modify-write-back phases of a write cycle, allowing them to occur simultaneously. The architecture preferably employs a nondestructive read memory cell such as 2T or 3T gain cells, achieving an SRAM-like cycle and access times with a smaller and more SER immune memory cell.
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RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to a process for preparing high purity, stoichiometric aluminum silicate (mullite).
Mullite (3Al 2 O 3 .2SiO 2 ) has long been known in the ceramic and refractory industries. Mullite is the most stable compound in the Al 2 O 3 -SiO 2 system. Consequently, it occurs as a main constituent in a large number of ceramic products which are fabricated from aluminosilicate materials. Considerable amounts of mullite are used to produce refractory bodies designed to withstand high temperatures. Its relatively low thermal coefficient of expansion makes such refractories more resistant to thermal stress in constrast to similar bodies prepared from aluminum oxide materials.
Mullite possesses a dielectric constant of approximately 5 to 6 and therefore presents a very attractive electrical characteristic as integrated circuit technology continues advancing to higher speed circuit devices. Moreover, mullite's low thermal coefficient of expansion offers an excellent match to large silicon integrated circuit chips or glass layers which may be placed on substrates. Although mullite has been mentioned for use as multi-layer electronic substrates for integrated circuit devices, high purity, dense substrates are not known to exist.
Commercially available mullite always contains significant amounts of impurities such as silica, iron oxide, and titania. These impurities influence the physical, electrical and chemical properties of the mullite, which in turn affect the ceramic compositions of which mullite may be embodied in.
The most common technique for mullite fabrication involves the heating of clays, feldspars, kyanites, etc. to a temperature in excess of 1300° C. The degree of completeness of the reaction is dependent on temperature and the time the sample is held at temperature. The higher the reaction temperature, the less the dwell time at temperature. During heating, the clay structure breaks down to form mullite and an amorphous silica phase. This silica glass is very viscous and can either crystallize to a crystalline silica phase or it can react with excess alumina that may have been added to the initial raw material mixture. This reaction will also yield mullite. Again, the degree of completion of this reaction is dependent on temperature and sample time at temperature.
If alumina and clay are mixed in the proper properties, production of a 100% mullite body is feasible. However, as the chemical reaction sequence has a volume change associated with it, the fabrication of 100% mullite articles by this technique to rigid dimensional specifications becomes very difficult, if not impossible. Therefore, the common method to circumvent this problem is to pre-react a portion of the material to 100% mullite and then grind this material and add it to a mixture of the initial raw material mixture. The ceramic industry term for any pre-reacted material is grog. This mixture of grog and initial raw material mixture often called binder is then fabricated into the desired shape and sintered at a high temperature to convert the raw material mixture to mullite and drive the sintering reaction to a satisfactory end-point. Variations of this technique are possible.
Mullite can also be fabricated by processes that do not use any glass phase point in the process. This solid state reaction technique makes use of the fact that the equilibrium Al 2 O 3 -SiO 2 phase diagram predicts that if Al 2 O 3 and SiO 2 are in contact and heated sufficiently, mullite will form as a natural product. This technique requires that the Al 2 O 3 and SiO 2 to diffuse to a common boundary and react chemically. The distance the constitutents diffuse is primarily influenced by the temperature, the time the material is held at temperature, and the particle size of the raw materials.
High purity, submicron mullite powder can be prepared by hydrolytically decomposing a mixture of stoichiometric amounts of aluminum tris-isopropoxide and a silicon tetra-alkoxide in the presence of a weak base or very dilute mineral acid. Mullite has also been prepared by reacting clear, aqueous alumina sol with silicon tetraethoxide.
It is an object of the present invention to provide a novel method for the preparation of mullite.
Other objects, aspects and advantages of the present invention will be apparent to those skilled in the art from the following disclosure of the invention.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a novel method for preparing high purity mullite which comprises the steps of
(a) partially hydrolyzing a dilute silicon alkoxide solution;
(b) adding an aluminum alkoxide to the partially hydrolyzed, dilute silicon alkoxide solution; and
(c) eliminating terminal alkoxide groups.
In one embodiment of the invention, the liquid is evaporated out and the remaining material is calcined at about 500° C. to yield an amorphous structure having the mullite composition. Further heating to about 650° C. eliminates alkoxide terminal groups still present in the amorphous material. Firing the material to about 985° C. converts the amorphous material to crystalline mullite.
In another embodiment of the invention, the solution resulting from step (b), above, is further hydrolyzed using a relatively small amount of water. A solution prepared in this manner will yield a clear gel and may be used to deposit a coating on a substrate. Firing the deposited coating to about 985° C. converts the amorphous material to crystalline mullite.
In yet another embodiment of the invention, the solution resulting from step (b), above, is further hydrolyzed using a relatively large amount of water to produce a precipitate. This precipitate converts to mullite at about 985° C.
DETAILED DESCRIPTION OF THE INVENTION
The aluminum and silicon alkoxides may be prepared using techniques known in the art. As one example, aluminum tris-isopropoxide may be prepared by the reaction of aluminum metal foil of 99.94% purity with excess isopropyl alcohol using about 10 -4 mol of HgCl 2 per mol of Al as a catalyst. The reaction that occurs is shown by the following general equation: ##STR1## wherein R is a C 1 to C 4 alkyl group. As another example, silicon tetrakis isopropoxide may be prepared by reacting silicon tetrachloride of 99.9+% purity with isopropyl alcohol. The reaction that occurs is shown by the following general equation:
SiCl.sub.4 +4ROH→Si(OR).sub.4 +4HCl
wherein R is a C 1 to C 4 alkyl group. In general, any of the C 1 to C 4 alcohols may be used in the present invention, e.g., methanol, ethanol, n-propanol, i-propanol, n-butanol, i-butanol, t-butanol and sec-butanol.
The silicon alkoxide is diluted with one of the above-listed alcohols, preferably the alcohol corresponding to the alkoxy group of the silicon alkoxide, to a concentration low enough to avoid gellation when later hydrolyzed, e.g., about 10 weight percent equivalent oxide or less.
The dilute silicon alkoxide is then partially hydrolyzed by adding about 0.1 to 1.0 moles of water per mole of the total of the silicon alkoxide already present plus the stoichiometric quantity of aluminum alkoxide to be later added. The dilute silicon alkoxide to which the water has been added is allowed to stand for a short period, e.g., about 5 to 15 minutes, to at least partially hydrolyze the silicon alkoxide.
A stoichiometric quantity of the aluminum alkoxide is next added to the partially hydrolyzed silicon alkoxide solution. Solution concentration of the combined mixture should be maintained sufficiently low to avoid gellation, generally about 10% by weight equivalent oxide, or less. The term "equivalent oxide" as used herein, and in the claims, is intended to mean the stoichiometric equivalent in terms of the oxide of the aluminum and/or silicon component. The solution concentration can be adjusted by diluting the water component or the aluminum alkoxide, or both, with a suitable alcohol, as listed previously.
Addition of the aluminum alkoxide is followed by a reaction period of about 8 to 48 hours, at an elevated temperature in the approximate range of 50° C. to 0° C., preferably about 30° C. to 10° C., below the normal boiling temperature of the alcohol diluent. The solution may be stirred, if desired, during the reaction period to ensure thorough mixing. The reaction vessel is preferably equipped with means, such as a reflux condenser, to prevent loss of the diluent. Following the reaction period, the solution, hereinafter referred to as the product solution, is cooled to ambient temperature. The overall reaction is given by the following general equation:
6Al(OR).sub.3 +2Si(OR).sub.4 +xH.sub.2 O→2Al.sub.3 Si(OH).sub.13.xH.sub.2 O+26ROH
The product solution is stable, at ambient temperature, for a relatively long period. Product solutions have been observed to be stable at room temperature for as long as three months.
Amorphous stoichiometric mullite can be recovered from the above product solution as a powder or as a coating on a substrate. If a powder product is desired, the alcohol(s) may be evaporated off, leaving an amorphous gel having the mullite composition, with terminal alkoxide groups still present. Alternatively, a very fine powder may be obtained by mixing water with the product solution, which causes the mullite composition in the form of hydroxyaluminosilicate to precipitate out of the solution. In a presently preferred embodiment, the product solution is diluted about 1:1, by weight, with dry ethanol or other suitable alcohol, prior to mixing the product solution with the water. The amount of water used to precipitate out the hydroxyaluminosilicate is not critical. In general, the amount used will be sufficient to dilute the alcohol to about 60 to 75% (w/w). The powder can be recovered by filtration.
If the mullite composition is recovered as an amorphous gel, as mentioned above, the gel can be converted to an amorphous oxide state by calcination at a temperature in the range of about 500° to 700° C. for about 1 to 24 hours. The material can be calcined statically (without the tumbling) or dynamically (with tumbling). Calcination at or near the lower calcination temperature yields a dark colored powder containing terminal alkoxide groups, while calcination at or near the higher calcination tempereature yields a clear product.
Recovery of material by dilution with excess water, as described above, directly yields an amorphous, finely divided powder having the mullite composition. Following separation from the liquid, the powder may be dried under vacuum, at, for example, 50° to 70° C., 0.5 go 2 mm Hg, 1 to 24 hours, to ensure dehydration of hydroxyaluminosilicate to amorphous mullite as shown by the following equation:
2Al.sub.3 Si(OH).sub.13 →3Al.sub.2 O.sub.3.2SiO.sub.2 +13H.sub.2 O
The powder recovered from the drying step can, optionally, be calcined, as described above.
The amorphous mullite powder, obtained by either of the above methods is converted to crystalline mullite by heating the powder at a temperature of about 985°-1000° C. for about 1 to 24 hours, either statically or dynamically. Higher temperatures are not required, inasmuch as differential thermal analysis of the powder indicates conversion to the crystalline form at about 985° C.
As mentioned previously, the product solution can be coated onto a substrate. The coating can then be converted to a crystalline mullite.
To prepare a solution for coating onto a substrate, the product solution is diluted with an amount of suitable alcohol sufficient to lower the concentration of equivalent oxides to about 5 weight percent or lower. To this quantity of alcohol is added a quantity of water sufficient to hydrolyze the terminal alkoxy groups in the mixture. A small quantity, generally about 0.5 w% or less, of a mineral acid, e.g., 70% nitric acid, is added to the diluted solution to promote dissolution and cause clearing of the solution.
The diluted solution is applied to a suitable substrate by spraying, dipping, spreading, etc. The term "substrate" includes any material having high temperature stability, e.g., metals, ceramic materials and the like. The coated substrate is heated in air to about 500° C. for about 15 min. to form a clear amorphous film thereon. Further heating in air to about 985° to 1000° C. converts the amorphous layer to the crystalline mullite structure.
The following examples illustrate the invention.
EXAMPLE I
69.5 g (0.33 mole) of tetraethylorthosilicate, Si(OC 2 H 5 ) 4 , was mixed into a liquid mixture containing 400 g of dry ethanol, 14.0 g distilled water and 0.009 g of 70% nitric acid. The resulting mixture was allowed to stand in a closed container for about 5 minutes at room temperature. 250 g (1.015 moles) of aluminum secondary butoxide, Al(OC 4 H 9 ) 3 , was added to the mixture in the container. The container was closed and shaken briefly to mix the ingredients. This mixing produced a stiff, gelatinous, opaque material which slowly dissolved, forming a milky liquid. The reaction mixture was then heated, with the container closed, to about 60° C. for about 16 hours. After about 30 minutes the material in the closed container took on a translucent appearance. After heating for several hours the material became clear. After the heating period, the material was allowed to cool to room temperature.
EXAMPLE II
A portion of the material obtained in Example I was placed in an open container at room temperature. Evaporation of the free alcohol from this portion yielded a clear gel. A portion of this amorphous gel was converted to an amorphous oxide state having the composition of mullite by heating in air at 500° C. for 1 hour. The oxide material ranged from brown to black. Another portion of the amorphous gel was heated in air at 650° C. for about 1 hour, yielding a clear product. Each of the above oxide products was converted to crystalline mullite by heating in air at 990° C. for 30 minutes.
EXAMPLE III
60 g of the material obtained in Example I was combined with 333.3 g of dry ethanol and 2.78 g water. The resulting milky liquid was allowed to stand overnight in a closed container. 2 g of 70% nitric acid was added to the mixture to promote dissolution and cause clearing of the solution.
The thus-cleared solution was deposited onto a fused silica substrate. The coated substrate was heated in air at 500° C. for 15 min. to form a clear amorphous film. Further heating in air to 990° C. yielded the crystalline mullite structure in the coating layer.
EXAMPLE IV
80 g. of the material obtained in Example I was combined with 80 g of dry ethanol in a closed container. 80 g of water was then added to this mixture, with stirring, causing precipitation of a fine powder. Excess liquid was evaporated off the powder. The dried amorphous powder was converted to crystalline mullite by heating in air to 1000° C. for 1 hour.
Various modifications of this invention can be made in view of the foregoing disclosure without departing from the spirit and scope of the invention.
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A method for preparing mullite (3Al 2 O 3 .2SiO 2 ) by partially hydrolyzing a dilute silicon alkoxide solution, combining an aluminum alkoxide with the partially hydrolyzed silicon alkoxide, eliminating terminal alkoxide groups and firing the material to about 985° C.
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[0001] This application claims priority from U.S. Provisional Application Ser. No. 61/449,877, filed Mar. 7, 2011, which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an arrangement for opening and closing coverings for architectural openings such as Venetian blinds, pleated shades, cellular shades, and vertical blinds.
[0003] Usually, a transport system for a covering that extends and retracts in the vertical direction has a fixed head rail which both supports the covering and hides the mechanisms used to raise and lower or extend and retract the covering. Such a transport system is described in U.S. Pat. No. 6,536,503, Modular Transport System for Coverings for Architectural Openings, which is hereby incorporated herein by reference. In the typical covering product that retracts at the top and then extends by moving downwardly from the top (top/down), the extension and retraction of the covering is done by lift cords suspended from the head rail and attached to the bottom rail. In a Venetian blind, there also are ladder tapes that support the slats, and the lift cords usually run through holes in the middle of the slats. In these types of coverings, the force required to raise the covering is at a minimum when the covering is fully lowered (fully extended), since the weight of the slats is supported by the ladder tapes, so that only the bottom rail is being raised by the lift cords at the outset. As the covering is raised further, the slats stack up onto the bottom rail, transferring the weight of the covering from the ladder tapes to the lift cords, so progressively greater lifting force is required to raise the covering as it approaches the fully raised (fully retracted) position.
[0004] Some window covering products are built to operate in the reverse (bottom-up), where the moving rail, instead of being at the bottom of the window covering bundle, is at the top of the window covering bundle, between the bundle and the head rail, such that the bundle is normally accumulated at the bottom of the window when the covering is retracted and the moving rail is at the top of the window covering, next to the head rail, when the covering is extended. There are also composite products which are able to do both, to go top-down and/or bottom-up. In the top-down/bottom-up (TDBU) arrangements, the window shades or blinds have an intermediate movable rail and a bottom movable rail.
[0005] Known cord drives have some drawbacks. For instance, the cords in a cord drive may be hard to reach when the cord is high up (and the blind is in the fully lowered position), or the cord may drag on the floor when the blind is in the fully raised position. The cord drive also may be difficult to use, requiring a large amount of force to be applied by the operator, or requiring complicated changes in direction in order to perform various functions such as locking or unlocking the drive cord. There also may be problems with overwrapping of the cord onto the drive spool, and many of the mechanisms for solving the problem of overwrapping require the cord to be placed onto the drive spool at a single location, which prevents the drive spool from being able to be tapered to provide a mechanical advantage.
[0006] It often is desirable to hide the cords so there are no loose cords. However, this can be difficult, especially when there is more than one movable rail, which generally means that there are many cords that have to be hidden.
SUMMARY
[0007] Various arrangements are presented for moving a covering from one position to another using lift cords that are hidden and eliminating loose cords. In one embodiment, the user actuates a mechanism on a handle on a movable rail, and then raises or lowers the movable rail to extend or retract the covering. Release of the handle mechanism automatically locks the movable rail in the position it was in when the handle mechanism was released.
[0008] In another embodiment, an indexing mechanism, functionally connected to the lift rod of the movable rail, functions to rotate lift stations in the movable rail that wind up or unwind the lift cord to raise or lower the movable rail.
[0009] In another embodiment, an upper movable rail rides up and down on the lift cords of a lower movable rail.
[0010] In still another embodiment, an upper movable rail is suspended on a first set of lift cords that extend upwardly to fixed points, and a lower movable rail is suspended from the upper movable rail by a second set of lift cords. This embodiment includes an arrangement that prevents the lower movable rail from extending beyond the bottom of the architectural opening when the upper movable rail is fully extended.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a cellular shade incorporating a lock mechanism shown in the locked position;
[0012] FIG. 2 is a perspective view of the shade of FIG. 1 , with the lock in the unlocked position;
[0013] FIG. 3 is a partially exploded perspective view of the shade of FIG. 1 , showing the components that are housed in the movable rail;
[0014] FIG. 4 is a plan view of the lock mechanism of FIG. 1 , with the top cover omitted for clarity, and showing the lift rod;
[0015] FIG. 5 is the same view as FIG. 4 , but with the lock mechanism in the unlocked position;
[0016] FIG. 6 is an exploded perspective view of the lock mechanism of FIG. 1 ;
[0017] FIG. 7 is a rear perspective view of the slide element of the lock mechanism of FIG. 6 ;
[0018] FIG. 8 is a front view the lock mechanism of FIG. 1 ;
[0019] FIG. 9 is a section view along line 9 - 9 of FIG. 8 ;
[0020] FIG. 10 is a perspective view of the cellular shade of FIG. 1 , but adding a pivot support attachment to aid in unlocking the shade if the lock mechanism is not readily accessible to the user;
[0021] FIG. 11 is a perspective view, similar to FIG. 10 , showing a lock release wand engaging the pivot support attachment for aiding in unlocking the shade;
[0022] FIG. 12A is a broken-away, section view along line 12 A- 12 A of FIG. 11 ;
[0023] FIG. 12B is the same view as FIG. 12A , but with the lock mechanism in the unlocked position;
[0024] FIG. 13 is a perspective view of the pivot support attachment of FIG. 11 ;
[0025] FIG. 14 is a perspective view of the tip of the lock release wand of FIGS. 10 and 11 ;
[0026] FIG. 15 is a perspective view of the tip of the lock release wand of FIG. 14 , as seen from a different angle.
[0027] FIG. 16 is a perspective view of a top-down bottom-up cellular shade;
[0028] FIG. 17 is an exploded perspective view of the head rail of the cellular shade of FIG. 16 ;
[0029] FIG. 18 is a perspective view of a top-down bottom-up cellular shade with a movable rail including a lock;
[0030] FIG. 19 is a partially broken away, perspective view of the cellular shade of FIG. 18 , with the rails omitted for clarity;
[0031] FIG. 20 is an exploded perspective view of the cellular shade of FIG. 18 , with the lift cords omitted for clarity;
[0032] FIG. 21 is a bottom-end perspective view of one of the windlass assemblies of FIG. 20 ;
[0033] FIG. 22 is a top-end perspective view of the windlass assembly of FIG. 21 ;
[0034] FIG. 23 is an exploded perspective view of the windlass assembly of FIG. 22 ;
[0035] FIG. 24 is section view along line 24 - 24 of FIG. 22 ;
[0036] FIG. 25 is a perspective view of the windlass of FIG. 24 ;
[0037] FIG. 26 is section view along line 26 - 26 of FIG. 22 ;
[0038] FIG. 27 is a perspective view of an alternate windlass assembly which may be used in the cellular shade of FIG. 20 ;
[0039] FIG. 28 is an exploded perspective view of the windlass assembly of FIG. 27 ;
[0040] FIG. 29 is a plan view showing the housing of the windlass assembly of FIG. 28 ;
[0041] FIG. 30 is a plan view showing the housing cover of the windlass assembly of FIG. 28 ;
[0042] FIG. 31 is a section view along line 31 - 31 of FIG. 27 ;
[0043] FIG. 32 is a front perspective view of a cellular shade, similar to that of FIG. 1 , but with a different drive mechanism;
[0044] FIG. 33 is a rear perspective view of the cellular shade of FIG. 32 ;
[0045] FIG. 34 is a partially exploded perspective view of the cellular shade of FIG. 32 ;
[0046] FIG. 35 is a section view along line 35 - 35 of FIG. 34 , but with the sprocket mounted onto the end cap;
[0047] FIG. 36 is a section view along line 36 - 36 of FIG. 35 ;
[0048] FIG. 37 is a perspective view of the end cap of FIG. 34 ;
[0049] FIG. 38 is a perspective view of the sprocket of FIG. 34 ;
[0050] FIG. 39 is a perspective view of a cellular shade, similar to that of FIG. 32 , but with index drive mechanisms at both ends of the shade;
[0051] FIG. 40 is a schematic of a top down/bottom up shade with an automatic variable stroke limiter, with both movable rails in their retracted positions;
[0052] FIG. 41 is a schematic of the shade of FIG. 40 with the upper movable rail in its fully extended position and the lower movable rail in its fully retracted position;
[0053] FIG. 42 is a schematic of the shade of FIG. 40 with the upper movable rail in a partially extended position and the lower movable rail in a partially extended position;
[0054] FIG. 43 is a schematic of the shade of FIG. 40 with the upper movable rail in a partially extended position and the lower movable rail in its fully retracted position; and
[0055] FIG. 44 is a schematic of the shade of FIG. 40 but showing a covering extending from the upper movable rail to the lower movable rail and including brakes on both movable rails.
DESCRIPTION
[0056] FIGS. 1 through 10 illustrate one embodiment of a horizontal covering for an architectural opening (which may hereinafter be referred to as a window covering or blind or shade). This particular embodiment is a cellular shade 10 , with a lock mechanism 12 (illustrated in further detail in FIGS. 4 through 9 ). The user applies an outside force to de-activate the lock mechanism 12 for raising or lowering the shade (retracting and extending the expandable material). When the shade is in the desired position, the user stops applying the outside force, and the lock mechanism automatically locks and holds the shade in place. This same lift arrangement could be used for a Venetian blind.
[0057] The shade 10 of FIGS. 1-3 includes a head rail 14 , a bottom rail 16 , and a cellular shade structure 18 suspended from the head rail 14 and attached to both the head rail 14 and the bottom rail 16 . Lift cords (not shown) are attached to the head rail 14 , extend through openings in the cellular shade 18 , and terminate at lift stations 20 housed in the bottom rail 16 . A lift rod 22 extends through the lift stations 20 and through the locking mechanism 12 . The lift spools on the lift stations 20 rotate with the lift rod 22 , and the lift cords wrap onto or unwrap from the lift stations 20 to raise or lower the bottom rail 16 and thus raise or lower the shade 10 . A spring motor 24 is functionally attached to the lift rod 22 to provide an assisting force when raising the shade.
[0058] These lift stations 20 and spring motor 24 , and their operating principles are disclosed in U.S. Pat. No. 6,536,503 “Modular Transport System for Coverings for Architectural Openings”, issued Mar. 25, 2003, which is hereby incorporated herein by reference. Very briefly, the lift rod 22 is rotationally connected to an output spool on the spring motor 24 . A flat spring (not shown) in the spring motor 24 has a first end connected to the output spool (having a first axis of rotation) of the spring motor 24 . The second end of the flat spring in the spring motor 24 is either connected to a storage spool (not shown) having a second axis of rotation, or is coiled about an imaginary axis defining this second axis of rotation. The flat spring is biased to return to its “normal” state, wound around the second axis of rotation, and typically this corresponds to when the shade 10 is in the fully raised position (retracted). As the shade 10 is pulled down (extended) the flat spring unwinds from the second axis of rotation and winds onto the output spool, increasing the potential energy stored in the spring. When the shade 10 is raised (retracted) the spring winds back onto the storage spool, using some of the potential energy to assist the user in raising the shade 10 by rotating the output spool and thus the lift rod 22 connected to the output spool of the spring motor 24 .
[0059] In this embodiment, the main purpose of the spring motor is to wind up the lift cord as the shade 10 is raised. To operate the shade, the user applies an external force to unlock the locking mechanism 12 and manually positions the rail 16 . He then releases the external force, and the locking mechanism 12 automatically locks to hold the rail 16 in the desired position regardless of the relationship of the spring power to the weight of the shade. The spring may be underpowered (having enough power to wind up the lift cord but not enough power to raise the shade) or it may be overpowered (having enough power to wind up the lift cord and additional power to raise the shade).
[0060] In one embodiment for a Venetian-type blind, this spring motor 24 includes a spring with a negative power curve such that, when the force required to raise the blind is at a minimum (when the Venetian blind is fully extended), the spring provides the least assist, and as a progressively greater lifting force is required to raise the slats of the blind (as the Venetian blind approaches the fully retracted position) the spring provides more of an assist. This spring with a negative power curve is disclosed in U.S. Pat. No. 7,740,045 “Spring Motor and Drag Brake for Drive for Coverings for Architectural Openings”, issued Jun. 22, 2010, which is hereby incorporated herein by reference.
[0061] Each lift station 20 includes a lift spool which rotates with the lift rod 22 . The lift stations 20 , lift rod 22 , and spring motor 24 are mounted in the bottom rail 16 . When the lift rod 22 rotates, so do the lift spools of the lift stations 20 , and vice versa. One end of each lift cord is connected to a respective lift spool of a respective lift station 20 , and the other end of each lift cord is connected to the top rail 14 , such that, when the lift spools rotate in one direction, the lift cords wrap onto the lift spools and the shade 10 is raised (retracted), and when the lift spools rotate in the opposite direction, the lift cords unwrap from the lift spools and the shade 10 is lowered (extended).
Lock Mechanism
[0062] FIGS. 4-9 show the details of the lock mechanism 12 of FIG. 3 . Referring to FIG. 6 , the lock mechanism 12 includes a housing 26 , a slide element 28 , a coil spring 30 , a splined sleeve 32 , and a housing cover 34 .
[0063] The housing 26 is a substantially rectangular box having a flat back wall 36 , a flat front wall 38 which defines an opening 40 , and a forwardly extending fixed tab 42 secured to the front wall 38 . The side walls 44 , 46 define aligned, U-shaped openings 48 , 50 which rotationally support the splined sleeve 32 . The left side wall 44 also defines an inwardly extending projection 52 sized to receive and engage one end 54 of the coil spring 30 . The other end 56 of the coil spring 30 is received in a similar projection 58 on the slide element 28 (See FIG. 7 ), as will be described in more detail later.
[0064] The bottom wall 60 defines a ridge 62 which extends parallel to the front and rear walls 38 , 36 . The bottom edge 64 of the slide element 28 is received in the space between the ridge 62 and the front wall 38 , so the ridge 62 and front wall 38 form a track that guides the slide element 28 for lateral, sliding displacement parallel to the flat front wall 38 of the housing 26 . A recessed shoulder 66 along the front of the housing cover 34 also extends parallel to the front wall 38 . The top edge 68 of the slide element 28 is received between the front wall 38 and the shoulder 66 to provide a similar linear, lateral guiding function for the top edge 68 of the slide element 28 , as described in more detail later.
[0065] Referring to FIG. 7 , the slide element 28 is a substantially T-shaped member with the leg of the “T” being a slide tab 70 which is substantially identical to the fixed tab 42 of the housing 26 , except that there is a through opening 27 through the slide tab 70 , the purpose of which is described later. As best appreciated in FIGS. 4 and 5 , the fixed tab 42 and the slide tab 70 are substantially parallel to each other when the lock mechanism 12 is assembled, and the slide element 28 slides to the left (as seen from the vantage point of FIGS. 4 and 5 ) toward the fixed tab 42 to unlock the lock mechanism 12 , as described in more detail later.
[0066] Again referring to FIG. 7 , the slide element 28 defines a wing projection 71 substantially opposite the spring-receiving projection 58 . As described in more detail later, this wing projection 71 slides between the splines of the splined sleeve 32 to prevent the splined sleeve 32 from rotating.
[0067] The splined sleeve 32 (See FIGS. 6 and 9 ) is a hollow, generally cylindrical body with an internal bore 72 having a non-circular profile. In this particular embodiment, it has a “V” projection profile. The lift rod 22 has a complementary “V” notch 22 A. The lift rod 22 is sized to nearly match the internal profile of the bore 72 , with the “V” projection of the bore 72 being received in the “V” notch 22 A of the lift rod 22 , such that the splined sleeve 32 and the lift rod 22 are positively engaged to rotate together. Thus, when the splined sleeve 32 is prevented from rotation, the lift rod 22 is likewise prevented from rotation.
[0068] The splined sleeve 32 also defines a plurality of splines 74 extending radially at the right end portion of the splined sleeve 32 (as seen from the vantage point of FIG. 6 ). The left end portion 76 of the splined sleeve 32 is a smooth, spline-less, cylindrical surface having the same outside diameter as the base from which the splines 74 project.
Assembly:
[0069] Referring to FIGS. 4-6 , to assemble the lock mechanism 12 , the first end 54 of the coil spring 30 is placed over the projection 52 on the housing 26 . The slide element 28 is then assembled such that the slide tab 70 projects through the opening 40 in the front wall 38 of the housing 26 , with the bottom edge 64 of the slide element 28 fitting in the space between the ridge 62 and the front wall 38 of the housing 26 . The second end 56 of the coil spring 30 receives the projection 58 (See FIG. 7 ) of the slide element 28 , so the coil spring 30 is trapped between and is held in position by the two projections 52 , 58 .
[0070] The coil spring 30 acts as a biasing means which urges the slide element 28 to the right (as seen from the vantage point of FIG. 4 ). To install the splined sleeve 32 , the user pushes the slide element 28 to the left, to the position shown in FIG. 5 , such that the wing projection 71 clears the splines 74 of the splined sleeve 32 . The splined sleeve 32 is then dropped into place so that its ends rest on the curved bottoms of the openings 48 , 50 in the side walls 44 , 46 , which support the splined sleeve 32 for rotation. (Shoulders 73 near the ends of the splined sleeve 32 lie inside the housing 26 adjacent to the side walls 44 , 46 and ensure that the splined sleeve 32 remains in the proper axial position relative to the housing 26 .) Finally, the housing cover 34 snaps on top of the assembly to keep the components together, with top edge 68 of the slide element 28 being received between the shoulder 66 of the housing cover 34 and the front wall 38 of the housing 26 , and the lift rod 22 is slid through the bore 72 of the splined sleeve 32 and through the lift stations 20 and into the spring motor 24 , as shown in FIG. 3 .
[0071] The assembled lock mechanism 12 , lift rod 22 , lift stations 20 , and spring motor 24 , are then mounted in the movable rail 16 . In this embodiment, the movable rail 16 is the bottom rail 16 , but it alternatively could be an intermediate rail, located between the head rail and a bottom rail (not shown). As another alternative, the entire mechanism, including the spring motor 24 , lift rod 22 , lift stations 20 and lock 12 could be located in the fixed head rail 14 , with the lift cords secured to the movable bottom rail, extending through the shade 18 , and winding up on the spools of the lift stations 20 in the fixed head rail.
Operation:
[0072] Referring to FIGS. 1 , 2 , 4 , and 5 , to raise or lower the shade 10 , the user pinches together the tabs 42 , 70 of the lock mechanism 12 , which pushes the slide element 28 to the left (as seen in FIG. 5 ), against the biasing force of the coil spring 30 . The wing projection 71 on the slide element 28 also moves to the left until it clears the splines 74 of the splined sleeve 32 , which frees the splined sleeve 32 and allows it to rotate. The lift rod 22 , which is functionally and positively connected to the splined sleeve 32 , now is also free to rotate. When the user is raising the shade 10 , the spring motor 24 assists the user by supplying some of the force required to rotate the lift rod 22 and with it the lift spools of the lift stations 20 to wind any lift cords onto these lift spools.
[0073] The spring on the spring motor 24 may be overpowered (more powerful than required to overcome the force of gravity acting on the shade 10 so that it raises the shade 10 ), or it may be underpowered, so that the user has to provide some of the lifting force to raise the shade 10 . As discussed earlier, the spring in the spring motor 24 may include a spring with a negative power curve such that, when the force required to raise the blind is at a minimum (when the blind is fully extended), the spring motor 24 provides the least assist, and as a progressively greater lifting force is required to raise the blind (as the blind approaches the fully retracted position) the spring motor 24 provides more of an assist.
[0074] When the user releases the tabs 42 , 70 of the lock mechanism 12 , the coil spring 30 automatically pushes the slide element 28 to the right, as shown in FIG. 4 , which slides the wing projection 71 to the right, so that it enters between two of the splines 74 , as shown in FIG. 9 . This prevents the splined sleeve 32 from rotating further. Since the lift rod 22 is directly connected to the splined sleeve 32 , this also prevents the lift rod 22 and the lift stations, which are functionally connected to the lift rod 22 , from rotating, so the lift cords cannot unwind from their lift stations 20 , and the shade 10 remains in the position where it was released by the user.
[0075] FIGS. 10-15 depict the shade 10 with an enhancement that may be added to make the lock 12 more readily accessible, especially when it might otherwise be too high up to reach.
[0076] Referring to FIGS. 10 and 11 , the enhancement includes a pivot support attachment 78 and a lock release wand 80 . Referring to FIG. 13 , the pivot support attachment 78 has a substantially flat horizontal surface 82 , defining a circular through opening 84 , and two downwardly projecting ears 86 , 88 defining countersunk openings 90 , 92 , for receiving screws to secure the attachment 78 to the movable rail 16 . As seen in FIGS. 10 and 11 , the pivot support attachment 78 is attached to the front, outside surface of the bottom rail 16 via screws 94 .
[0077] FIGS. 14 and 15 show the engagement tip 96 , which is secured to the top of the lock release wand 80 (See FIG. 11 ). This engagement tip 96 defines a first frustoconical surface 98 coaxial with the longitudinal axis of the lock release wand 80 , and a second frustoconical surface 100 mounted on an arm 102 which projects radially from the engagement tip 96 . The second frustoconical surface 100 is oriented perpendicular to the arm 102 . The bottom of the engagement tip 96 defines an opening 104 which receives the end of the lock release wand 80 , as seen in FIG. 10 .
[0078] If it is desirable to have means for extending the reach of the user to raise or lower the shade 10 , the pivot support attachment 78 is attached (using screws 94 , for instance) to the outer surface of the bottom rail 16 such that the two ears 86 , 88 straddle the lock 12 and the ear 86 abuts the fixed tab 42 of the lock 12 . The lock release wand 80 is then inserted into the pivot support attachment 78 such that the first frustoconical surface 98 goes into the opening 84 , as shown in FIGS. 10 and 11 . This first action properly locates the lock release wand 80 relative to the pivot support attachment 78 in preparation for controlling the lock 12 .
[0079] Once the lock release wand 80 is in position, as shown in FIG. 11 , it is rotated in a counter-clockwise direction about its longitudinal axis, as depicted by the arrow 106 in FIG. 10 , until the second frustoconical surface 100 projects into the opening 27 (See FIG. 12A ) in the slide tab 28 of the lock 12 , and the arm 102 is pressing against the slide tab 28 . Further rotation in the same counter-clockwise direction results in the arm 102 pushing the slide tab 28 toward the fixed tab 42 , which unlocks the lock 12 (See FIG. 12B ). The shade 10 may now be raised or lowered by raising or lowering the lock release wand 80 . The second frustoconical surface 100 projecting through the opening 27 of the slide tab 28 creates a positive engagement between the lock release wand 80 and the lock 12 such that the lock release wand 80 does not separate from the lock 12 even when pulling down on the lock release wand 80 .
[0080] Once the shade 10 is in the desired position, the user rotates the lock release wand 80 in a clockwise direction which allows the spring 30 to urge the slide tab 28 back to the locking position. Further rotation of the lock release wand 80 pulls the second frustoconical surface 100 out of the opening 27 in the slide tab 28 and allows the user to pull down on and remove the lock release wand 80 .
Top-Down, Bottom-Up Shade
[0081] FIGS. 16 and 17 show a top-down, bottom-up cellular shade 10 ′. This general type of shade 10 ′ is described in the aforementioned U.S. Pat. No. 7,740,045 “Spring Motor and Drag Brake for Drive for Coverings for Architectural Openings”, issued Jun. 22, 2010, which is hereby incorporated herein by reference.
[0082] The shade 10 ′ includes a head rail 14 ′, a movable intermediate rail 15 ′, a movable bottom rail 16 ′, and a cellular shade structure 18 ′ suspended from the intermediate rail 15 ′ and attached to both the intermediate rail 15 ′ and the bottom rail 16 ′.
[0083] There is a first set of lift cords 108 ′ that extend from the head rail 14 ′ to the intermediate rail 15 ′. These first lift cords 108 ′ have first ends attached to lift stations 21 ′ located in the head rail 14 ′ and second ends attached to the intermediate rail 15 ′. These first lift cords 108 ′ are raised and lowered with the rotation of a first lift rod 23 ′.
[0084] There is a second set of lift cords 110 ′ that extend from the head rail 14 ′ to the bottom rail 16 ′. These second lift cords 110 ′ have first ends attached to lift stations 20 ′ in the headrail 14 ′, extend through the intermediate rail 15 ′ and through the covering 18 ′ and have second ends attached to the bottom rail 16 ′. These second lift cords 110 ′ are raised and lowered with the rotation of a second lift rod 22 ′. Other components include spring motors with drag brakes 24 ′, as described below.
[0085] The first lift rod 23 ′ extends through the lift stations 21 ′. A spring motor with drag brake 24 ′ is functionally attached to the first lift rod 23 ′ to provide an assisting force when raising the intermediate rail 15 ′ of the shade 10 ′. When the first lift rod 23 ′ rotates, the lift spools on the lift stations 21 ′ also rotate, and the lift cords 108 ′ wrap onto or unwrap from the lift stations 21 ′ to raise or lower the intermediate rail 15 ′.
[0086] The second lift rod 22 ′ extends through the lift stations 20 ′ in the headrail 14 ′. A spring motor with drag brake 24 ′ is functionally attached to the second lift rod 22 ′ to provide an assisting force when raising the bottom rail 16 ′ of the shade 10 ′. When the second lift rod 22 ′ rotates, the lift spools on the lift stations 20 ′ also rotate, and the lift cords 110 ′ wrap onto or unwrap from the lift stations 20 ′ to raise or lower the bottom rail 16 ′.
[0087] This arrangement results in two sets of lift cords 108 ′, 110 ′ extending adjacent to each other, with both of these two sets of lift cords 108 ′, 110 ′ being exposed as the intermediate rail 15 ′ travels down toward the bottom rail 16 ′.
[0000] Arrangement with Intermediate Rail Riding on Lift Cords of Lower Rail:
[0088] FIGS. 18-20 show a top-down/bottom-up cellular shade 10 *, which eliminates one of the sets of lift cords from the embodiment of FIG. 16 . As explained in more detail below, a single set of lift cords 108 * extends from the head rail 14 *, through the intermediate rail 15 *, through the covering 18 *, and on down to the bottom rail 16 *.
[0089] The shade 10 * of FIGS. 18-20 includes a head rail 14 *, an intermediate rail 15 *, a bottom rail 16 *, and a cellular shade structure 18 * suspended from the intermediate rail 15 * and attached to both the intermediate rail 15 * and the bottom rail 16 *.
[0090] Single lift cords 108 * are attached to the head rail 14 *, extend through a set of windlass assemblies 112 * in the intermediate rail 15 *, and then on through openings in the cellular shade 18 *, to terminate at lift stations 20 * housed in the bottom rail 16 *. A lift rod 22 * extends through the lift stations 20 * in the bottom rail 16 *. When the lift rod 22 * rotates, the lift spools on the lift stations 20 * also rotate, and the lift cords 108 * wrap onto or unwrap from the spools on the lift stations 20 * to raise or lower the bottom rail 16 *. A spring motor with drag brake 24 * is functionally attached to the lift rod 22 * to provide an assisting force when raising the bottom rail 16 * and to hold the bottom rail 16 * in place when released by the user.
[0091] A connecting rod (or lift rod) 23 * in the intermediate rail 15 * extends through the locking mechanism 12 * and through the windlass assemblies 112 * to functionally interconnect them as described later.
[0092] The spring motor with drag brake 24 * in the movable bottom rail 16 * of FIGS. 19 and 20 is identical to the spring motor with drag brake 24 ′ of FIG. 17 , including the possibility of incorporating overpowered or underpowered springs, as well as the possibility of incorporating a spring with a negative power curve as has already been discussed. The lift stations 20 * of FIGS. 19 and 20 are substantially identical to the lift stations 20 ′, 21 ′ of FIG. 17 , which has already been described. Finally, the locking mechanism 12 * of FIGS. 19 and 20 is substantially identical in design and operation to the locking mechanism 12 of FIG. 3 , which already has been described.
[0093] The windlass assemblies 112 * shown in FIGS. 19 and 20 are shown in more detail in FIGS. 21-26 . Each windlass assembly 112 * includes a windlass (or capstan) 116 * and a windlass housing 118 *. The windlass (or capstan) 116 * is a spool that rotates within the windlass housing 118 *. The windlass housing 118 * is a substantially rectangular housing with a top wall 120 *, a front wall 122 *, a rear wall 124 *, a right wall 126 *, and a left wall 128 *, which define a hollow cavity 130 * for rotationally housing the windlass spool 116 *. The windlass spool 116 * is assembled to the windlass housing 118 * through the bottom of the windlass housing 118 * as discussed below.
[0094] The right and left walls 126 *, 128 * include arms 132 *, 134 * respectively, which, in turn, define ramps 136 *, 138 * respectively which rotationally support the windlass spool 116 *, as described in more detail later. The top wall 120 * defines a cord entry port 140 *, and the bottom of the windlass housing 118 * defines a cord outlet port 142 *. Finally, a biasing member 144 *, resembling a paddle or a flat finger, projects downwardly inside the cavity 130 *, adjacent the windlass spool 116 *, as best appreciated in FIGS. 21 , 23 , and 24 . As explained in more detail later, the purpose of the biasing member 144 * is to press the windings of the lift cord 108 * against the ribs 145 *(See FIG. 23 ) of the windlass spool 116 * to prevent slippage between the lift cord 108 * and the windlass spool 116 *, that is, to prevent the possibility of the lift cord 108 * surging the windlass spool 116 *.
[0095] Referring to FIGS. 23 and 25 , the windlass spool 116 * is a hollow, cylindrical body with an internal bore 146 * having a non-circular profile. In this particular embodiment, it has a “V” projection profile. The connecting rod 23 * has a “V” notch and it is sized to nearly match the internal profile of the bore 146 *, with the “V” projection of the bore 146 * being received in the “V” notch of the connecting rod 23 *, such that the windlasses (or capstans) 116 * of the windlass assemblies 112 * and the connecting rod 23 * are positively engaged to rotate together. The windlass spool 116 * defines two coaxial frustoconical surfaces 152 *, 154 * tapering from a larger diameter at the end to a smaller diameter toward the center, and these surfaces are interconnected by a coaxial, generally cylindrical surface with a plurality of friction-enhancing, spaced apart ribs 145 *.
[0096] To assemble the windlass assembly 112 *, a first end of the lift cord 108 * is fed up through the cord exit port 142 in the bottom of the housing 118 * into the cavity 130 * of the housing 118 *, then is pulled downwardly out through the open bottom of the housing 118 * and is wound one or more times around the central portion of the windlass spool 116 *(as shown in FIG. 25 ) and then is fed back into the open cavity 130 * and upwardly through the entry port 140 * out of the windlass housing 118 * and is secured to the head rail 14 ′. The windlass spool 116 * is then installed in the windlass housing 118 * by pushing the windlass spool 116 * upwardly into the open cavity 130 * through the bottom of the windlass housing 118 *. The stub shafts 148 *, 150 *(See FIGS. 23 and 26 ) of the windlass spool 116 * slide up the ramps 136 *, 138 * and push outwardly against the arms 132 *, 134 *, gradually prying them apart as the windlass spool moves upwardly until the windlass spool 116 * clears the tops of the arms 132 *, 134 *, at which point the arms 132 *, 134 * snap back to their original positions, securing the windlass spool 116 * in the housing 118 * as shown in FIGS. 21 , 22 and 26 . The second end of the lift cord 108 * is then extended through the covering 18 * and is secured to the respective lift station 20 * in the bottom rail 16 *.
[0097] The connecting rod 23 * is inserted through both windlass assemblies 112 * and through the splined sleeve 32 * of the locking mechanism 12 *, as shown in FIG. 19 .
[0098] As was discussed with respect to the locking mechanism 12 of FIGS. 3-5 , when the user squeezes the slide tab 70 * and fixed tab 42 * together, the wing that is fixed to the slide tab 70 * moves away from the splined portion of the splined sleeve 32 *, unlocking the locking mechanism 12 * and allowing rotation of the connecting rod 23 * and associated windlass spools 116 *.
The Operation of the Shade 10 * is as Follows:
[0099] To raise the bottom rail 16 *, the user grabs the bottom rail 16 *(See FIG. 20 ) and lifts it up. The spring motor with drag brake 24 * located in the bottom rail 16 * assists in raising the bottom rail 16 *. The spring motor 24 * causes rotation of the spools in the lift stations 20 * in order to wind up any excess lift cord 108 * onto the spools as the bottom rail 16 * is raised. When the user releases the bottom rail 16 *, the drag brake portion of the spring motor with drag brake 24 * holds the bottom rail 16 * in place. Since the spools in the lift stations 20 * rotate together, they keep the bottom rail 16 * horizontal as it travels up and down.
[0100] To lower the bottom rail 16 *, the user pulls down on the bottom rail 16 *. The lift cords 108 * are attached to the head rail 14 *, are cinched tightly around their respective windlasses (or capstans) 116 *, and extend to the spools on the lift stations 20 * in the bottom rail 16 *. Since the locking mechanism 12 * has not been released, the connecting rod 23 * is locked against rotation, as are the windlass spools 116 *, so the intermediate rail 15 * remains stationary. The lift cords 108 * unwind from the lift stations 20 * in the bottom rail 16 *, and the bottom rail 16 * is lowered. Again, once the user releases the bottom rail 16 *, the drag brake portion of the spring motor with drag brake 24 * holds the bottom rail 16 * in position.
[0101] To raise the intermediate rail 15 *, the user squeezes the tabs 42 *, 70 * together, which releases the splined sleeve 32 * for rotation. Since the connecting rod 23 * and the windlass spools 116 * are keyed to the splined sleeve 32 *, they also can rotate. If the user lifts up on the intermediate rail 15 * while squeezing the tabs 42 *, 70 * together, the windlass spools 116 * will rotate in their respective windlass housings 118 *, travelling upwardly along the lift cord 108 * as they transfer a portion of the lift cord 108 * that is above the windlass assemblies 112 * to below the windlass assemblies 112 *, so the intermediate rail 15 * also travels upwardly along the cords 108 *. Once the intermediate rail 15 * is in the desired location, the user releases the tabs 42 *, 70 * of the locking mechanism 12 *, which locks the splined sleeve 32 *, and therefore the connecting rod 23 * and the windlass assemblies 112 *, against further rotation, thereby locking the intermediate rail 15 * in place.
[0102] To lower the intermediate rail 15 *, the procedure is the reverse of that for raising the intermediate rail 15 * described above. The user squeezes together the tabs 42 *, 70 * of the locking mechanism 12 *, which releases the splined sleeve 32 * for rotation, which allows the connecting rod 23 * and the windlass assemblies 112 * to rotate. While squeezing together the tabs 42 *, 70 *, the user pulls down on the intermediate rail 15 *. The windlass spools 116 * rotate in the opposite direction, and the intermediate rail 15 * travels downwardly along the lift cords 108 *. Once the intermediate rail 15 * is in the desired position, the user releases the tabs 42 *, 70 * of the locking mechanism 12 *, which locks the intermediate rail 15 * in place. Since the windlass spools (or capstans) 116 * are tied together by the rod 23 * and rotate together, they keep the intermediate rail 15 * horizontal as it travels up and down.
[0103] It should be noted that the bottom rail 16 * remains in position as the intermediate rail 15 * is raised and lowered, since the position of the bottom rail 16 * is determined by the rotation of the spools on the lift stations 20 *, not by the position of the intermediate rail 15 *.
[0104] The tapered surfaces 152 *, 154 * on the windlass spools 116 * ensure that the lift cords 108 * remain centered on the windlass spools 116 *, and the ribs 145 * on the windlass spools 116 * together with the biasing leg 144 * which presses the lift cord 108 * against the ribs 145 * ensures that the cord 108 * does not slip relative to the windlass spools 116 *, so the cord 108 * serves as a type of indexing mechanism. This helps ensure that the intermediate rail 15 * remains horizontal as it travels up and down along the lift cords 108 *.
Alternate Embodiment of a Windlass
[0105] FIGS. 27-31 show an alternate embodiment of a windlass assembly 112 ** which may be used in the cellular shade of FIGS. 18-20 instead of the windlass assembly 112 *. As best appreciated in FIG. 28 , the windlass assembly 112 ** includes a windlass spool (or capstan) 116 **, a windlass housing 118 **, and a windlass housing cover 119 **.
[0106] The most important difference between this windlass assembly 112 ** and the windlass assembly 112 * described above is that this windlass assembly 112 ** does not have a biasing member 144 *. Instead, and as best appreciated in FIGS. 28 , 29 , 30 and 31 , the windlass housing 118 ** and the windlass housing cover 119 ** each have semi-circular surfaces 156 **, 158 ** which define circumferential guiding grooves 160 **, 162 ** respectively, which tightly guide the lift cord 108 * around the windlass spool 116 **, pressing the lift cord 108 * against the ribs 145 ** (See FIGS. 28 and 31 ) of the windlass spool 116 ** to prevent slippage between the lift cord 108 * and the windlass spool 116 **, that is, to prevent the possibility of the lift cord 108 * surging the windlass spool 116 **.
[0107] The operation of the cellular shade 18 using this second embodiment of a windlass assembly 112 ** is identical to the operation described earlier with respect to the first embodiment of the windlass assembly 112 *.
[0000] Alternate Embodiment of a Cellular Shade with a Drive with a Lock Mechanism
[0108] FIGS. 32-38 depict an embodiment of a cellular shade 10 ′, similar to the shade 10 of FIG. 1 , except that an indexing mechanism 164 ′ is used to rotate the lift rod 22 instead of using a spring motor. (It should be noted that a windlass and cord could be substituted as an alternative indexing mechanism.)
[0109] FIGS. 32 , 33 , and 34 show the cellular shade 10 ′ which includes a top rail 14 ′, bottom horizontal movable rail 16 ′, a cellular shade structure 18 ′, and an anchoring ledge 166 ′. It should be noted that the anchoring ledge 166 ′ may be part of the frame of the window opening and serves the purpose of providing an anchoring point to secure a bead chain 168 ′ which extends from the top rail 14 ′ to the anchoring ledge 166 ′.
[0110] As shown in FIG. 34 , the bottom rail 16 ′ houses a slide lock mechanism 12 , lift stations 20 , and a lift rod 22 , which are identical to the corresponding items in the cellular shade 10 of FIG. 3 . The most important difference is the absence of the spring motor 24 (See FIG. 3 ) which has been replaced by the indexing mechanism 164 ′ (See FIG. 34 ), as explained in more detail below.
[0111] Referring to FIGS. 35-38 , the indexing mechanism 164 ′ includes a bottom rail end cap 170 ′ and a sprocket 172 ′, and utilizes the bead chain 168 ′ to rotate the lift rod 22 when the bottom rail 16 ′ is raised or lowered, as explained later. The sprocket 172 ′ and lift rod 22 cause the lift spools 20 to rotate together, which keeps the rail 16 ′ horizontal as it travels up and down.
[0112] Referring to FIG. 37 , the bottom rail end cap 170 ′ defines ramped approaches 174 ′, 176 ′ to guide the bead chain 168 ′ to the sprocket 172 ′, as may also be appreciated in FIG. 35 . The end cap 170 ′ also includes flat projections 178 ′, 180 ′, 182 ′, and 184 ′ which project inwardly from the end cap 170 ′ and which are used to releasably secure the end cap 170 ′ to the bottom rail 16 ′. Finally, the end cap 170 ′ also includes a support shaft 186 ′ with an enlarged diameter, barbed end 188 ′. The support shaft 186 ′ rotationally supports the sprocket 172 ′, as shown in FIG. 36 .
[0113] FIG. 38 shows the sprocket 172 ′ which includes a plurality of semi-circular, circumferentially-arranged, evenly-spaced and alternatingly-opposed cavities 190 ′ designed to receive and engage the beads of the bead chain 168 ′ as the indexing mechanism 164 ′ is raised or lowered together with the bottom rail 16 ′. The hollow shaft 192 ′ of the sprocket 172 ′ has a non-cylindrical cross-sectional profile 194 ′ which matches up with a similarly shaped cross-sectional profile on the lift rod 22 for positive rotational engagement between the sprocket 172 ′ and the lift rod 22 . The portion of the hollow shaft 192 ′ that is located inside the sprocket “teeth” 190 ′ has a reduced inside diameter portion 193 ′ (See FIG. 36 ), which helps retain the sprocket 172 ′ onto the shaft 186 ′ as describe below.
[0114] To assemble the indexing mechanism 164 ′ to the shade 10 ′, the sprocket 172 ′ is first rotationally mounted to the shaft 186 ′ on the end cap 170 ′ by pushing the sprocket 172 ′ onto the shaft 186 ′ and compressing the barbed end 188 ′ until the reduced diameter portion 193 ′ of the sprocket 172 ′ passes the barbed end 188 ′, at which point the barbed end 188 ′ snaps open to its non-compressed position, locking the sprocket 172 ′ onto the shaft 186 ′, as shown in FIG. 36 . Then, one end of the bead chain 168 ′ is fed through the ramped approach 174 ′ (See FIG. 37 ) and the sprocket 172 ′ is manually rotated to feed the bead chain 168 ′ around the sprocket 172 ′, with the beads on the bead chain 168 ′ engaging the cavities 190 ′ on the sprocket 172 ′. The bead chain 168 ′ wraps around the sprocket 172 ′ and then exits the end cap 170 ′ via the ramped approach 176 ′. The indexing mechanism 164 ′ is then pressed onto the end of the bottom rail 16 ′, with the lift rod 22 being inserted into and engaging the non-cylindrical cross-sectional profile 194 ′ of the shaft 192 ′ of the sprocket 172 ′. The end of the bead chain 168 ′ is then secured to the anchoring ledge 166 ′ such that the bead chain 168 ′ is fairly taut between the top rail 14 ′ and the anchoring ledge 166 ′.
Operation:
[0115] To raise the shade 10 ′ the lock 12 is unlocked, as explained earlier with respect to the embodiment described in FIGS. 1-3 , and the operator manually raises the bottom rail 16 ′ to the desired height. As the bottom rail 16 ′ is raised, the bead chain 168 ′ rotates the sprocket 172 ′ in a first direction, which also rotates the lift rod 22 and the lift stations 20 , so as to gather up the lift cords (not shown) onto the spools of the lift stations 20 in the movable rail 16 ′. When the operator releases (lets go of) the lock mechanism 12 , it locks the lift rod 22 against further rotation, holding the bottom rail 16 ′ where it was released, as described earlier with respect to the shade 10 of FIGS. 1-3 .
[0116] To lower the shade 10 ′, the operator again unlocks the lock 12 and lowers the bottom rail 16 ′ to the desired position. As the bottom rail 16 ′ is lowered, the bead chain 168 ′ rotates the sprocket 172 ′ in the opposite direction which then also rotates the lift rod 22 and the lift stations 20 in the opposite direction, unwinding the lift cords (not shown) from the spools of the lift stations 20 . When the operator releases (lets go of) the lock mechanism 12 , it locks the lift rod 22 against further rotation, holding the bottom rail 16 ′ where it was released.
[0117] FIG. 39 shows yet another embodiment of a cellular shade 10 ″ which is very similar to the shade 10 ′ described above, except that it has two indexing mechanisms 164 ′, one on each end of the bottom rail 16 ′, which ride along their corresponding bead chains 168 ′. Other than this difference, the shade 10 ″ is identical to the shade 10 ′ and operates in the same manner. It should be obvious that other indexing mechanisms may be used instead of the bead chain and sprocket mechanism shown in the figures. For instance, a rack and pinion arrangement may be used in which the rack replaces the bead chain and the pinion replaces the sprocket. Any indexing mechanism that is used to rotate the lift rod without the need for a motor may be used to replace the bead chain and sprocket mechanism described above.
[0000] Two Movable Rail Shade with Automatic Variable Stroke Limiter
[0118] While the embodiment shown in FIGS. 18-20 is one way to arrange for raising and lowering two (or more) movable rails without the addition of a second set of lift cords 110 ′ as in FIG. 16 , another way to achieve this result is shown in FIGS. 40-44 .
[0119] FIGS. 40-44 are schematics of a shade 200 with two movable rails in which the upper rail is suspended by lift cords that extend to fixed points above the upper rail, and the lower rail is suspended by lift cords that extend down from the upper rail.
[0120] With this type of arrangement, the issue arises that if the lower rail lift cords are long enough so the lower movable rail can extend to the bottom of the architectural opening when the upper rail is at the top of the opening, then the lower movable rail may extend below the bottom of the architectural opening when the upper rail moves down. Of course, this is not desirable. For that reason, an automatic variable stroke limiter has been incorporated into this design.
[0121] As explained in more detail later, the automatic variable stroke limiter controls the overall length of the shade 200 so that the bottom rail will not extend beyond a desired position, such as beyond the bottom of the opening, regardless of the position of the upper movable rail.
[0122] Referring to FIG. 40 , the shade 200 includes a head rail 202 , an upper movable rail 204 , and a lower movable rail 206 . Extendable covering materials 208 (See FIG. 44 ) such as a pleated shade material or a plurality of slats supported by ladder tapes may be secured to the upper and lower rails 204 , 206 , so that, when the rails move up and down, they extend and retract the covering materials. For example, in FIG. 44 , the covering material 208 extends between the upper movable rail 204 and the lower movable rail 206 . As another possibility, a first covering material 208 could extend from the head rail 202 to the upper movable rail 204 , and a second covering material 208 could extend from the lower movable rail 204 to the bottom of the architectural opening.
[0123] The upper movable rail 204 houses first and second cord spools 212 , 214 mounted for rotation together on an elongated upper rail lift rod 216 . The cord spools 212 , 214 may be located anywhere along the upper rail lift rod that is desired. For example, if a pleated shade material is extending between the head rail 202 and the upper movable rail 204 , the cord spools 212 , 214 will be located inwardly far enough to ensure that the pleated shade material remains under control and does not “blow out”. If no covering material is extending between the head rail 202 and the upper movable rail 204 , then it may be desirable to move the cord spools 212 , 214 further outwardly so the cords that wrap around them do not interfere with the user's line of sight.
[0124] First and second upper rail lift cords 218 , 220 have their first ends secured to the head rail 202 at fixed points 218 a , 220 a and their second ends secured to the cord spools 212 , 214 . As an alternative, the head rail 202 may be omitted and the first set of lift cords may be secured directly to the frame of the window opening at the fixed points 218 a , 220 a . It also should be noted that the fixed points 218 a , 220 a may alternatively be points on a movable rail located above the upper movable rail.
[0125] In these schematics, the angled arrows on the cord spools (such as the arrow 222 on the cord spool 212 in FIG. 40 ) indicate the extent to which the lift cord is wrapped onto the cord spool. If the lift cord is shown coming off of the respective spool at the end near the tip of the arrow, that means it is fully wound onto that spool. If it is shown coming off the respective spool at the opposite end, that means it is unwound from that spool.
[0126] For example, in FIG. 40 , the lift cord 218 is fully wrapped onto the cord spool 212 , while in FIG. 41 the same lift cord 218 is fully unwrapped from the cord spool 212 , and in FIG. 42 the same lift cord 218 is approximately half way wound onto the cord spool 212 .
[0127] Referring again to FIG. 40 , two counterwrap cord spools 224 , 226 are mounted on the same upper rail lift rod 216 , between the first and second cord spools 212 , 214 , for rotation together with the lift rod 216 . These counterwrap cord spools 224 , 226 may be located anywhere along the lift rod 216 , as desired. Lower rail lift cords 238 , 240 are counterwrapped onto these additional cord spools 224 , 226 (wrapped in the direction opposite to the direction of the wrap on the first and second cord spools 212 , 214 ) so that, as the upper lift rod 216 rotates to wind up the upper rail lift cords 218 , 220 onto the first and second lift spools 212 , 214 , it causes the lower rail lift cords 238 , 240 to unwind from their respective counterwrap spools 224 , 226 . Similarly, as the upper rail lift rod 216 rotates in the opposite direction, to unwind the upper rail lift cords 218 , 220 from their lift spools 212 , 214 , it causes the counterwrapped lower rail lift cords 238 , 240 to wrap onto the counterwrap spools 224 , 226 .
[0128] It should be noted that, while the lift spools 212 , 214 and counterwrap spools 224 , 226 are shown as separate pieces mounted on the upper lift rod 216 and individually movable along that lift rod 216 , it would be possible for two (or even more) of the cord spools to be made as a single piece. Also, while the first and second upper rail lift cords 218 , 220 are shown in this schematic as being separate from the first and second counterwrap cords 238 , 240 , it is understood that the first upper rail lift cord 218 and the first counterwrap cord 238 could actually be a single cord, and, similarly that the second upper rail lift cord 220 and the second counterwrap cord 240 could be a single cord.
[0129] A motor 228 , such as the spring motor 24 of FIG. 3 , also is mounted on the upper rail lift rod 216 to assist in wrapping the lift cords 218 , 220 onto their respective cord spools 212 , 214 when raising the upper movable rail 204 . (The motor 228 could alternatively be a battery-powered electric motor.)
[0130] The shade 200 also includes a lower movable rail 206 which houses two cord spools 230 , 232 mounted on a lower rail lift rod 236 for rotation together with the rod 236 . As with the previous cord spools, these lower rail cord spools 230 , 232 may be located anywhere along the lower rail lift rod 236 . The two lower rail lift cords 238 , 240 have their first ends secured to the counterwrap cord spools 224 , 226 , respectively, and their corresponding second ends secured to the corresponding cord spools 230 , 232 on the lower movable rail 206 . The vertical line 242 shown on the left side of FIGS. 40-43 represents the full length of the window opening on which the shade 200 is installed.
[0131] Referring to FIG. 40 , the shade 200 is shown with both the upper movable rail 204 and the lower movable rail 206 in the fully retracted positions. That is, the upper movable rail 204 is all the way up against the head rail 202 , and the lower movable rail 206 is all the way up against the upper movable rail 204 . When the rails are in this position, the first and second upper rail lift cords 218 , 220 are fully wrapped onto their respective first and second cord spools 212 , 214 . The lower rail lift cords 238 , 240 are fully wrapped onto their respective lower rail cord spools 230 , 232 and fully unwrapped from their respective counterwrap cord spools 224 , 226 .
[0132] The user now may lower the upper rail until it is fully extended, while the lower movable rail 206 remains all the way up against the upper movable rail 204 , as shown in FIG. 41 . In this instance, as the upper movable rail 204 is lowered, the first and second upper rail lift cords 218 , 220 unwrap from their corresponding first and second cord spools 212 , 214 and, as they do so, they cause the upper rail lift rod 216 to rotate, which causes the counterwrap cord spools 224 , 226 to rotate, which causes the lower rail lift cords 238 , 240 to wrap onto the counterwrap cord spools 224 , 226 . Since the lower rail 206 already is abutting the upper rail 204 and therefore cannot move up any further relative to the upper rail 204 , as the user pulls down on the upper movable rail 204 , he is also pushing down on the abutting lower movable rail 206 , so the lower rail lift cords 238 , 240 unwrap from the lower rail cord spools 230 , 232 as they wrap onto the counterwrap cord spools 224 , 226 .
[0133] In FIG. 41 , the upper movable rail 204 is in the fully extended position, with the upper rail lift cords 218 , 220 fully unwound from their spools 212 , 214 . The lower movable rail 206 is abutting the upper movable rail 204 , with the lower rail lift cords 238 , 240 fully wound onto the counterwrap spools 224 , 226 and fully unwound from the lower rail spools 230 , 232 . The total length of the shade 200 matches the length of the opening (depicted by the arrow 242 ), so the lower movable rail 206 is at the bottom of the architectural opening. The lower movable rail 206 cannot be lowered any further relative to the upper movable rail 204 because the lower rail lift cords 238 , 240 are already fully unwrapped from the lower rail cord spools 230 , 232 .
[0134] It might be suggested that the lower rail lift cords 238 , 240 could unwrap from the counterwrap cord spools 224 , 226 to further lower the lower movable rail 206 . However, in order to unwrap the lower rail lift cords 238 , 240 from the counterwrap cord spools 224 , 226 the counterwrap spools 224 , 226 would have to rotate together with the upper rail lift rod 216 and the first and second cord spools 212 , 214 , which would wind the upper rail lift cords 218 , 220 onto the first and second cord spools 212 , 214 to raise the upper rail 204 . Thus, rotating the upper lift rod 216 to extend the lower rail lift cords 238 , 240 would also retract the upper rail lift cords 218 , 220 by the same distance, such that the lower movable rail 206 would remain stationary relative to the head rail 202 ; it would not drop below the length of the opening (depicted by the arrow 242 ).
[0135] Referring now to FIG. 42 , the user has raised the upper movable rail 204 to an intermediate position approximately half way between the fully retracted position (shown in FIG. 40 ) and the fully extended position (shown in FIG. 41 ). The upper rail lift cords 218 , 220 are approximately half way wrapped onto their corresponding first and second cord spools 212 , 214 . The lower rail lift cords 238 , 240 are approximately half way unwrapped from the counterwrap cord spools 224 , 226 on the upper movable rail 204 and are fully unwrapped from the lower rail cord spools 230 , 232 . Again, the lower movable rail 206 cannot be lowered any farther than the bottom of the opening 242 . The lower rail cord spools 230 , 232 already are fully unwrapped. Therefore, any lengthening of the lower rail extension cords 238 , 240 would have to come from their unwrapping from the counterwrap cord spools 224 , 226 . However, these counterwrap cord spools 224 , 226 are tied to the first and second cord spools 212 , 214 by the upper rail lift rod 216 , so any unwrapping of the lower rail lift cords 238 , 240 from the counterwrap cord spools 224 , 226 would only occur along with corresponding wrapping of the upper rail lift cords 218 , 220 onto their corresponding first and second cord spools 212 , 214 , thus shortening these upper rail lift cords 218 , 220 by the same distance the lower rail lift cords 238 , 240 are lengthened. Thus, while the lower movable rail 206 would move some distance away from the upper movable rail 204 , the upper movable rail 204 would be moving the same distance toward the head rail 202 , resulting in the lower movable rail 206 remaining in the same position relative to the fixed points 218 a , 220 a.
[0136] Comparing FIGS. 42 and 43 , it may be appreciated that in both figures the lower rail lift cords 238 , 240 are wrapped halfway onto the counterwrap cord spools 224 , 226 . In FIG. 42 , the lower rail lift cords are fully unwrapped from the lower rail spools 230 , 232 , so the balance of the lower rail lift cords 238 , 240 spans the distance between the upper movable rail 204 and the lower movable rail 206 . When the lower movable rail 206 is raised to the position shown in FIG. 43 , where it abuts the upper movable rail 204 , the counterwrap cord spools 224 , 226 do not move, so no more cord is wrapped onto them. All the excess of the lower rail lift cords 238 , 240 resulting from the raising of the lower movable rail 206 wraps onto the lower rail cord spools 230 , 232 , which, in FIG. 43 , are shown to be half-way wrapped with the lower rail lift cords 238 , 240 .
[0137] In this embodiment, the motors 228 , 234 provide at least enough force to wrap any excess cords onto their respective spools as the movable rails are raised. The motors 228 , 234 may also provide additional force to aid the user in lifting the movable rails so as to reduce the catalytic force required from the user to raise the movable rails. In this embodiment, the forces acting to raise the shade 200 (essentially the force provided by the motors 228 , 234 ) are close enough to forces acting to lower the shade 200 (essentially the force of gravity acting on the components) that the friction and inertia in the system are sufficient to prevent the rail from moving up or down once the rail is released by the user.
[0138] As an alternative embodiment, the number 228 , which represents a motor in the upper movable rail 204 , could instead represent a lock that is operable by the user, such as the lock 12 shown in FIG. 1 . In that case, if the user begins with the shade 200 in the position shown in FIG. 42 , when the user releases the lock in the upper movable rail 204 and raises the upper movable rail from the position shown in FIG. 41 , the lower rail lift cords 238 , 240 will cause the counterwrap spools 224 , 226 to unwind, which will rotate the upper rail lift rod 216 and the upper rail lift spools 212 , 214 , winding up the upper rail lift cords 218 , 220 onto the spools 212 , 214 . Then, when the user releases the upper rail 204 , the lock will hold the upper rail 204 in position. Similarly, if the user begins with the shade 200 in the position shown in FIG. 42 , when the user releases the lock in the upper movable rail 204 and pushes downwardly on the upper rail 204 , the upper rail lift cords 218 , 220 will pull on the upper rail lift spools 212 , 214 , causing those spools to unwind, which, in turn, will cause the lower rail lift cords 238 , 240 to wind up onto the counterwrap spools 224 , 226 .
[0139] Of course, either or both of the upper and lower rails 204 , 206 could have both a motor and a releasable lock functionally connected to their respective lift rods 216 , 236 .
[0140] FIG. 44 shows a shade 200 * which is similar to the shade 200 of FIGS. 40-43 except that it shows the covering material 208 and has brakes 210 , 211 acting on their corresponding lift rods 216 , 236 . The brakes 210 , 211 and their corresponding motors 228 , 234 may be a combination spring motor and drag brake, similar to the spring motor and drag brake 24 * of FIG. 20 to selectively stop the rotation of their corresponding lift rods 216 , 236 . A brake could be used on one or more of the lift rods, as needed, depending upon the forces involved.
[0141] It will be obvious to those skilled in the art that additional movable rails may be added, with each movable rail being suspended from the next adjacent movable rail above it, and with each pair of adjacent movable rails having its corresponding automatic variable stroke limiter to ensure that the overall length of the resulting shade does not exceed a desired length, which is usually the length of the opening to which it is mounted.
[0142] It should also be noted that the lift mechanisms in either of the movable rails may alternatively make use of other known mechanisms that provide for the cord spools to rotate together. For instance, U.S. Pat. No. 7,117,919 “Judkins” shows interconnected spools and spring motors. U.S. Pat. No. 7,093,644 “Strand” shows gear driven spools.
[0143] It also will be obvious to those skilled in the art that additional modifications may be made to the embodiments described above without departing from the scope of the invention as claimed.
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A covering for an architectural opening has a horizontal movable rail supported by cords, with a variety of configurations which allow the movable rail to be moved up and down while concealing the cords.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a linear actuator.
2. The Prior Art
An actuator for industrial purposes of the above-mentioned type is marketed by the U.S. company Warner Electric Brake & Clutch Company under the trade mark ELECTRAC. The actuator is provided with an overload clutch in the form of a ball and ratchet clutch arranged between the spindle and the output side of the reduction gear. This position of the overload clutch also puts a limit on the speed of the actuator because of the high moment load on the clutch. The actuator has been marketed in an unchanged version at least for the last 30 years.
The object of the invention is to provide an actuator of this type with improved properties and greater flexibility in the building of the structure.
SUMMARY OF THE INVENTION
The actuator according to the invention is characterized in that the overload clutch is arranged in connection with the first stage or one of the first stages in the reduction gear, which means that the overload clutch is not subjected to so great moment loads, whereby it may be made more compact and reliable. The lower moment load also allows the speed of the actuator to be increased relative to the known structure by selecting spindles with greater pitches. With the same basic structure up to and including the overload clutch, the actuator may be adapted easily to customer-specific needs with various spindle units and subsequent gear stages. In extension of the transmission line from motor to overload clutch, it is possible to add, as desired, a brake for increasing the self-blocking capacity of the actuator, an adapter for a crank for driving the actuator manually in special situations, and other add-on features.
It should be mentioned for the sake of completeness that DE 103 27 736 A1 to Dewert Antriebs-und Systemtechnik GmbA & Co. KG and EP 1 101 571 A2 to Dana Corporation disclose an actuator for smaller loads with a ball and ratchet clutch. The spindle is driven here by a single worm gear where the clutch is incorporated in the side of the worm wheel and in engagement with the side of a cylinder member fixedly mounted on the spindle against the worm wheel. It should also be mentioned that it is known to provide a frictional clutch in the spindle nut itself, cf. U.S. Pat. No. 4,846,011 to Edward J. Faffney, but this is just for small actuators.
Owing to the smaller torque on the overload clutch because of its position in the structure, it is now easier to use other forms of clutches than just a ball and ratchet clutch. Generally, however, it is sill attractive to use a ball and ratchet clutch which is extremely sturdy. Pressing the cap down by a predetermined force and securing it so that the clutch appears as a unit ready for mounting in the actuator, ensure for one thing a unique overload moment, and for another allow easy testing of them prior to the mounting in the actuator. A finished unit also facilitates the mounting operation of the actuator considerably.
The transition to the subsequent stages in the gearing to the spindle is provided in a simple manner in that the ring with the balls is connected with a shaft member with a gear wheel. This also makes it easy to adapt these stages to customer-specific wishes.
To increase the self-blocking capacity of the actuator, the shaft member may be connected with a brake device, which may e.g., be formed by a screw spring and a claw clutch in engagement with the ends thereof.
In certain situations, it is desirable that the actuator may be driven manually. For this purpose, the shaft member or an extension thereof may be a device to receive a crank or the like through an opening in the cabinet. The actuator may hereby be driven with the crank.
A sturdy and simple fixing of the rear mount and a bearing for the spindle is achieved by a mounting element consisting of two parts mounted in a depression in the cabinet and secured by a nut screwed on to the part of the rear mount which protrudes through the cabinet. The mounting element may be polygonal so that that the rear mount may be set in a desired position.
As an industrial actuator is involved which may be severely loaded, a guide profile for the activation element, in addition to being secured with the end to the cabinet, may be attached additionally to the cabinet by two claws which grip down around the edge on the outer side of the guide profile. Thereby, the guide profile is secured in a simple manner against deflection.
When the electrical control of the actuator is incorporated in the cabinet, a compact structure is achieved, especially when the control is provided on a single printed circuit board which is arranged along the motor.
A particularly reliable and sturdy end stop concept with two end stop switches is achieved by a longitudinally movable element with two arms seated in a slot in a housing, said arms having interposed between them a single spring whose ends additionally engage a stop in the housing. The element is activated directly or indirectly by the spindle nut in the outer positions against the spring force. Use of just a spring, preferably biased, provides for a well-defined movement. When, additionally, the element is allowed to guide towards the outer side of the switches, an even more well-defined activation of the switches is achieved.
The position of the activation element is typically determined by Hall sensors, which are likewise provided on the printed circuit control board, but where an absolute positional determination is desired, it is possible to use a potentiometer constructed as an add-on unit in engagement with down gearing between the safety clutch and the spindle. The construction of the potentiometer as an add-on unit greatly simplifies the mounting without intervention in the rest of the structure.
Further features of the invention will appear from the following embodiment of the invention, which will be described more fully below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the actuator seen in perspective from the front,
FIG. 2 shows the actuator seen in perspective from behind,
FIG. 3 shows a sketch of the basic structure of the actuator,
FIG. 4 shows a longitudinal section through the actuator,
FIG. 4 a shows the same longitudinal section as in FIG. 4 but wherein an Allen screw is used to rotate the claw part of the claw clutch,
FIG. 5 shows the actuator seen directly from the front,
FIG. 6 shows a cross-section along the line K-K in FIG. 4 ,
FIG. 7 shows the actuator seen directly from behind,
FIG. 8 shows the actuator seen directly from below,
FIG. 9 shows a cross-section along the line G-G in FIG. 8 ,
FIG. 10 shows a cross-section along the line 1 - 1 in FIG. 8 ,
FIG. 11 shows a longitudinal section through the actuator,
FIG. 12 shows a cross-section along the line F-F FIG. 11 ,
FIG. 13 shows a cross-section along the line J-J in FIG. 11 ,
FIG. 14 shows a cross-section along the line Q-Q FIG. 11 ,
FIG. 15 shows a cross-section along the line S-S in FIG. 11 ,
FIG. 16 shows the actuator seen from above with a longitudinal section along the line H-H in FIG. 11 ,
FIG. 17 shows an exploded view of the printed circuit control board,
FIG. 18 shows an exploded view of the potentiometer unit, and
FIG. 19 shows a perspective view of a bracket on the front end of the motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As will appear from the drawing ( FIG. 4 ), the main components of the actuator are formed by a cabinet 1 , a reversible electric motor 2 , a reduction gear 3 with several stages, a spindle 4 , a spindle nut 5 , an activation element 6 in the form of a tubular piston, also called the inner pipe, a guide 7 therefor, also called the outer pipe, and finally a rear mount 8 .
The cabinet 1 , which is made of moulded aluminium for strength purposes, has an end cover 1 a which is mounted with screws, and the joint is moreover water-tight ( FIGS. 1 and 2 ). The outer pipe 7 , which is an extruded aluminium pipe having an essentially square cross-section, is mounted with screws, and here, too, the joint is water-tight. On its one side, the outer pipe 7 is provided with two longitudinal grooves 9 a , 9 b , which may be used for the mounting of extra equipment. Further, the pipe 7 is extruded with a screw channel in each corner, which externally forms a longitudinal, projecting strip 10 a - d having a cross-section similar to a segment of a circle. To secure the outer pipe, the outer pipe is pushed during the mounting with the two strips 10 a , 10 b into recesses, intended for the purpose, in the front end of the cabinet 1 , which has two claw-like projections 11 a , 11 b which grip the strips 10 a , 10 b.
The motor 2 is fixed in the cabinet in that a depression is provided internally in this to receive a rubber ring 12 on the rear end of the motor ( FIG. 4 ). A specially configured bracket 13 ( FIG. 19 ) having a central tubular shaft 14 positioned in extension of the motor shaft 15 is secured by two screws on the front end of the motor.
The first stage in the reduction gear is formed by a planetary gear. An extended end of the motor shaft is configured as a sun wheel 17 in engagement with a pair of obliquely toothed gear wheels 18 positioned diametrically opposite ( FIG. 10 ). A planetary wheel 19 in engagement with an orbital wheel 20 is moulded integrally with each gear wheel 18 .
The orbital wheel, which is bell-shaped with a central opening, forms the basis for a ball and ratchet clutch 21 . A ring-shaped disc 22 is secured on the upper side, said disc having a plurality of depressions ( FIG. 11 ), here six, as seats for a corresponding number of balls 23 disposed in through bores in a ring 24 , whose thickness is slightly smaller than the diameter of the balls so that these protrude slightly on both sides of the ring. This ring 24 is secured on a tubular shaft member 25 which, with one end, is seated inwardly over a hub 26 on the orbital wheel 20 . A loose ring-shaped disc 27 , likewise with depressions for the balls, is provided on top of the balls. The balls are kept in engagement with the two ring-shaped discs 22 , 27 by means of a spring force, here in the form of two disc springs 28 , which extend toward the ceiling in an overlying cap 29 which is fixed with the sides to the outer side of the orbital wheel 20 . For this purpose, the orbital wheel is provided with an annular groove. The cap is pressed by a predetermined pressure down over the orbital wheel to bias the disc springs 28 . When the determined pressure is achieved, the side wall of the cap is deformed locally into the groove of the orbital wheel for mutual locking of these with each other. This ensures, in a simple manner, a well-defined maximum torque for the overload clutch independently of manufacturing tolerances of the constituent parts. Under normal conditions of operation, the torque is transferred from the planetary gear via the engagement of the balls with the two ring-shaped discs. When the maximally permissible torque is reached, the balls 23 are forced against the spring force 28 out of their seats in the ring 22 on the orbital wheel 20 , and the connection is interrupted with generation of strong noise as the balls jump into and out of their seats. When the torque drops below the maximally permissible torque, the balls settle again in the seats.
The overload clutch 21 appears as a finished unit ( FIGS. 4 and 11 ) which is applied inwardly over the tubular shaft 14 on the bracket 13 to the front end of the motor and is secured with a screw 30 and a washer in engagement with an internal shoulder in the shaft. The planetary wheels 19 with the obliquely toothed wheels 18 in engagement with the sun wheel 17 are likewise secured on the bracket, there being holes in two opposed walls for stub shafts for the wheels. A gear wheel 31 is secured to the tubular shaft 14 for the further transmission to the spindle 4 .
For spindle types which themselves are not self-blocking, such as ball spindles and spindles with acme threads having a great pitch, or if so needed, the actuator may be equipped with a brake based on a screw spring 32 with inwardly bent ends 33 ( FIGS. 4 and 6 ). The spring extends out to the side wall in a cylindrical insert 34 in the housing. The brake effect is a consequence of friction between the outer side of the spring and the cylindrical wall against which the spring is fixed. A first part 35 a of a claw clutch is mounted on the side of the mentioned gear wheel 31 on the bracket shaft and may be engaged with one spring end 33 . The part has two knobs which are seated in holes in the side of the gear wheel 31 . The other part 35 b of the claw clutch has a tubular part which is seated in the end of the tubular shaft 14 from the overload clutch and is secured with a splined connection. When the motor is active, the one claw part 35 b rotates into engagement with the spring end 33 closest to the rear end of the actuator and contracts the spring, whereby it is disengaged from the side wall, and the actuator may thereby run freely. When the motor stands still, the spring 32 , owing to its bias against the side wall, causes braking. If the spindle 4 , because of a great load thereon, applies a torque to the first claw part 35 a , then this rotates into contact with the spring end closest to the overload clutch and thereby fixes the spring 32 additionally against the side wall and increases the braking force.
Where it is desired to drive the actuator manually, e.g., because of repair of the structure in which the actuator is incorporated, adjustment or general power failure, then the actuator may be driven manually. For this purpose, a screw 36 in the cabinet is removed, which gives access to the other claw part 35 b ( FIG. 4 a ). The screw is an Allen screw, and the same Allen key 36 ′ as is to be used for the screw, fits in a central hexagonal hole 35 b ′ in the claw part 35 b . When the claw part is rotated by the Allen key, the brake spring 32 is loosened, and the actuator may be rotated by the key.
A gear wheel train, which may be adapted to specific wishes, extends from the overload clutch. The gear wheel 31 on the bracket shaft 25 is currently in engagement with another gear wheel 37 on the side of which a smaller gear wheel is provided, which, in turn, is in engagement with a larger gear wheel 38 mounted with a double D-groove connection 39 on the shaft of the spindle. The motor has a number of revolutions of the order of 3000 rpm./min., and the gearing up to and including the planetary gear is of the order of 15. The gearing of the gear wheel train may be changed freely within the given framework. If a great maximum load is desired, the gear wheel train may e.g. be provided with a gearing of the order of 3, which corresponds to a maximum load of the order of 7000 N. In case of smaller loads, the gear wheel train may e.g. be provided with a gearing of the order of 1, which corresponds to a maximum load of the order of 2500 N. The total gearing will thus be of the order of 45 down to 15. With a spindle pitch of 12 mm and the stated motor speeds, this gives a speed of the inner pipe of 800 mm/sec. to 2400 mm/sec.
FIG. 3 of the drawing shows the basic structure of the actuator. The part A is applied as a standard unit, as mentioned, while the part B may be adapted to customer-specific wishes.
The end of the rear mount 8 of the actuator, which is seated in the cabinet, is mounted in a mounting element 40 of hexagonal cross-section which is received in a corresponding recess in the end cover of the cabinet ( FIGS. 6 and 11 ). The rear mount may thus be rotated in steps of 30° for adaptation of its position to the structure in which the actuator is incorporated. The mounting element consists of two parts 40 a , 40 b which are assembled around the rear mount 8 which is secured in that a flange on the element 40 engages a groove in the rear mount. The element 40 also includes a seat for a ball bearing 41 secured via a bushing on the shaft of the spindle. The bearing is secured against a breast on the bushing 43 and a head 44 mounted on the outer end of the shaft. The mounting element 40 with the spindle unit 4 is secured to the cover 1 a by a nut 42 on the part of the rear mount which protrudes from it and is fixed against the outer side of the cover. The rear mount 8 has a cylinder element with an eye 45 , but it will be appreciated that the actuator may be provided with customer-specific rear mounts.
As mentioned before, the outer pipe 7 is an aluminium profile having an external square cross-section and a circular internal cross-section which encloses the spindle 4 and the inner pipe 6 ( FIG. 4 ). The spindle nut 5 is mounted on the end of the inner pipe 6 facing the actuator; the spindle nut is of plastics and may be provided with a safety nut of metal mounted in a recess in the end of the spindle element and secured by tearable elements which are torn if the spindle nut fails, whereby the safety nut takes over the load. The end of the spindle 5 protruding rearwardly from the inner pipe 6 is constructed as a guide bushing 5 a which guides toward the inner side of the outer pipe 7 . To rotationally secure the spindle nut 5 , the part 5 a of the nut is provided with four bosses 5 b which are seated in grooves in the outer pipe 7 intended for the purpose ( FIG. 15 ). Further, a guide bushing 46 , toward which the inner pipe 6 guides, is likewise provided at the end of the outer pipe 7 facing away from the actuator. Finally, an end cover containing a sealing ring with lip sealing for the inner pipe is screwed on to the outer pipe. As an extra safeguard, a mechanical stop, a buffer, in the form of a ring is secured to the outer end of the spindle 4 in the event that the end stop should fail. A mount 48 is secured in the end of the inner pipe 6 , with a shaft part inserted therein, whereby the inner pipe may be secured to the structure in which the actuator is to be incorporated. The mount is configured here as a piston rod eye, but it may be adapted to customer-specific wishes, of course.
A CS printed circuit board 49 with all the components and circuits necessary for the control of the actuator is inserted into the cabinet 1 below the motor 2 ( FIG. 11 ). The CS printed circuit board is arranged such that the actuator may run an DC as well as an AC power supply positioned outside the actuator. A bridge having four FET transistors is used for reversing the direction of rotation of the motor rather than mechanically operating relays like before. The CS printed circuit board extends to the front end of the cabinet which has a gate at each side for a cable 50 , 51 ( FIG. 16 ). In connection with the gates, the CS printed circuit board has a plug 50 a , 51 a for the cables. The one cable 50 is a power supply cable, while the other 51 is a control cable, e.g. for a manual control or for a PLC control. The position of the inner pipe 6 is determined by two Hall sensors 52 arranged at the rear edge of the CS printed circuit board, which is activated by a multi-polar magnet 53 arranged on the side of the gear wheel 37 . The end stop positions of the inner pipe are determined by means of two end stop switches 54 , 55 mounted on the CS printed circuit board. A slide element 56 is arranged around the switches, which are rectangular, said slide element being provided with two frame-shaped openings which guide toward the side of the switches, and which activate these in specific positions ( FIGS. 11 and 17 ). The slide has an angular leg 56 a which extends down behind the spindle nut 5 . When the spindle nut is in its innermost position, it hits the leg 56 a with the rear edge and pulls the slide 56 along to activate the respective switch 54 to interrupt the power to the motor. Further, an elongate plate-shaped rod 57 is secured with one end to the leg, guided in a groove internally in the outer pipe 7 and moved to the front end thereof, said rod having a flap 57 a which extends down in front of a collar on the spindle nut 5 . In the outer position, the collar hits the flap and pulls the rod and thereby the slide element along to activate the other switch 55 , thereby interrupting the power to the motor. The slide element 56 is kept in a neutral position in that it has two fingers 58 a , 58 b which extend through a slot in the CS printed circuit board, on whose other side an elongate housing 59 is mounted, in which a slightly biased helical spring 60 is mounted between the ends. A slot is provided at both ends of the housing for the fingers of the slide element which engage the ends of the spring. The slide element is thereby kept in a neutral position by a single helical spring. When the slide element 56 is moved toward the rear end of the actuator, the spring 60 is compressed against the rear end of the housing by the finger 58 b farthest off at the front end of the actuator, while the finger 58 a farthest off at the rear end of the actuator is displaced in its slot away from the housing 59 . At reversing, i.e. when the spindle nut 5 leaves its innermost end position and runs outwards, the spring tension ensures that the slide element 56 assumes a neutral position, and since the spring 60 is biased, the neutral position is determined uniquely. The same happens at the other switch 55 when the spindle nut 5 is in its outer position.
Instead of Hall sensors, the actuator may be provided with a potentiometer 61 for absolute positional determination of the position of the inner pipe ( FIG. 18 ). This potentiometer is configured as an add-on unit which may be secured with a bushing 66 on a shaft member on the bracket on the front end of the motor. The potentiometer unit is constructed on a chassis 62 with a gearing, where the potentiometer with its rotary shaft 61 a is moved via two O-rings 63 into a tubular shaft member 64 a on a gear wheel 64 . When the potentiometer reaches its outer positions, the O-rings serves as a slip clutch. The last gear wheel 65 in the gearing is in engagement with a gear wheel provided integrally with the gear wheel 37 which drives the gear wheel on the spindle.
An actuator has been described above where a tubular spindle rod guided in a guide profile is secured to the spindle nut. It will be appreciated that the actuator may alternatively be constructed without a piston rod, but where the nut is secured to the structure in which the actuator is incorporated, as is known e.g. from DK 174 457 B1 to Linak A/S.
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A linear actuator includes a reversible electric motor which drives a spindle via a reduction gear with several stages and an activation element connected with it, and an overload clutch in connection with the first stage or one of the first stages in the reduction gear. This is advantageous in terms of structure and load and greater flexibility is achieved in the construction of the structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for the preparation of polydiorganosiloxane having a pendant alkenyl radical in the middle of the molecular chain. More specifically, the present invention relates to a method for the preparation, by nonequilibrium polymerization, of polydiorganosiloxane having an alkenyl radical at least as a pendent radical in the middle of the molecular chain and having freely selected groups at both molecular terminals.
2. Prior Art
Equilibrium polymerization involving the ring-opening polymerization of cyclic trisiloxane under alkali metal catalysis is a procedure known and practiced in the art, such as described by Johannson in U.S. Pat. No. 3,002,951, issued Oct. 3, 1961. Johannson teaches alkali metal polyorganosiloxane salts, such as the compound of the formula ##STR3## can be used to polymerize polydiorganosiloxane cyclic trimers by heating the mixture at temperatures in the range of from 30° C. to 250° C. for 5 minutes to 3 days to produce linear polydiorganosiloxanes. Johannson teaches that with his method that the cyclotrisiloxanes will form high polymers at a rate appreciably greater than the degradation of these high polymers to cyclic siloxanes where these are primarily cyclotetrasiloxanes.
Another method for preparing polymers under nonequilibrium conditions is described in McVannel in U.S. Pat. No. 3,294,740, issued Dec. 27, 1966. McVannel teaches that cyclotrisiloxanes can be polymerized without the need to deactivate the catalyst to stabilize the produced linear polymers. McVannel achieves this by using as the polymerization catalyst alkali metal phenoxides or other phenyl compounds having from one to three MO- groups bonded to the aromatic ring of the formula ##STR4## where R" is a monovalent hydrocarbon radical, a monovalent halogenated hydrocarbon radical, halogen atom, or monovalent hydrocarbonoxy radical, and p is 0 to 3, r is 1 to 3, and M is an alkali metal atom. McVannel teaches that the polymerization temperature can be any temperature including room temperature, but preferably from 50° C. to 200° C. McVannel teaches that traces of water may cause depolymerization and that certain metal oxides can be used to remove the water, such as calcium oxide. McVannel also teaches carrying out the polymerization in an organic solvent.
Razzano in U.S. Pat. No. 4,075,169, issued Feb. 21, 1978, teaches that perfluoroalkylethylene substituted cyclic trisiloxanes can be polymerized to make block copolymers using certain dilithium compounds, such as those of the formulae: ##STR5## where R 3 is hydrogen or a lower alkyl radical of one to eight carbon atoms. Razzano teaches using a solvent promoter at reflux temperatures of 55° C. to 85° C. The block copolymers prepared by Razzano's method are particularly described as containing trifluoropropylmethylsiloxane units and diphenylsiloxane units, but alkylvinylsiloxane units are also suggested.
Bluestein in U.S. Pat. No. 4,287,353 issued Sept. 1, 1981 teaches a method for producing silanol chain-stopped fluorosilicone fluid by reacting at 25° C. to 100° C. cyclic fluorosiloxane trimer, water, a polymerization catalyst such as KOH, and a polyethyleneglycol dimethyl ether promoter. In a more specific method Bluestein teaches using a mixture of fluoro-substituted cyclotrisiloxane and one or more of dimethylsilicone cyclic trimer, methylvinylsilicone cyclic trimer, methylphenylsilicone cyclic trimer, and diphenylsilicone cyclic trimer.
Furthermore, it is also known that nonequilibrium polymerization can be carried out by so-called "living polymerization" using a lithium catalyst. For example, as disclosed in J. Saam, et al., in Macromolecules, Volume 3, Number 1, page 1 (1970), after the ring-opening of hexamethylcyclotrisiloxane using butyllithium, polymerization is terminated by the addition of vinylchlorosilane to afford polydiorganosiloxane having a vinyl group at one terminal. The same method for the preparation of organopolysiloxane is also disclosed in Japanese Patent Application Laid Open [Kokai] Number 59-78236 [78236/84], published May 7, 1984, assigned to Toa Gosei Chem. Ind. Ltd. This method of introducing functional groups through a functionalized polymerization termination agent is generally known as the "termination method."
3. Problems in the Prior Art
However, this prior art suffers from the following problem: in the termination method in living polymerization, the chain-capping reaction at the terminals is conducted when high molecular weights have been reached, and alkenyl thus can be introduced only at the molecular chain terminals. Furthermore, when the introduction of pendant alkenyl into the molecule is attempted by equilibrium polymerization, not only is it not possible to control the position of the alkenyl group, but polydiorganosiloxane completely lacking alkenyl in the molecule is produced as a by-product.
SUMMARY OF THE INVENTION
The present inventors carried out extensive research in order to improve upon the drawbacks to the prior methods as described above, and achieved the present invention as a result. That is, the present invention has as its object the introduction of a method for the preparation, by living polymerization, of polydiorganosiloxane in which an alkenyl radical has been introduced at least as a pendant group in the middle of the molecular chain.
Said goal of the present invention is achieved by means of a method for the preparation of a polydiorganosiloxane with the following formula having a pendant alkenyl radical in the middle of the molecular chain ##STR6## comprising polymerizing cyclic trisiloxane of the formula ##STR7## using an organopolysiloxane alkali metal salt of the formula ##STR8## as the polymerization initiator under nonequilibrium conditions, terminating the polymerization when the desired polydiorganopolysiloxane is obtained, in the above formulas, R 1 is an alkenyl radical; each R is a monovalent hydrocarbon group or monovalent halogenated hydrocarbon group, and these groups may be the same or different; M is an alkali metal; x is an integer having a value from one to ten; R' is the hydrogen atom or a monovalent end-capping group; m is at least x+3; and n is at least x±3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To explain the preceding in detail, the organopolysiloxane alkali metal salt used as the polymerization initiator characteristically has an alkenyl radical bonded to the silicon atom at one molecular chain terminal, while alkali metal replaces the hydrogen atom on the hydroxyl group bonded to this same silicon atom and bonded to the silicon atom at the other molecular chain terminal. The organopolysiloxanes of the organopolysiloxane alkali metal salts are polydiorganosiloxanes. Method for the preparation of these organopolysiloxane alkali metal salts are in fact known. For example, polydiorganosiloxane simultaneously containing silanol and an alkenyl radical can be prepared by the careful hydrolysis of the corresponding alkenyl-containing dichloropolysiloxane in dilute aqueous base solution, and this product is then reacted with an alkali metal compound. Examples of the alkali metal comprising M are lithium, sodium, and potassium. As is generally the case in the living polymerization of organopolysiloxane, the use of lithium is most preferred. Furthermore, the lithuim salt of the silanol group is tyipcally prepared by reaction with alkyllithium, and the use of n-butyllithium is most suitable in the present invention.
In contrast to the general tendency of the ethylenic double bond to undergo polymerization under alkali catalysis, a distinctive feature of the present invention is that the alkenyl radical remains stable throughout the entire process for the preparation of the target polydiorganosiloxane as a consequence of the use of organopolysiloxane with a special structure as a starting material for the polymerization initiator in the present invention.
Considering ease of starting material purification and ease of handling, the alkenyl radical, R 1 , preferably has from two to ten carbon atoms and more preferably has from two to six carbon atoms. These alkenyl groups are exemplified by vinyl, allyl, butenyl, hexenyl, and decenyl. No particular restriction obtains on the location of the double bond in the alkenyl group. It will be advantageous for the double bond to appear at the terminal of the alkenyl radical when considering the reactivity of the obtained polymer. R represents the same or different monovalent hydrocarbon group or monovalent halogenated hydrocarbon group. Considering ease of synthesis, it is preferred that methyl comprise all or most of these groups. Other than methyl, these silicon-bonded groups are exemplified by alkyl groups such as ethyl, propyl, butyl, and pentyl; aryl groups such as phenyl, tolyl, and xylyl; aralkyl groups such as benzyl and phenethyl; and halogenated alkyl groups such as chloromethyl, chloropropyl, and 3,3,3-trifluoropropyl. R can be an alkenyl groups when plural alkenyl groups are to be introduced.
In the organopolysiloxane alkali metal salt, x is an integer having a value from one to ten. The lower limit is one; at a value of zero, one finds that the silanol bonded in the precursor organosilane is unstable and dehydration/condensation immediately occurs. An upper limit of ten is given because it is difficult to purify the initial SiCl-containing organopolysiloxane precursor when ten is exceeded. When ease of synthesis is taken into consideration, the use of organopolysiloxane having values of x of three to six will be preferred.
The cyclic trisiloxane used in the present invention comprises those known as monomers for living polymerization. The silicon-bonded substituent is the same or different and is a monovalent hydrocarbon group or monovalent halogenated hydrocarbon group, and these groups are exemplified as above. Again, R can be alkenyl when plural alkenyl groups are to be introduced into the molecular chain. Taking into consideration ease of handling, it is advantageous for the silicon-bonded substituents R in this cyclic trisiloxane to be methyl or phenyl.
The conditions for the polymerization reaction will vary with the type of monomer used. For example, in the case of the polymerization of hexamethylcyclotrisiloxane, the reaction is preferably carried out in a solvent at a temperature of zero to 30 degrees Centigrade for 1 to 50 hours. Any aprotic solvent which can dissolve the starting materials and polymer product is suitable, and examples are aromatic solvents such as benzene, toluene, and xylene; aliphatic solvents such as hexane and heptane; ether solvents such as tetrahydrofuran and diethyl ether; ketone solvents such as acetone and methyl ethyl ketone; ester solvents such as ethyl acetate and butyl acetate; as well as dimethylformamide, dimethyl sulfoxide, and hexamethylphosphoric acid triamide. Furthermore, good results are often obtained for the use of combinations of two or more of these solvents. For example, when a low-polarity solvent like toluene is used, the addition of a high-polarity solvent such as dimethylformamide, dimethyl sulfoxide, hexamethylphosphoric acid triamide, etc., may be recommended in order to accelerate the reaction.
With regard to polymerization conditions such as the reaction temperature and time, these must be very carefully regulated in order to avoid redistribution reactions, that is the conditions must be nonequilibrium. When the polymerization reaction becomes an equilibrium reaction through redistribution instead of living polymerization, it becomes impossible to retain the pendant alkenyl radical in the middle of the molecular chain. In other words, when an equilibrium reaction occurs, by-product polymers are generated which lack the alkenyl radical or in which the alkenyl radical is present at an unspecified position in the molecule.
The consumption of starting monomer in the polymerization reaction is generally monitored by gas chromatography. When the extent of the reaction has reached a particular value, the reaction is terminated preferably by a neutralization treatment. Termination at any particular percentage for the extent of the reaction depends entirely on the type of starting monomer and target polymer. In general, the extent of the reaction will be 70 to 100% and preferably will be 80 to 95%.
Water must be removed from the solvent and starting monomer to the extent possible prior to the reaction. The presence of water will cause a reduction in the molecular weight of the polydiorganosiloxane product and an increase in the proportion of polydiorganosiloxane without the alkenyl radical. The following methods are recommended for drying the solvent and monomer: distillation; heating; dry gas bubbling; adsorption by active alumina, silica gel, and zeolite; dehydration over alkali metal or their compounds.
In the method of the present invention, the molecular weight of the polydiorganosiloxane product is determined by the ratio between the initiator and the cyclic trisiloxane consumption. Furthermore, because the silanol group undergoes an exchange reaction with alkali silanolate at very high velocities, the silanol-containing organopolysiloxane used as the starting material for the alkali silanolate initiator can be added in order to adjust the molecular weight. Finally, with regard to the alkali metal, it is suitably present in a quantity sufficient to cause the ring-opening reaction.
The neutralization agent use for termination of the reaction may be any compound which reacts with alkali silanolate to form a stable alkali metal salt. Examples are wet carbon dioxide; mineral acids such as hydrochloric acid and sulfuric acid; carboxylic acids such as acetic acid, propionic acid, and acrylic acid; and chlorosilanes such as trimethylchlorosilane, dimethylchlorosilane, dimethylphenylchlorosilane, and dimethylvinylchlorosilane, etc. When the reaction is terminated with wet carbon dioxide, mineral acid, or carboxylic acid, the terminal of the terminated polymer will be the silanol group. When the reaction is terminated by chlorosilane, the silyl group formed by the elimination of chlorine from the chlorosilane becomes the end-capping group. Thus, the reaction is preferably terminated by the addition of acid when the objective is the introduction of the silanol group at the molecular chain terminals. The reaction is preferably terminated by the addition of the properly functionalized chlorosilane when the objective is the introduction of silicon-bonded functional groups. Furthermore, various types of functional groups can be introduced through a dehydrochlorination reaction by the addition of various types of chlorsilane to the silanolterminated polydiorganosiloxane obtained by termination with acid. In these cases, the use of a hydrochloric acid binder such as an amine is recommended. Various functional groups can also be introduced by reacting the silanol-terminated polydiorganosiloxane with the silazane, aminosilane, silylamide, or alkoxysilane.
With regard to the obtained polydiorganosiloxane, m and n have values of at least 4, an alkenyl radical is present in the middle of the molecular chain, and the group R' at the two molecular chain terminals is either a hydrogen atom or a silyl group which contains, for example, an alkyl group, aryl group, alkenyl group, alkynyl group, or hydrogen atom.
The polydiorganosiloxane with an alkenyl radical in the middle of the molecular chain obtained according to the present invention can be used to prepare graft copolymers with other polymers through the use of this alkenyl radical or functional groups present at both terminals. For example, a graft copolymer of polydiorganosiloxane partners can be prepared by reaction with a trimethylsiloxy-terminated methylhydrogenpolysiloxane in the presence of a platinum catalyst. Also, using polydiorganosiloxane having at least 3 functional groups prepared according to the present invention, one can readily obtain elastomers or resins by reaction with crosslinking organopolysiloxane or other polymers.
The present invention will be explained in the following with reference to illustrative examples and the scope of the invention is properly delineated in the claims. In these examples, Me=methyl, Vi=vinyl, and Hex=Vi(CH 2 ) 4 --. The properties were measured at 25 degrees Centigrade unless specified otherwise. The solvents and reagents were dried prior to the experiments to a negligible water content.
EXAMPLE 1
A hydrolysis mixture of 500 g water, 200 g ice, 100 g dietyyl ether, and 84.5 g sodium bicarbonate were placed in a stirrer-equipped four-neck flask. A mixture of 140 g ClMeViSi(OSiMe 2 ) 3 Cl and 120 g diethyl ether was added dropwise with vigorous stirring to the hydrolysis mixture. After liquid separation, the other phase was dried over anhydrous sodium sulfate. Removal of the ether by evaporation afforded HOMeViSi(OSiMe 2 ) 3 OH (OH-1).
5 g OH-1, 40 mL tetrahydrofuran, and 20 mL 1.53 N n-butyllithium solution in hexane were placed in a stirrer-equipped four-neck flask. Mixing produced a solution of the lithium salt of OH-1, LiOMeViSi(OSiMe 2 ) 3 OLi. This is denoted as OLi-1 (concentration by titration=0.55 N).
5.58 mL (3.07 meq) OLi-1, 75 g hexamethylcyclotrisiloxane, and 75 g tetrahydrofuran were placed in a stirrer-equipped four-neck flask, and a reaction was carried out for 4 hours at 25 degrees Centigrade under a nitrogen atmosphere. After the extent of the reaction has reached 89% according to gas chromatography, the reaction mixture was neutralized with wet carbon dioxide. After filtration, the solvent and unreacted starting materials were removed by distillation in vacuo to produce a polymer (VP-1). Based on the results of gel permeation chromatography (GPC), Fourier-transforms nuclear magnetic resonance (FT-NMR), and quantitative vinyl group analysis by iodemetry, VP-1 was identified as a polydiorganosiloxane with the following average formula:
HO(Me.sub.2 SiO).sub.260 MeViSiO(Me.sub.2 SiO).sub.263 H.
The dispersion in the molecular weight distribution (M w /M n ) of the polymer was 1.3 by GPC.
EXAMPLE 2
0.34 mL (0.19 meq) OLi-1 as prepared in Example 1, 0.473 g OH-1 (1.45 mmol), 75 g hexamethylcyclotrisiloxane, 75 g toluene, and 1.5 g diemthyl sulfoxide were placed in a stirrer-equipped four-neck flash, and a reaction was carried out for 2.5 hours at 23 degrees Centigrade under an argon atmosphere. After the extent of the reaction had reached 83% according to gas chromatography, neutralization was carried out using acetic acid. After filtration, the solvent and unreacted starting materials were removed by distillation in vacuo to produce polymer (VP-2). Based on the results of GPC and FT-NMR, VP-2 was identified as a polydiorganosiloxane having the following average formula.
HO(Me.sub.2 SiO).sub.275 MeViSiO(Me.sub.2 SiO).sub.278 H
The dispersion in the molecular weight distribution (M w /M n ) of the polymer was 1.13 by GPC.
EXAMPLE 3
HOMeHexSi(OSiMe 2 ) 3 OH (OH-2) was synthesized by the procedure described in Example 1 for OH-1. Again as in Example 1, a solution of the lithium salt of OH-2 (OLi-2, concentration by titration=0.54 N) was prepared from OH-2 and n-butyllithium. 20.34 mL (0.184 meq) OLi-2, 3.93 g OH-2 (10.3 mmol), 75 g hexamethylcyclotrisiloxane, 75 g toluene, and 2.5 g dimethyl sulfoxide were placed in a four-neck flask equipped with a stirrer and thermometer, and the mixture was stirred at 20 degrees Centigrade for 8 hours. After the extent of the reaction had reached 81% according to gas chromatography, neutralization was carried out using set carbon dioxide. After filtration, the solvent and unreacted starting materials were removed by distillation in vacuo to produce a polymer (VP-3). Based on the results of GPC, FT-NMR, and iodometry, VP-3 was identified as a polydiorganosiloxane of the following formula:
HO(Me.sub.2 SiO).sub.48 MeHexSiO(Me.sub.2 SiO).sub.51 H
The dispersion in the molecular weight distribution (M w /M n ) of the polymer was 1.21 by GPC.
50 g VP-3 (6.87 mmol), 2.0 g dimethylvinylchlorosilane (16.5 mmol), 3.03 g triethylamine (30 mmol), 50 g toluene, and 40 g tetrahydrofuran were placed in a stirrer-equipped four-neck flask, and a reaction was carried out at room temperature for 24 hours. After filtration, the solvent and unreacted starting materials were removed by distillation in vacuo to produce a polymer (VP-4). Based on the results of analysis by GPC, FT-NMR, and iodometry, VP-4 was identified as a polydiorganosiloxane of the following formula:
Vi(Me.sub.2 SiO).sub.49 MeHexSiO(Me.sub.2 SiO).sub.51 SiMe.sub.2 Vi
EFFECTS OF THE INVENTION
The method of the present invention for the preparation of polydiorganosiloxane provides for the preparation of polydiorganosiloxane having a pendant alkenyl radical in the middle of the molecular chain and freely selected groups at both molecular chain terminals. Such polydiorganosiloxanes can be used as a starting material for silicone rubber, as a starting material for novel grafted organopolysiloxane, and as a copolymerization partner with resins and plastics other than organopolysiloxanes. Accordingly, one can assign a high degree of utility to these polydiorganosiloxanes in the field of chemical technology.
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Polydiorganosiloxanes which have a pendant alkenyl radical in the middle of the molecular chain are prepared by a nonequilibrium, living polymerization of cyclic trisiloxanes using an organopolysiloxane alkali metal salt of the formula ##STR1## where M is lithium, sodium, or potassium, which takes place under substantially anhydrous conditions, and the polymerization is terminated with an end-capping reaction to produce a polydiorganosiloxane of the formula ##STR2## where R 1 is an alkenyl radical. These polymers can be used to make graft copolymers and can be made more functional when the ends are capped with functional groups.
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This invention pertains to steam turbines operable in a steam bypass mode and, in particular, to a steam flow system and to a steam flow method which permit bypass mode operation in a manner that avoids the overheating and excessive thermal stresses that otherwise result from rotation loss heating.
BACKGROUND OF THE INVENTION
Operating a large electric utility type steam turbine in a steam bypass mode entails the use of bypass valving systems to shunt steam around sections of the turbine whenever the load demand is such that the boiler is producing more steam than is required to support the load. The principal advantage of the bypass mode of operation is that the boiler may be operated at high level of output independently of the turbine's demand for steam which, in turn, is a reflection of demand for electrical energy. Other advantages inherent in a bypass mode of operation include the ability to quickly follow changes in load demand, the ability to more rapidly start the turbine, and the avoidance of boiler tripout upon sudden loss of load.
A problem encountered in the bypass mode of operation, however, and for which a solution has been sought by those skilled in the art, is the potentially damaging increase in temperature which can occur within the turbine sections as a result of rotational loss heating under no-load and low-load operating conditions. This heating effect, also commonly referred to as windage loss heating, is due to the friction between the steam and the turbine rotor blading occurring at or near synchronous speeds, and is pronounced in the bypass mode of operation because of the high back pressure resulting from the bypass steam flow and because of the relatively low flow of steam required to pass through the turbine when it is under very light load. The severity of the problem depends upon the rated power capacity of the turbine; the greater the power capability the higher the turbine temperatures are likely to become during these low load conditions. Windage losses at the exhaust end of the high-pressure (HP) section of a turbine can elevate the temperature to an extent that the turbine structure is subjected to excessive thermal stress, resulting in permanent structural damage.
The problem is accentuated by the fact that, as the turbine takes on more load and therefore more steam from the bypass system, the windage losses will be cut sharply and the turbine actually cooled by the increased steam flow. This sudden reversal of temperature puts a severe and sharp stress upon the turbine metal and may cause permanent deformation or cracking thereof.
With the present trend to larger, more efficient power-generating units, and with heightened interest in the bypass mode of turbine operation, solutions to the problem of rotational loss heating have been eagerly sought. However, an entirely satisfactory solution to the problem has not heretofore been available.
One previous approach to the problem, as exemplified by U.S. Pat. No. 4,132,076 entitled "Feedback Control Method for Controlling the Starting of a Steam Turbine Plant" has been to devise a rather elaborate and complicated feedback control system with which a greater quantity of steam is caused to pass through the high-pressure section of the turbine than through the lower pressure sections. This is accomplished by having a control system in which one subsystem provides control of the bypass and steam admission valves at low and no-load conditions and a second subsystem which provides control at elevated loading. While there is thus provided an acceptable means for dealing with the problem of rotational loss heating, other and simpler methods and apparatus are desired.
Accordingly, it is an object of applicants' invention to provide a simple, satisfactory solution to the problem of rotational loss heating such as may occur in steam turbines during bypass mode operation.
SUMMARY OF THE INVENTION
The method and apparatus of the present invention limit and control rotational loss heating by admitting a portion of the high-pressure bypass steam to the lower pressure sections of the turbine in sufficient quantity to provide motive fluid for driving the turbine. Simultaneously, a second portion of the steam bypassed around the high-pressure section is admitted to the high-pressure sections of the turbine in a reverse-flow direction to pass backwards therethrough. In other words, the turbine is driven entirely by the portion of HP bypass steam admitted to the lower pressure sections of the turbine while a second portion of the HP bypass steam is admitted in reverse-flow to the HP section of the turbine to create a braking and cooling effect. The flows may be proportioned to prevent overheating in both the HP and lower pressure (LP) sections.
A reverse-flow valve is provided to admit the reverse-flow, or cooling steam, to the HP section of the turbine and a ventilator valve is provided to discharge the cooling steam to the atmosphere or to the condenser associated with the turbine.
When load on the turbine has been increased to the point at which steam flow in the forward direction of the HP section can be established without excessive temperatures in either the HP or LP sections, the ventilator valve is closed and the conventional control valve will open. This valving action occurs in a relatively short time, i.e., a matter of seconds.
BRIEF DESCRIPTION OF THE DRAWING
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as the invention, the invention will be better understood from the following description taken in connection with the accompanying FIGURE which schematically illustrates the method and flow system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The FIGURE illustrates the invention within the context of an electric power-generating station in which a boiler 10 supplies steam as motive fluid for a turbine 12 comprised of a high-pressure (HP) turbine section 14, an intermediate pressure section (IP) 16, and low-pressure (LP) section 18. The turbine sections 14, 16, and 18 are shown tandemly coupled to each other and to electric power generator 20 by a shaft 22, although many other turbine shaft arrangements are possible.
With turbine 12 operating under a substantial load and able to utilize the entire output of boiler 10, the steam flow path is as follows. From boiler 10 and conduit 24, steam enters HP section 14 through valve 26. Although shown schematically as a single valve to illustrate and explain the invention, valve 26 is a composite representation of a plurality of valves, including the stop and admission control valves commonly used in practice and necessary for turbine operation. Steam exhausted from HP section 14 passes through check valve 28, steam reheater 30, and into IP section 16 through valve 32. Valve 32 is a composite representation of the usual stop and intercept valves which control the flow of steam to the IP section 16. Steam exhausted from IP section 16 passes by crossover conduit 34 to the LP section 18 of turbine 12 and then is exhausted to condenser 36 for ultimate recycle to the boiler 10. In each section 14, 16 and 18 of turbine 12, a portion of the energy contained in the steam is released to drive the turbine 12 and its load as represented by electrical generator 20.
At lesser loads, whenever the demand for electrical energy from generator 20 is less, and with boiler 10 producing steam in excess of that required to support the load, the excess steam is shunted around the turbine 12 by high-pressure (HP) bypass system 38 and a lower pressure bypass system 40. The HP bypass system 38 includes HP bypass valve 42 and desuperheater 44; the lower pressure bypass system 40 includes bypass valve 46 and desuperheater 48. In the bypass mode of operation, the portion of steam from boiler 10 required for the HP section 14 is taken from conduit 24 and the balance passes around the HP section 14 by way of HP bypass 38. The steam thus bypassed and that exhausted from the HP section 14 are rejoined to flow through reheater 30.
Steam from the reheater 30 is similarly split, with the portion necessary for IP section 16 and LP section 18 being taken through valve 32 and the balance being bypassed through bypass system 40 to condenser 36.
In the bypass mode of operation as described above, and whenever the turbine 12 is being started up, or whenever it is supporting a small load, most of the steam is bypassed and relatively little is taken as motive fluid for the turbine 12. Under these conditions a considerable back pressure is created at the low temperature side of reheater 30 and on the exhaust end of HP section 14. The combination of high pressure and low steam flow in the HP section 14 gives rise to the rotational loss heating which is potentially destructive to the turbine 12. In this situation, the spinning turbine blades are imparting energy to the steam rather than extracting energy therefrom. The temperature of the steam in the HP section 14 may thus be increased to a point at which excessive thermal stress to the turbine results.
According to the present invention, to eliminate this effect, (which occurs under low and no load conditions, including turbine startup), valve 26 is kept closed to prevent the forward flow of steam through HP section 14 and the output of turbine 12 is supported by steam admitted to IP section 16 and LP section 18 through valve 32. Simultaneously, reverse flow valve 50 is open to admit a portion of the steam from the HP bypass system 38 to the HP section 14 to flow therethrough in a reverse-flow direction. Ventilator valve 52 is also open to discharge the reverse-flow steam from the HP section 14 to the condenser 36. However, since the reverse steam flow is relatively small it may be simply disposed of without significant economic loss. The cooling steam path through reverse-flow valve 50 and ventilator valve 52 comprises a cooling steam system or subsystem and may be so referred to herein.
The cooling steam, passing backwards through the turbine HP section 14, is effective to remove the rotational loss heating and prevent any likelihood of overheating. In the FIGURE, arrows indicate the steam flow paths as the cooling steam system is being utilized.
It will be recognized that the reverse flow of steam results in a temperature gradient, or temperature distribution, across the HP section 14 that more nearly matches the temperature distribution which the HP section 14 has under normal, loaded conditions. That is, as the HP section 14 is producing power and the steam flow is in the forward direction, the temperature gradient is negative along the steam path. A similar gradient is established under reverse-flow conditions and, in fact, the reverse steam flow may be adjusted to vary the gradient. This is highly advantageous since the sudden cooling shock which would ordinarily accompany increased steam flow with increasing load is avoided.
Desuperheater 44 provides cooling of the steam in the HP bypass system 38 and therefore aids the reverse flow cooling effect. In a preferred embodiment of the invention, the temperature within the HP section 14 is controlled by varying the temperature of the cooling steam through regulation of the desuperheater 44.
In another embodiment, the ventilator valve 52 is an adjustable, or a control-type valve, and is used to control the reverse flow of steam and therefore the maximum temperature and the temperature gradient across HP section 14. In yet another embodiment, reverse flow valve 50 is an adjustable or control-type valve to control the flow of steam and the resulting temperature within HP section 14. Although each embodiment of the invention is not specifically illustrated separately, those of ordinary skill in the art will clearly recognize the adaptations required to achieve such embodiments.
The lower pressure sections 16 and 18 of turbine 12 are also subject to overheating due to rotational loss heating under very low steam flow conditions. Such heating is also overcome by the present invention. This is achieved by increasing the flow of steam in the IP and LP sections 16 and 18 by an amount sufficient to reduce the rotational loss heating therein and offsetting the increased power produced by the added flow by increasing the reverse flow of steam to HP section 14. Since the reverse-flow steam has a braking effect on the turbine 12, the net output power is unchanged.
Operation
It will be useful to describe the startup procedure of the power plant as illustrated in the FIGURE to provide further description of the principles and advantages of the invention.
With the turbine 12 shut down and boiler 10 producing a large quantity of steam, valve 26 is closed and bypass valves 42 and 46 are open in order to bypass all the steam to the condenser 36. Startup of the turbine 12 is begun by opening valve 32 to admit steam to the lower pressure sections 16 and 18. Valve 26 remains closed and the entire turbine output is thus generated by the steam admitted to the lower pressure sections 16 and 18 of the turbine 12. Simultaneously, desuperheated steam is admitted to the HP section 14 through the reverse-flow valve 50 and flows backwards through the HP stages taking away the windage losses. This steam passes through a ventilator valve 52 ahead of the first stage of the HP section 14 and is then dumped to the condenser 36. The reverse-flow, cooling steam increases in temperature as it flows through the HP section 14. The actual temperature distribution can be varied by admitting more or less cooling steam, or preferably, by varying the temperature of the cooling steam through control of desuperheater 44.
When load on the turbine 12 is increased to the point at which steam flow in the forward direction of the HP section 14 can be established without excessive temperatures occurring either in the HP section 14 or the lower pressure sections 16 and 18, then in a relatively short time (a matter of seconds) the ventilator valve 52 can be closed and valve 26 opened. The opening of valve 26, of course, will be sufficient to allow enough steam to flow into the HP section 14 to prevent excessive temperatures.
While a preferred and alternative embodiments of the invention have been described, it will occur to others of ordinary skill in the art to make adaptations of this invention which will remain within the concept and scope thereof and will not constitute a departure therefrom. Accordingly, it is intended that the invention be not limited by the details in which it has been described but that it encompass all within the purview of the following claims.
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Method and apparatus to limit and control rotational loss heating such as occurs in a large steam turbine in the bypass mode of operation under no-load and low-load operating conditions. According to the invention, a portion of the high pressure bypass steam is admitted to the lower pressure sections of the turbine to provide motive fluid for driving the turbine while, simultaneously, a second portion of the high-pressure bypass steam is admitted to the high-pressure section of the turbine in a reverse-flow direction to pass backwards therethrough and limit the rotational loss heating. The two flows may be proportioned to control rotational loss heating in both the high-pressure and lower pressure sections of the turbine. A reverse-flow valve and a ventilator valve are provided for routing the reverse-flow of steam.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my patent application Ser. No. 556,760 filed July 23, 1990 titled Dispersal Valve and Canister.
FIELD OF THE INVENTION
This invention relates to dispersal valves and more specifically to improvements to dispersal valves and removable canisters for dispersal valves.
BACKGROUND OF THE INVENTION
A valve with a canister for dispersing materials into a liquid is shown in U.S. Pat. No. 4,662,387. Such dispersal valves are used to disperse a solid dispersant into a liquid. Typical applications are to disperse chlorine or bromine into a water supply to disinfect the water. In general, the prior art in line dispersal valve controls the rate of dispersant by controlling the amount of water flowing through a canister in the dispersal valve. The canister includes a removable top for inserting additional dispersant material in the canister. The present invention is an improvement to the dispersal valve shown in U.S. Pat. No. 4,662,387 by providing more precise control of the rate of dispersal over an extended period of time as well as providing a visual indication of when the dispersant in the canister is used up.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 4,731,036 shows an indicating means using a magnet to indicate the presence of metallic objects in the water.
U.S. Pat. No. 3,258,968 shows a liquid level indicating device that uses a magnetic switch and a float.
U.S. Pat. No. 4,552,090 showing a floatable follower with a magnet and a switch to indicate the position of the follower.
U.S. Pat. No. 4,763,685 shows a floating dispersal member that tips over when the dispersant is dissolved.
U.S. Pat. No. 3,915,340 shows an indicator for a dispensing device for a copier that uses a magnetic switch.
U.S. Pat. No. 885,675 shows a liquid level indicator that uses a magnet that rotates a second magnet on the outside of the container. A spiral groove in the side of the container and a float coact to causes the internal magnet to rotate the outside magnet to provide an indication of whether the container is full.
U.S. Pat. No. 4,208,376 shows an indicator that is mechanical pushed up to a visible state from a a recess.
U.S. Pat. No. 1,469,065 shows a sight glass to permit a user to observe and indicator in a fertilizer spreader.
U.S. Pat. No. 2,069,179 shows a pointer that follows the level of the liquid in the container.
Offenlegungsschrift 2210827 shows an indicator that with a pointer that moves in response to the weight on a spring.
U.S. Pat. No. 4,750,512 shows a fertilizer container with the rate of solution dependent on the the water flow.
U.S. Pat. No. 4,010,708 shows a an indicator for a helicopter blade.
U.S. Pat. No. 4,662,387 shows an inline dispersal valve with a keyed cannister to disperse material into a liquid.
BRIEF DESCRIPTION OF THE INVENTION
Briefly, the present invention comprise a dispersal valve and canister with the dispersal valve resiliently supporting a loaded canister in the dispersal valve. The canister includes a visual indicator to permit a user to determine when the canister needs to be replaced with the canister having an air pocket for retaining at least a portion of the dispersant above the liquid in the dispersal valve so that the amount of dispersant in contact with the liquid remains substantially constant during a substantial portion of the time the dispersal valve is dispersing material into the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described by reference to the drawings in which:
FIG. 1 is a pictorial view of a dispersal valve;
FIG. 2 is a partial cut-away view of the dispersal valve and canister;
FIG. 3 is a top sectional view of the dispersal valve;
FIG. 4 is a partial sectional view of the bottom of the dispersal valve;
FIG. 5 is an alternate embodiment partial sectional view of the bottom of the dispersal valve;
FIG. 6 is a partial cut-away view of an alternate embodiment inside a sectional cut-away dispersal valve;
FIG. 7 is a partial cut-away view of the emptied canister and the dispersal valve;
FIG. 8 is a front view of a further alternate embodiment of a canister;
FIG. 9 is a partial side view of the canister of FIG. 8;
FIG. 10 is a partial side view of the top of the canister of FIG. 8 and the top of the dispersal valve;
FIG. 11 is a graph showing dependent variable, dispersal rate, along the Y-axis versus the independent variable, time, along the X-axis;
FIG. 12 is a top view of an end spout for a canister;
FIG. 13 shows a partial cutaway view of a side elevation of a canister containing a granular dispersant.
FIG. 14 shows a pictorial view of an alternate embodiment of a canister;
FIG. 15 shows a partial cross sectional view of the canister of FIG. 14 and a dispersal valve;
FIG. 16 shows a cross sectional view without the dispersant material in the canister taking along lines 16--16 of FIG. 17;
FIG. 17 shows a cross sectional view of the canister of FIG. 14 and a dispersal valve;
FIG. 18 shows a partial cross section view of the trough located in the canister of FIG. 15;
FIG. 19 shows a cross sectional view of the canister of FIG. 14 and a dispersal valve with the canister containing granular material;
FIG. 20 shows a pictorial view of the keypost used in the dispersal valve;
FIG. 21 shows a bottom view of the keypost of FIG. 20;
FIG. 22 shows a sectional view of the keypost of FIG. 20; and
FIG. 23 shows a bottom view of the canister of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 reference numeral 10 general identifies a dispersal valve for controllable dispersing a solid dispersant such as bromine or chlorine tablets into a liquid. Dispersal valve 10 includes a housing 17 having a removable cover 11 fastened thereto by threads or the like. Located on top of cover 11 is an air vent 16 that can be opened to bleed air from dispersal valve 10. Located on top center of cover 11 is a visual indicator means 15 comprising an outer transparent, hollow sight member that permits an observer to peer through the sight member to determine if any visual indication means is present in the sight member.
Dispersal valve 10 includes a fluid inlet 13 on one side of housing 17 and a fluid outlet 12 located on the opposite side of housing 17. A rotary plug 14 permits a user to control the amount of fluid that can be directed through the dispersal valve. An example of a dispersal valve with a rotatable plug for controllable directing fluid through the dispersal valve to disperse materials such as bromine and chlorine into swimming pools, hot tubs, spas, and the like is shown in greater detail in U.S. Pat. No. 4,662,387.
FIG. 2 shows a partial cross sectional view of a dispersal valve 10 containing a removable, buoyant canister 30 that is filled with solid disk shaped disperant tablets 9. Canister 30 is displaceable upward in response to the dispersing of solid dispersant tablets 9 in canister 30. The upward displacement of canister 30 is used to provide a visual indication that the dispersant in canister 30 has been depleted and that the empty canister 30 should be replaced with a full canister.
Dispersal valve 10 comprises an interior chamber 45 for holding removable canister 30. In order to permit removal of canister 30 from housing 17 there are provide threads 20 on housing 17 and threads 21 on cover 11. The thread connection between housing 17 and cover 11 permits the user to remove cover 11 and replace an empty canister with a full canister.
The lower portion of chamber 45 includes a fluid outlet port 51 extending upward into a fluid inlet cap 32 which is located in the bottom portion of canister 30. Fluid inlet cap 32 includes a grid work to support and prevent disperant tablets 9 from falling out of canister 30. A plurality of openings 31 in fluid cap 32 permits liquid 42 to circulate through and around dispersant tablets 9. Located around port 51 is a resilient member 52 comprising a compression spring that provides a normal upward force on an annular lip 32a of canister 30. FIG. 2 shows canister 30 filled with disperant tablets 9 with the weight of canister 30 and dispersant tablets 9 compressing spring 52 downward to hold the inlet cap 32 in fluid communication with outlet port 51.
Located on the side of canister 30 is a fluid outlet port 33 that permits liquid 42 entering canister 30 to be discharged to a fluid inlet port 53 located in the bottom of chamber 45. Reference numeral 41 generally identifies the interface between the air and the liquid 42 in dispersal valve 10. The arrows indicate the general flow of liquid through the interior of valve 10 and canister 30.
FIG. 2 shows that there are two distinct compartments in canister 30, a lower compartment 30b filled with liquid 42 and solid dispersant tablets 9 and an upper compartment 30a filled with a fluid such as air or a gas and additional dispersant tablets 9. The upper compartment comprises an air pocket where air remains trapped since there is no opening in the top portion of canister 30. FIG. 2 shows the dispersant valve with a full canister with the dispersant tablets 9 located in both lower compartment 30b and upper air pocket 30a. In the present invention the utilization of a canister that contains an air pocket prevents all of the liquid dissolvable dispersant tablets 9 from being in contact with liquid 42. Consequently, only those tablets 9 that are located in liquid 42 can be dissolved and carried away by liquid 42. As the tablets 9 dissolve in the liquid 42 the fresh, undissolved tablets in upper air compartment 30a fall into the liquid 42 in compartment 30b and begin to dissolve. Thus with the present invention and the utilization of an air compartment in the top of the canister, one prevents all of the tablets 9 from simultaneously dissolving or dispersing into liquid 42. By limiting the amount of tablets in contact with liquid 42 one can control the rate at which the tablets 9 disperse into liquid 42 since the dissolution rate of dispersant is directly proportional to the amount of dispersant tablets in contact with the liquid. Thus the present invention by providing an air chamber in the canister 30 can control the rate of dispersant by maintaining the same amount of dispersant tablets in the liquid even though the dispersant tablets are being continually dissolved. One can also disperse material at a lesser rate. For example if one wanted to use valve 10 to disperse dispersant at a much slower rate one would use a canister with an air pocket to limit the amount of liquid in contact with the dispersant tablets. An advantage of the present invention is that not only can the rate of dispersing be slowed down by using a canister with an air pocket but the rate of dispersant remains substantially constant while the dispersant tablets 9 are being dissolved and carried away by liquid 42 since the tablets that are dissolved are being continually being replaced by fresh tablets 9 that fall from upper compartment 30a into lower compartment 30b.
One of the benefits of the present invention with the use of an air pocket is that it has been found to limit the amount of gas in the canister that results from the dissolution of the solid dispersant. For example, if chlorine tablets are used one will limit the amount of chlorine gas that escapes from the system in comparison to dispersal valves that have open canisters since the canister and its air pocket limit the amount of space for chlorine gas in the dispersal valve. This advantage is particular true in applications where the dispersal valve is located at a lower level than the pool or spa. In these instances the water flows over the top of the canister as the system is shut down but it does not flow into the air pocket.
In normal dispensing operation of dispersal valve 10 liquid from valve inlet 13 enters canister 30 through passages 50 in rotary plug 14 and openings 31 in fluid cap 32. The liquid flows around the tablets 9 in the lower portion of canister 30 and out through the side opening 33. As the liquid flows around tablets 9 depending on the type of tablets the tablets will either dissolve or erode and be carried away by liquid 42. From canister outlet port 33 liquid flows through port 53 and openings 59 in rotary plug 14. Liquid 42 then flows back and into valve outlet port 12 to the pool, spa, or other liquid which requires treatment.
FIG. 3 shows a top sectional view of the lower portion of valve 10 showing the location of fluid port 55 with spring 52 extending around port 55. Although port 55 is shown as being circular, port 55 could be elliptical or other shape as long as port 55 matches up with the inlet port to canister 30 to thereby direct liquid 42 into canister 30 as the canister moves upward in chamber 45. The fluid port 53 shows openings 59 in plug 14 that permit liquid to flow back into the chambers located in the lower portion of valve 10. Similarly, the fluid port 55 shows openings 50 in plug 14 to permit liquid to enter canister 30.
FIG. 4 shows a side sectional view showing the diversion of a portion of the liquid to the canister and the relative direction of liquid flowing from inlet port 13 to outlet port 12. Located in the lower portion of valve 10 is a fluid outlet chamber 12a and a fluid inlet chamber 13a. Located on the bottom portion of valve 10 is a venturi ramp 61 having a first ramped surface 61a and a second ramped surface 62b that coacts with extension lip 62 to smoothly and gradually decrease the area for fluid to pass through opening 60. The purpose of venturi ramp 60 is to provide a smaller region or opening 60 for the liquid to flow through and consequently increase the velocity of the liquid while decreasing the local pressure on the fluid. It has been found that if a venturi ramp 61 is located at the bottom of valve 10 it generally renders the volume of the air in compartment 30a relatively insensitive to changes in downstream pressure located beyond the outlet port 12. Consequently, if the volume of the compressed air in canister 30 remains relatively constant even though the downstream pressure may vary, the level of liquid in the valve remains substantially constant and one can maintain substantially the same amount of tablets in contact with the liquid to thereby maintain a constant rate of dispersant from valve 10. FIG. 4 also shows a two way valve 58 that permits liquid in the upper portion of valve 10 to drain into the lower portion when the system is shut down. When the system is pressurized the opposite occurs since valve 58 seals lower chamber 13a from valve chamber 45. In operation of valve 10 a liquid such as water flows into chamber 13a with a portion of the liquid entering opening 63 and into plug 14 where it flows through port 55. A portion of the liquid continues on through chamber 13a by flowing under lip 62 where the velocity increases and the pressure decreases as the area decreases. As the fluid flows down ramp surface 61a the area increases and the velocity decreases as the liquid discharges from the discharge side of plug 14. It should be understood that in most applications the downstream pressure remains relatively constant, however in those applications where there may be substantial variation a restricter such as a venturi 61 in valve 10 may be used
FIG. 5 shows an alternate embodiment of a dispersal valve where the venturi ramp 61 has been replaced by an upward extending weir 68 that also restricts the area for fluid as it flows from chamber 13a to chamber 12a. In either case the fluid velocity is increased by the decreasing of cross sectional area thereby increasing the velocity of the fluid flowing through the lower portion of valve 10. In both embodiments the use of a weir or a venturi ramp the effect is to render the pressure P 3 in the interior of valve 10 and the volume of the air in compartment 30a less sensitive to changes in pressure downstream of valve 10.
FIG. 6 shows an alternate embodiment of a canister 70 located in a valve housing 17. Canister 70 includes a tapered neck 80 that limits the volume of tablets in contact with the liquid in the canister 70. Canister 70 has a top diameter D and a lower cross sectional dimension X located at the liquid level line 41. The purpose of having a smaller region at the bottom of a canister is to extend the lower range of dispersing rates of the dispersal valve. That is, a dispersal valve that is normally used to disperse material at a minimum rate through control of the size of the openings in the plug 14 can be adapted to provide even lower more controlled dispersant rates with the present invention. For example with control of only the rate of water flowing through the dispersal valve the minimum rate of dispersal is determined by the minimum rate of liquid that flows through the valve. To illustrate the effect of dispersant rate on time reference should be made to FIG. 11 which shows the dispersal rate as a function of time. Curve A denotes the dispersal rate with a prior art dispersal valve where the all the dispersant tablets remained in contact with the liquid. Curve B illustrates the rate of dispersal with the present invention using a canister where a portion of the tablets are stored in the canister above the liquid. By having a smaller portion of the dispersant tablets in contact with the liquid, and more fresh tablets located above the liquid to fall into the lower portion of the canister extends the time t where the dispersal rate remains relatively constant. Thus a feature of the present invention is not only the ability to scale down the rate of dispersant but also provide for a more uniform dispersion rate of material into the liquid. With the present invention one can conventionally disperse dispersant at high rates or the dispersant rate can be quickly changed to disperse small amounts of dispersant by merely changing the size of the canister in the dispersal valve. That is, with the same volume flow of liquid through chamber 45 canister 70 disperses dispersant at a slower rate than the canister 30 which has a wider lower section that permits more dispersant tablets to be in contact with the water for the same water level h.
Canister 70 includes a top having a magnet 71 embedded within the central top region of canister 70. The axis of magnet 71 is located so that one pole of magnet 71 faces upward and the opposite pole of magnet 71 faces downward. Magnet 71 is shown as a permanent part of canister 71. Located in the cover 11 is a visual indicating member comprising a transparent sight member 15 that contains a second magnet 15a. Magnet 15a is positioned with its poles so that the two magnets repel each other when magnet 71 is brought close to magnet 15a. Consequently, if the magnets 71 and 15a repel one another as canister 70 rises because the dispersant has dissolved it forces magnet 15a upward in sight member 15 thereby visually alerting a user that it is time to replace canister 70.
FIG. 7 illustrates canister 70 in a nearly empty condition with substantially all of tablets 9 dissolved. In this condition canister 70 is forced upward by the combination of the buoyant forces and spring 52. Note, the magnet 15a is positioned at the top of the sight member thereby providing a visual indicating means to alert a user to the fact that canister 17 needs replacement.
FIG. 8 shows a further variation of the visual indicating means wherein a canister 100 includes a sight post 109 mounted in a protruding manner at the top of canister 100. Located on the top end of canister 100 are a pair of recesses 105 and 106 with a corresponding hand gripping areas 105a and 106a that permit a user to grasp canister 100 from the top and lift the empty canister from the dispersal valve.
In addition to the hand grips canister 100 includes an outward extending fluid outlet member 102 that has a cylindrical break line 103 where the the outlet member 102 must be cut off if one wants to insert canister 100 into housing 17. That is, as FIG. 9 shows if one attempts to insert canister 100 into housing 17 the canister will not fit. Consequently, one is prevented from inserting the canister into the container unless one is familiar with handling of the dispersant canisters.
FIG. 10 illustrates how the canister 100 provides a visual indication of the amount of dispersant tablets in the canister. Canister 100 includes the post 109 with a colored region 109a that projects partial up into the transparent sight cup located on the top of cover 120. With the transparent sight cover located on the top of canister 100 it is apparent that upward displacement of the canister 100 produces a visual indication of the movement of the canister in housing 17 and consequently of the amount of dispersant remaining in the canister. In an alternate embodiment the entire cover 11 can be made from a transparent material with markings on the interior of cover 11. Consequently, upward displacement of canister 100 could be determined by merely observing the vertical position of the canister with regard to the interior markings on cover 11. Also if the canister were made of clear material the user could visually observe the amount of remaining dispersant.
FIG. 12 shows a top view of a canister 230 having a keyed inlet spout 229 for engaging a port in the dispersal valve. Spout 229 has a lip 231 and a tapered neck 232 that fits into a mating opening in the fluid port on the dispersal valve. Located inside spout 229 is a screen 235 that has sufficiently small openings so as to prevent granules from falling into the fluid port on the dispersal valve. In order to prevent the canister with the spout from being improperly inserted into a dispersal valve the the spout include an extension 242 having an opening 238 for engaging a stud (not shown) in a dispersal valve. Similar located on the other side of the spout is an extension member 237 having a rectangular opening 239 for engaging a rectangular shaped stud (not shown) on a dispersal valve. The combination of keyed opening on the spout for the canister and a stud like key in the dispensing valve prevents one from inserting a cannister into the wrong dispersal valve.
FIG. 13 shows a partial cross sectional view of a canister and a spout 229. Located in container 230 is a granular dispersant 240. The purpose of using a granular dispersant is to enable one to more effectively disperse the dispersant into the liquid as it flows through canister 230.
FIG. 14 shows an alternate embodiment of a canister 130 having a handgrip ridge 131 with a finger recess 132 to permit a user to lift canister 130 out of a dispersal valve. Canister 130 comprises a housing having an upper region 133 and a lower region having a first fluid port 134 and a second fluid port 135. A cap 136 extends over ports 134 and 135 to seal the canister during storage. A break line 138 extends around each of the ports to permit cap 136 to be quickly separated from canister when the canister is in use. A mating line 137 identifies where the top half and the lower half of canister have been joined together to form a closed canister.
FIG. 15 shows a partial sectional view of canister 130 mounted in dispersal valve 10. FIG. 15 illustrates the fluid tight sealing relationship of port 134 with an elongated mating extension port 140 located in the bottom of valve 10 through the use of closely mating tapered male and female members. Similarly, the port on the opposite of canister 130 forms a fluid tight sealing relationship with the second mating extension located in the bottom of valve 10. The sealing relationship of the ports and extensions can be better seen in FIG. 17. The purpose of having the ports and extensions forming sealing relationships is that the fluid flowing through my valve must pass through the canister rather than around it and thus avoid contact with the dispersant. Canister 130 also includes an elongated cap 142 having a screen 141 on one end and a keyed recess 175 on the other end for matingly engaging a key post 170 in valve 10. The key post 170 can be better seen in FIGS. 20-22 and comprises a circular base 172 having a circular extension 171 with a male extension 174 comprising the letter K extending upward from base 171 to from a male member for fitting into a female recess. FIG. 23 shows the female recess 175 for engaging the male extensions 174 shown in FIG. 20. A feature of the invention is that the user can make a single all purpose dispersal valves 10 unique to the chemical used in the dispersal valve. That is, by merely sonic welding keypost 170 with a unique key onto an extension on the inside of valve 10 one makes an all purpose dispersal valve receptive to only the type of canister having a mating recess for the key on the keypost. FIG. 15 and 22 show a cylindrical post 129 extending upward from keypost base 128 in valve 10. The recess 173 (FIG. 21) in the bottom of keypost 170 forms a mating opening with surface 129s on post 129. The surface 173b forms a mating surface with valve surface 106 to permit a manufacturer to instal keypost 170 in a valve through sonic welding or the like. The advantage of having a keypost that is installed after the valve is made is that the manufacture can key the valve for the proper canister so only the proper canister is used in the dispersal valve. For example, if one dispersal valve is to be used in a chlorine system that uses only a chlorine canister and another dispersal valve is to be used in a bromine system that uses only a bromine canister the two dispersal valve can be keyed with different keyposts to prevent a user from accidently inserting the bromine canister into the dispersal valve that dispenses chlorine or vice versa.
One of the features of my invention is that my canister allows one to controllable dispense material into a fluid at a substantially constant rate over an extended period of time through the use of an air pocket that limits the amount of fluid in contact with the dispensing material. Another feature of my invention is that I can control where the liquid flows through the dispersant as well as the amount of dispersant in contact with the liquid flowing through my valve. Still another feature of my invention is that I can dispense material from the granular state without having to tabletize the material. Heretofore the material has been tabletized before use in dispersal valves. Typically, bromine dispersant is formed into a powder. The powder is then formed into granules referred to as granular material. The granular material may have 9% of the particles with a diameter of less than 0.020 inches with about 91% of the particles having a diameter over 0.020 inches and generally not greater than about 0.040 inches in diameter. The material in the granular state has been unsuitable for use in canister in dispersal valves since it has been difficult to control the dispersal rate of the granular material into the liquid. Consequently, the granular dispensing material such as chlorine or bromine has been formed into cylindrical tablets that may have a diameter of 1 to 3 inches. These tablets have then been inserted into the canister of the dispersal valve to controllable dispense the material into the liquid in the dispersal valve. The present invention provides a canister that can both hold and controllable disperse a dispersant into a liquid while the dispersant is in a granular state.
In order to appreciate the operation of my invention reference should be made to FIG. 18 which shows a portion of the lower region of canister 130 without any dispensing material therein. The lower region of canister 130 includes an elongated trough 153 having sides 131a and 130a that funnel material downward into trough 153 under the force of gravity. Canister 130 differs from the other canisters shown in the drawings in that the inlet and the outlet passage for canister 130 are located in the same horizontal plane and at the bottom of though 153. Port 134 includes an internal passage 151 for directing liquid inward into a first bottom end of trough 153 and port 135 includes and outlet passage 152 for directing liquid through the opposite bottom end of trough 153. In operation of canister 130 the liquid is directed into trough 153 and flows along the bottom of trough 153 until it discharges through passage 152. The air pocket located above trough 153 prevents the liquid from rising in canister 130 and causes the liquid to reach a maximum level indicated by liquid line 155. That is, the level of liquid in trough 153 remains relatively low and is confined to the trough area. For example, the trough volume 153 may be only 5% of the total volume of the canister. Consequently, only a very small portion of the dispensing material will remain in contact with the liquid flowing through trough 153. Thus with the present invention one can place a canister containing a dispersant into a dispersal valve that normally may fill with the liquid without having the entire contents of the canister filled with a liquid.
FIG. 17 illustrates valve 10 and canister 130 in cross section with tablets 9 located in trough 153. The height of trough 153 is indicated by h and the liquid level in trough 153 is indicated by L. P 2 indicates he pressure at the inlet passage 151, P 1 indicates the pressure at the outlet 152 and P 3 indicates the pressure in the air pocket 150. In the embodiment shown the tablets in air pocket P 3 remain free of contact with liquid and remain in an undispensed state. However, the tablets 9 located in trough 153 are in contact with the liquid resulting in dispensing of dissolvable or erodible tablets directly into the liquid in proportion to the rate of liquid flowing past the tablets and the amount of tablets in contact with the surface of the tablets. Consequently, the use of a dispersal valve that directs only a portion of the fluid through the trough permits a user to controllable dispense the dispersant in the trough at a substantially constant rate over an extended period of time. In addition the use of a canister that continually funnels unspent dispersant into the trough permits one to controllable dispense material at a substantially constant rate for two weeks or longer.
FIG. 19 shows an alternate embodiment of a canister that is identical to the canister in FIG. 17 except that canister 130 contains a granular material 160 rather than a tabletized or solid material. Prior to my canister bromine and chlorine which was in granular form needed to be tabletized in order to be used in dispersal valves. The present invention permits one to use granular material in the canister thus eliminating the step of having to tabletize the material before dispensing. Because the present invention limits the liquid contacting the dispensing material and allows fresh dispensing material to fall into a dispensing trough as the dispensing material is removed from the dispensing trough one can obtain both limited and uniform dispersion rates of the dispensing material over an extended period of time. In addition the control of the size of the dispensing trough permits one to control the amount of liquid in contact with the dispensing material. The use of an upper region that funnels materials from the upper region to the lower region containing the dispensing trough permits one to continually replenish spent dispensing material.
Although not shown a spring support for canister 130, similar to canister spring support 52, can be used to have canister 130 provide a visual indication of the amount of unspent dispersant material remaining in the canister. However, in such an arrangement a different sealing relationship between the extension and port would be required to ensure that the fluid is directed through valve 10 as the canister moves up in response to the removal of dispersant.
When my invention includes a pocket with a compressible gas such as air located therein I provide an automatic method for forcing the liquid away from the dispersant to stop the liberation of dispersant when the line pressure to the valve is shut down. That is, under normally operating pressure in the valve the air in the air pocket compresses to a smaller volume to permit liquid to flow through the valve and the dispersant in the canister. When the liquid pressure to the line is shutoff the liquid pressure deceases and the air pressure of the compressed air forces the compressed air to expand to its original volume and thus force the liquid in the canister back into the liquid line and out of the canister thus preventing further liberation of dispersant by any residual liquid remaining in contact with the dispersant in the canister.
A still further feature of my invention is my canister provides an effective means for holding and safely disposing of substantially all toxic or noxious dispersant gas remaining in the valve. In prior art systems when the dispersant was used up one would remove the cover of the valve and place a new dispersant tablet into the valve. A drawback was that the valve may contain residual gas from the dispersant even though the dispersant had been used up. For example, if the valve contained chlorine gas once the cover of the valve was removed the chlorine gas could escape and be inhaled by the person attempting to refill the valve. In the present embodiment most of the gas from the dispersant remains in the canister and can be removed with the canister. Once the cover is removed from the valve only a small amount of gas between the outside of the canister and the interior of the valve housing can escape. By removing the canister and covering the ports one can take the canister with any noxious gas to a disposal area where the canister and the gas can be disposed of without injuring humans. Consequently, my invention makes it safer to replace the dispersant by permiting the user to remove the canister and substantially all the noxious gases without letting the noxious gases escape into the immediate users environment around the valve.
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A dispersal valve and canister with the dispersal valve resiliently supporting a loaded canister in the dispersal valve. The canister includes a visual indicator to permit a user to determine when the canister needs to be replaced with the canister having an air pocket for retaining at least a portion of the dispersant above the liquid with the canister including sides to funnel the unused dispersant into the trough to displace the dispersant in the liquid that is dispensed into the liquid so that the rate of dispersant of dispensing material into the liquid remains substantially constant during a substantial portion of the time the dispersal valve dispenses material into the liquid.
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BACKGROUND OF THE INVENTION
This invention relates to a tubular handling system and method. More specifically, but not by way of limitation, this invention relates to a modular system for threadedly engaging tubular members.
In the drilling and production of hydrocarbons, operators utilized tubular members such as work string, drill strings, production tubing, and snubbing pipe in wells and wellbores. Many times these wells and wellbores are located in remote areas with harsh environments. Operators will find it necessary to threadedly engage a first tubular member with a second tubular member. As well understood by those of ordinary skill in the art, the application of torque is critical for several reasons. For instance, the threadedly connected tubulars must need to contain thousands of pounds of pressure in a caustic, hot downhole environment. Failures of tubulars may mean catastrophic failure of the tubular, platform and rig, which in turn may mean loss of human life as well as property and environmental damage.
Operators will measure the applied torque in an effort to assure that the proper torque is applied for making-up tubular connections. Prior art systems attempt to measure applied torque and record the applied torque for analysis and record keeping.
SUMMARY OF THE INVENTION
In one embodiment, a modular system for connecting a first tubular with a second tubular is disclosed. The system comprising a skid and a tong assembly operatively associated with the skid, wherein the tong assembly includes a rotary tong for applying a torque force to the tubular member, with the rotary tong having a receiving end for receiving the first tubular and a back-up tong, operatively associated with the rotary tong, for providing a fixed point for torqueing the first tubular, with the back-up tong configured to receive and grasp the second tubular. The system also includes a hydraulic power unit, operatively positioned on the skid, for providing hydraulic power to the rotary tong and back-up tong. The system further comprises a spring assembly including a plurality of spring stands attached to the skid, wherein the spring stands have a top end, a frame containing the tong assembly, a plurality of springs having a proximal end abutting the top end of the spring stands, a plurality of rods disposed within the springs, with the rods containing a stop structure on the rod, and wherein the springs have a distal end abutting the stop structure, and a plurality of lanyards attached to the rods on a first end and attached to the base on a second end so that vibratory and displacement forces created during torqueing of the first tubular onto the second tubular are absorbed.
The system may further comprise sensor means, operatively positioned on the skid, for sensing an applied torque to the first tubular and the second tubular, and generating a sensor signal, and processor means for receiving the sensor signal and generating a torque reading. The system may include a control unit for receiving the torque reading from the processor means and producing a command signal to the hydraulic power unit to provide hydraulic power to the rotary tong and back-up tong. The system may also include a tubular platform, operatively associated with the hydraulic power unit, for raising the first tubular for entry into the tong assembly and advancing means, positioned on the tubular platform, for advancing the first tubular to the tong assembly. A ball transfer device may be included that comprises a ball positioned within a socket, with the ball configured to engage the first tubular, the ball capable of rotating in a 360 degree phase, and a hydraulic activator shaft operatively attached to the hydraulic power unit, the hydraulic power unit capable of delivering hydraulic fluid to the activator shaft so that the ball lifts and lowers during torqueing of the tubular member.
A process for making-up a first tubular with a second tubular is also disclosed. The process may comprise providing a skid with a tong assembly contained thereon, providing a tubular platform that includes: a base; a lifting scissor unit operatively attached to the base, the lifting scissor unit configured to be raised and lowered; and, a landing operatively attached to the lifting scissor unit, and wherein the first tubular rest on the landing. The process further comprises positioning the first tubular on the landing, raising the landing for entry of the first tubular into the tong assembly and advancing the first tubular with rollers contained on the tubular platform to the tong assembly. The process may further include engaging and lifting the first tubular with a ball transfer device, wherein the ball transfer device comprises a ball positioned within a socket, with the ball configured to engage the first tubular and capable of rotating in a 360 degree phase. The process may also comprise inserting the first tubular into the tong assembly and making-up the first tubular and the second tubular. The process may also comprise absorbing vibratory and displacement forces with a spring assembly, wherein the spring assembly comprising: a plurality of spring stands attached to the skid, wherein the spring stands have a top end; a base having attached thereto the tong assembly; a plurality of springs operatively associated with the spring stands, the springs having a proximal end abutting the top end of the spring stands; a plurality of rods disposed within the springs, with the rods containing a stop structure threadedly engaged with thread means on the rods, and wherein the springs have a distal end abutting the nut; a plurality of lanyards having a first end and a second end, the first end attached to the rods and the second end attached to the base; and wherein the vibratory and displacement forces created during torqueing of the first tubular with the second tubular are absorbed by the springs. In one embodiment, the tong assembly includes: a rotary tong for applying a torque force to the first tubular, with the rotary tong having a receiving end for receiving the first tubular; a back-up tong, operatively associated with the rotary tong, for providing a fixed point for torqueing the second tubular, with the back-up tong configured to receive and grasp the second tubular; and wherein the step of making-up the first tubular with the second tubular includes grasping the second tubular with the back-up tong and rotating the first tubular with the rotary tong. In one embodiment, the process may further comprise sensing the torque applied during the making-up step, recording the torque applied as a torque reading, storing the torque reading, and displaying the torque reading. The process may also include releasing the second tubular from the back-up tong, releasing the first tubular from the rotary tong, and rolling the first tubular and the second tubular from the tong assembly with the rollers.
A spring assembly is also disclosed. The spring assembly may comprise: a plurality of spring stands attached to the skid, wherein the spring stands have a top end; a frame having attached thereto the tong assembly; a plurality of springs operatively associated with the spring stands, the springs having a proximal end abutting the top end of the spring stands; a plurality of rods disposed within the springs, with the rods containing a stop structure, and wherein the springs have a distal end abutting the stop structure; and, a plurality of lanyards attached to the rods on a first end and attached to the base on a second end so that vibratory and displacement forces created during torqueing of the tubular member with the collar are absorbed.
In yet another embodiment, a modular system for threadedly connecting a tubular member with a collar is disclosed. In this embodiment, the system may comprise: a skid; a tong assembly operatively associated with the skid, the tong assembly having a rotary tong for applying a torque force to the tubular member, with the rotary tong having a receiving end for receiving the tubular member or collar, a back-up tong, operatively associated with the rotary tong, for providing a fixed point for torqueing the tubular member, with the back-up tong configured to receive and grasp the collar or the tubular member; and, a spring assembly, operatively attached to the skid, for absorbing vibratory and displacement forces created during torqueing of the tubular member onto the collar. The system may also include: a hydraulic power unit, operatively positioned on the skid, for providing hydraulic power to the rotary tong and back-up tong; sensor means, operatively positioned on the skid, for sensing an applied torque to the tubular member and the collar by the rotary tong as a sensor reading; a processor unit for receiving the sensor reading, storing the sensor reading, processing the sensor reading, and displaying the sensor reading; and, a tubular platform, operatively associated with the hydraulic power unit, for raising the tubular member for entry into the tong assembly. In one embodiment, the spring assembly comprises: a plurality of spring stands attached to the skid, wherein the spring stands have a top end; a frame having attached thereto the tong assembly; a plurality of springs operatively associated with the spring stands, the springs having a proximal end abutting the top end of the spring stands; a plurality of rods disposed within the springs, with the rods containing a stop structure threadedly engaged with thread means on the rod, and wherein the springs have a distal end abutting the stop structure; and a plurality of lanyards attached to the rods on a first end and attached to the frame on a second end so that vibratory and displacement forces created during torqueing of the tubular member with the collar are absorbed. Also, the system may include advancing means, positioned on the tubular platform, for advancing the tubular member relative to the tong assembly. In one embodiment, a truck is utilized to transport the system to a rig site, wherein the system further comprises a flatbed configured to contain the skid, wherein the flatbed contains a first segment containing the skid and a second segment attached to the truck, wherein the first and second segment are operatively attached. A crane may be mounted to the skid, with the crane having a swing arm extending from a vertically mounted arm. In one disclosed embodiment, the processor unit may include a graphing module for printing a graph of the torqued applied to the tubular member and the collar thread connection. Additionally, the tubular platform may comprise: a base having a set of wheels for movability; a lifting scissor unit operatively attached to the base, with the lifting scissor unit configured to be raised and lowered by the hydraulic power unit; and a landing operatively attached to the lifting scissor unit, and wherein the tubular member rest on the landing.
In another disclosed embodiment, a modular system for threadedly connecting a tubular member with a collar is disclosed. The system comprises: a skid; a tong assembly operatively associated with the skid, the tong assembly including a rotary tong and a back-up tong; a spring assembly, operatively attached to the skid, for absorbing vibratory and displacement forces created during torqueing of the tubular member onto the collar; a hydraulic power unit, operatively positioned on the skid, for providing hydraulic power to the rotary tong and the back-up tong; and sensor means, operatively positioned on the skid, for sensing an applied torque to the tubular member and the collar by the rotary tong as a sensor reading. The system may also include: a processor unit for receiving the sensor reading, storing the sensor reading, processing the sensor reading, and displaying the sensor reading; and a tubular platform, operatively associated with the hydraulic power unit, for raising the tubular member for entry into the tong assembly. Advancing means, positioned on the tubular platform, for advancing the tubular member relative to the tong assembly and a graphing module for printing a graph of the torqued applied to the tubular member and the collar thread connection may be included. In one embodiment, tubular platform comprises: a base having a set of wheels for movability; a lifting scissor unit operatively attached to the base, the lifting scissor unit configured to be raised and lowered by the hydraulic power unit; and a landing operatively attached to the lifting scissor unit, and wherein the tubular member rest on the landing. In one embodiment, a ball transfer means, operatively attached to the landing, for dampening the transfer of weight of the tubular member during torqueing is included. The ball transfer means may comprise: a ball positioned within a housing, the ball configured to engage the tubular member, with the ball capable of rotating in a 360 degree phase; a hydraulic activator shaft operatively attached to the hydraulic power unit, the hydraulic power unit capable of delivering hydraulic fluid to the activator shaft so that the ball lifts and lowers during torqueing of the tubular member. The scissor unit may include: a first scissor frame containing a first member pivotally attached to a second member; a second scissor frame containing a third member pivotally attached to a fourth member; a hydraulic driver cylinder, operatively connected to the hydraulic power unit, for pivoting the first and second scissor frame so that the landing can be raised and lowered. Also, the hydraulic driver cylinder may comprise a piston disposed within a housing, and wherein the housing is connected to the first scissor frame and the piston is connected to the second scissor frame.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective side view of one embodiment of the present system.
FIG. 2 is a partial side view of one embodiment of the present system seen in FIG. 1 .
FIG. 3A is a perspective view of the system seen in FIG. 1 while in the process of connecting a first and second tubular.
FIG. 3B is a perspective view of a second embodiment of the system while in the process of connecting a first and second tubular.
FIG. 4A is a perspective view of a prior art tong assembly.
FIG. 4B is a partial cross-sectional view of the tong assembly seen in FIG. 4A with a tubular member and collar disposed therein.
FIG. 5A is a perspective view of the system of FIG. 1 mounted on a flatbed, wherein the flatbed is attached to a transportation vehicle.
FIG. 5B is a perspective view of the system seen in FIG. 5A wherein the flatbed has been pivoted in order to offload or on-load the skid unit.
FIG. 6A is a partial top view of the system seen in FIG. 1 .
FIG. 6B is a partial cross-sectional view of the spring assembly taken along line “ 6 B” of FIG. 6A .
FIG. 7A is a partial view of one embodiment of the tubular platform in the raised position.
FIG. 7B is a partial view of the tubular platform seen in FIG. 7A in the lowered position.
FIG. 7C is a schematic of one embodiment of the ball transfer device.
FIG. 8 is a process flow chart of the sensor and processor unit associated with one embodiment of the present system.
FIG. 9 is a schematic on one of the embodiments of the present hydraulic system.
FIG. 10 is an exemplary graph of the torque applied by one embodiment of the present system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a perspective view of one embodiment of the present system 2 will now be described. The system 2 includes the skid unit 4 , wherein the skid unit 4 will be operatively associated with the tong assembly, and more specifically, the rotary tong 6 and the back-up tong 8 . The skid unit 4 will contain the control unit 10 , wherein the control unit 10 directs hydraulic oil from the hydraulic power unit 12 to the various hydraulic components as will be more fully explained later in this disclosure. Hydraulic lines operatively connect the hydraulic components of the system 2 to the hydraulic power unit 12 . A diesel engine means 14 , which includes the engine and fuel tank, for powering the supply of hydraulic fluid used with the hydraulic power unit 12 is also included.
The skid unit 4 will also contain the spring assembly, seen generally at 16 , wherein the spring assembly 16 absorbs vibratory and displacement forces created during the torqueing of the tubulars and collars. The vibratory forces may be as a result of the mechanical and hydraulic equipment during operation and the displacement forces may be the result of bending and twisting of the tubulars during operation. The spring assembly 16 , in one embodiment, includes a first spring member 18 , a second spring member 20 , a third spring member (not seen in this view), and a fourth spring member (not seen in this view). The spring assembly 16 is operatively attached to a tong assembly frame which will be described later in this disclosure.
FIG. 1 depicts the crane member 26 which is mounted to the skid unit 4 . The crane 26 includes a vertical arm 27 a and a horizontal arm 27 b . The crane member 26 can be used to aid in rigging up and rigging down operations once the system 2 is delivered to the remote location. For instance, the crane 26 can be used to store the tubular platforms, as will be more fully described later in the disclosure. An electric air compressor means 28 for providing pressure to the hydraulic system is also included. An electric generator 30 is also included on the skid as well as an air compressor means that contains an air tank.
FIG. 1 also illustrates the tubular platforms 32 , 34 for raising the tubular member for entry into the tong assembly and in particular the rotary tong 6 or back-up tong 8 . The tubular platforms 32 , 34 can also lower the tubular. During transportation of the skid 4 , the tubular platforms 32 , 34 are positioned on the skid 4 , with the aid of the crane 26 so that the skid 4 may contain the entire components of the system 2 for purposes of transporting the system 2 to different locations. The tubular platforms 32 , 34 are operatively associated with the hydraulic power unit 12 , which will be described in further detail later in this description.
The back-up tong 8 includes movable jaws 36 which can grasp tubulars and hold stationary. The rotary tong 6 has means for spinning the tubulars, seen generally at 38 , and thus, the rotary tong 6 and the back-up tong 8 work in conjunction. In one embodiment, the tubulars may include a tubular (such as a casing string) and a collar. The back-up tong 8 and the rotary tong 6 are components of the tong assembly, which will be further descripted with reference to FIG. 4A . The rotary tong 6 and back-up tong 8 are commercially available from McCoy Global under the name Type III Bucking Unit (Power & Control Console) CLEBU1175-3. It should be noted that the tubular can either be inserted into the rotary tong 6 first and then into the back-up tong 8 ; or, the tubular can be first inserted into the back-up tong 8 and then into the rotary tong 6 . In the instance where the tubular is first inserted through the rotary tong 6 , the tubular can contain a collar threadedly attached on one end, and wherein the collar will be grasped by the back-up tong. In the instance where the tubular is inserted first through the back-up tong 8 , the back-up tong 8 can grasp the tubular and the rotary tong 6 will engage the collar. Additionally, FIG. 1 depicts the telescoping tubular stand 40 that can be used for lifting, lowering and/or resting the tubular if the operator deems it necessary during operation . . . . The tubular stand 40 can be raised and lowered by the operator via the control unit 10 .
In one disclosed embodiment, sensors will measure the applied torque in foot-pounds. A processor unit of the system 2 will receive the sensor signal, process and record the applied torque and provide means for displaying the applied torque in a chart format to the operator, as will be more fully explained later in the disclosure.
Referring now to FIG. 2 , a partial second side view the system 2 seen in FIG. 1 will now be described. It should be noted that like numbers appearing in the various figures refer to like components. FIG. 2 depicts the hydraulic power unit 12 operatively associated with the control unit 10 as well as the diesel engine means 14 . The spring members 18 , 22 are shown in this view along with the tubular centering guide stand 40 . The back-up tong 8 and the rotary tong 6 are also depicted in this view. The tubular platforms 32 , 34 are depicted in the folded (i.e. collapsed) position. As noted earlier, the folded tubular platform 32 , 34 can be placed onto the skid for transportation.
FIG. 3A is a perspective view of the system 2 seen in FIG. 1 while making up a tubular. More specifically, a tubular member 50 is shown, wherein the tubular member 50 may be a casing string used in a wellbore as well understood by those of ordinary skill in the art. Examples of other types of tubular members may be production tubing, drill string, collars, and snubbing pipe. The tubular member 50 may have outer threads on both ends and wherein on one end a second tubular (such as a collar) is threadedly attached (not seen in this view). As seen in FIG. 3 , the collar end has been inserted into the rotary tong 6 and the collar will be operatively associated with the back-up tong 8 . As FIG. 3A depicts, the tubular platforms 32 , 34 have the tubular member 50 positioned on the landing 52 of the tubular platform 32 and the landing 54 of the tubular platform 34 . As will be more fully explained later in this disclosure, the tubular platforms 32 , 34 will raise the tubular member 50 as well as lower the tubular member 50 via the control unit 10 . Additionally, advancing means (not seen in this figure) for advancing the tubular member 50 into and out of the tong assembly may be provided on the tubular platforms 32 , 34 .
FIG. 3B is a perspective view of a second embodiment. In this alternate embodiment of FIG. 3B , the first tubular is inserted through the back-up tong 8 and the back-up tong 8 grasps the tubular 50 and the rotary tong 6 grasps the collar for torqueing. In this alternate embodiment, the operator can also break (i.e. unscrew) the thread connections or make-up (i.e. screw) the thread connections. Hence, with this alternate embodiment, the tubular platforms 32 , 34 would be positioned on the opposite side of the skid 4 illustrated in FIGS. 1 and 2 . An aspect of this disclosure is that it is possible to have the tubular member 50 to be grasped and held by the back-up tong 8 and the collar 66 be grasped and rotated by the rotary tong 6 .
FIG. 4A is a perspective view of a prior art tong assembly 60 . As noted earlier, the tong assembly includes the back-up tong 8 and the rotary tong 6 . As previously mentioned, the tong assembly 60 is commercially available from McCoy Global under the name Type III Bucking Unit (Power & Control Console) CLEBU1175-3. FIG. 4B is a partial cross-sectional view of the tong assembly, seen generally at 60 , with the tubular member 50 operatively associated therein. More specifically, the tubular member 50 will have thread means 62 disposed on one end and thread means 64 disposed on the other end. As seen in FIG. 4B , a collar 66 is provided, and wherein the collar 66 has internal thread means 68 , 70 . FIG. 4B depicts the outer threads 62 of tubular member 50 are engaged with the inner threads 68 of the collar 66 . In operation of the tong assembly 60 , the tubular member 50 is inserted into the tong assembly 60 according to one disclosed embodiment. The back-up tong 8 will close and grasp the collar 66 via the movable jaw 36 with the stationary teeth 72 . The rotary tong 6 will close and grasp the tubular member 50 via the spinning means 38 with the rotary teeth 74 . In one disclosed embodiment, the operator, utilizing the control unit 10 , will cause the rotary teeth 74 to rotate while the stationary teeth 72 grasp and hold the collar 66 so that torque is applied to make-up the connection. FIG. 4A also depicts the sensors 162 , 164 for measuring the applied torque in foot-pounds. In one embodiment, the sensors 162 , 164 are hard wired to the processor unit.
Referring now to FIG. 5A , a perspective view of the system 2 of FIG. 1 mounted on a flatbed trailer 90 , wherein the flatbed trailer 90 has wheels and is attached to a transportation vehicle 92 , such as a truck. An aspect of one embodiment herein disclosed is the modular nature of the system 2 and the ability to transport the system 2 to remote areas where a drilling rig may be located. Hence, the entire system 2 can be loaded onto the flatbed trailer 90 and delivered to a user specified location. FIG. 5B is a perspective view of the system 2 seen in FIG. 5A wherein the flatbed trailer 90 has been titled. Once the vehicle 92 arrives on site, the flatbed trailer 90 will tilt about a lifting point 94 , as seen in FIG. 5B . Lifting/tilting flatbeds trailers are commercially available from Contral Container Trailer Source Company under the name Model CDU 32. As seen in FIG. 5B , the distal end 96 will be tilted until the distal end 96 contacts the ground. The proximal end 97 is lifted by a driver mechanism. Hence, the flatbed trailer 90 has a first segment 98 (which remains horizontal to the ground) and a second segment 99 which is tilted. The flatbed 90 contains a wench and conveyor rail system so that the skid unit 4 is offloaded from the flatbed trailer 90 via the wench and conveyor system. After the tubular handling functions have been performed by the operator, and according to the teachings of the present disclosure, the system can be loaded onto the flatbed trailer 90 with the wench and conveyor rail system in a like fashion.
Referring now to FIG. 6A , a partial top view of the system 2 on the skid 4 will now be described. FIG. 6A depicts the spring members 18 , 20 , 22 , 104 that are positioned at four corners of the tong assembly frame 106 , and wherein the frame 106 is operatively positioned on the top of the skid 4 , as will be more fully described later. Also seen in FIG. 6A is the hydraulic power unit 12 , diesel engine means 14 , electric generator 15 a , electric air compressor 15 b , jib crane 26 , and folded scissor lift 32 , 34 .
FIG. 6B is a partial cross-sectional view of the system taken along line “ 6 B” of FIG. 6A . More specifically, FIG. 6B illustrates the spring assemblies (such as spring assembly 16 ), which includes individual spring members 18 , 20 , 104 (not seen in this view), and 22 (not seen in this view). The spring assembly includes, in one embodiment, individual coiled springs, such as spring 107 a and 107 b . The view of FIG. 6B depicts the spring members 18 , 20 operatively positioned on the top of the frame 106 and the skid 4 . The spring members 18 , 20 , 22 , and 104 are all similar in construction, and therefore, only spring member 18 will be described. The spring member 18 includes coiled spring 107 a disposed about a threaded rod 108 , wherein a stop structure 109 is provided, and wherein in one embodiment, the stop structure 109 is a nut that is threadedly engaged with the threaded rod 108 . The spring 107 a will therefore have one end engaged with the stop structure 109 and a second end with a lip 110 of the stand 111 . The stand 111 has a plurality of legs, and in one embodiment, the stand is a tripod, with legs L1 and L2 shown. The legs L1 and L2 are attached to the skid 4 which may be by welding. A lanyard LY has a first end attached to the rod 108 and a second end attached to the frame 106 at attachment point AP. The clearance between the tong frame 106 and the skid frame 4 , in one embodiment, is two inches. Hence, this clearance allows an area that is used to dissipate the displacement and rotational forces generated during torqueing by allowing the spring assemblies to bias the frame 106 up and down, and back and forth in a 360 degree phase.
Referring now to FIG. 7A , a partial view of one embodiment of the tubular platform 32 in the raised position will now be described. The tubular platform 32 includes a structural base 120 which is rectangular in shape. The base 120 will include wheels such as wheels 122 , 124 , 126 for movability, and wherein the wheels are attached to a pivoting flap, such as flaps 128 , 130 , that can be folded for storage or unfolded for use. In other words, the flaps 128 , 130 can be folded by removing the pins 129 a , 129 b , and in this way the tubular platform 32 can rest on the ground which can aid in stability during operations.
The tubular platform 32 will contain a lifting scissor unit. More specifically, a first lifting scissor frame 132 is operatively attached to the base 120 and a second lifting scissor frame 134 is also operatively attached to the base 120 . Each scissor lifting frame 132 , 134 contains a first arm pivotally connected to a second arm, such as first arm 136 pivotally connected to the second arm 138 at the pivot point pin 140 . The first lifting scissor frame 132 and the second lifting scissor frame 134 will connected to a landing 142 , wherein the landing 142 is a rectangular structure that provides a platform for resting the tubular, as well as advancing and/or retracting the tubular during operation. FIG. 7A shows the roller 144 for advancing the tubulars as well as the hydraulic motor 146 for powering the rotation of the roller 144 . Hydraulic motors are commercially available from White Drive Products under the name RS Motors/200. FIG. 7A also depicts the ball transfer device for dampening the transfer weight of the tubular during advancing and torqueing, seen generally at 147 .
FIG. 7A also depicts the hydraulic driver cylinder 148 , operatively connected to the hydraulic power unit, for pivoting the lifting scissor frames 132 , 134 so that the landing 142 can be raised and lowered. More specifically, the cylinder 148 has a piston 150 disposed within a hydraulic cylinder housing 151 therein, and wherein the hydraulic power unit will act to expand and retract the piston 150 from the cylinder housing 151 , as well understood by those of ordinary skill in the art. As seen in FIG. 7A , the housing 151 is attached to the base 120 and the piston 150 is connected to the scissor frames 132 , 134 via the connector brace 152 , such as connector brace 152 being attached to arm 138 . Hence, as the piston 150 expands and retracts from housing 151 , the scissor frames 132 , 134 will expand and retract, and the landing 142 will be raised and lowered.
FIG. 7B is a partial view of the tubular platform 32 seen in FIG. 7A in the lowered (i.e. collapsed) position having been collapsed along the pivot point pin 140 . In the position shown in FIG. 7B , the operator may stow the tubular platform 32 onto the skid for transportation. FIG. 7B depicts the base 120 with the wheels 122 , 124 , 126 operatively attached for movement. The landing 142 is shown along with the roller 144 and ball transfer device 147 .
FIG. 7C is a schematic of the ball transfer device 146 , which includes a flange socket ball transfer unit 153 a . The flange socket ball transfer unit 153 a is commercially available from Omni Track under the name Flange Socket 93 Series. The ball transfer unit 153 a includes a ball 153 b which is secured within a housing (i.e. socket) 153 c . The ball transfer device 146 also includes a hydraulic piston device which includes a piston activator shaft 154 a that extends from hydraulic housing 154 b . The housing 154 b is connected via a hydraulic line 154 c , wherein the line 154 c may, but not necessarily, contain a hydraulic fluid accumulator 155 . The line 154 c is connected to the hydraulic pump and thus is controlled by the operator via the control unit 10 . Thus, the operator can raise the ball transfer unit 153 a to engage, lift and allow rotation of the tubular. The ball allows rotation in all phases (i.e. 360 degree phase). Also, due to the connection with the hydraulic fluid system, the ball transfer device 153 a allows for dampening the transfer weight of the tubular member during torqueing.
Referring now to FIG. 8 , a process flow chart of one embodiment of the sensor and processor unit associated with the present system will now be described. The control unit 10 receives inputs from an operator 159 , the hydraulic power unit 12 as well as the processor unit 160 . The control unit 10 will output hydraulic fluid to the rotary tong 6 and the back-up tong 8 . In one embodiment, during the process of operating the tong assembly, a sensor 162 is operatively associated with the rotary tong 6 and a sensor 164 is operatively associated with the back-up tong 8 . The sensors 162 , 164 will detect the torque applied to the connections of the tubulars. The sensors 162 , 164 will transmit a signal to the processor unit 160 , wherein the processor unit 160 will receive the sensor reading, store the sensor reading, process the sensor reading, and display the sensor reading to the operator. The processor unit 160 may be a desktop computer commercially available from McCoy Global under the name FarrWincatt.
The control unit 10 is also operatively connected to the tubular platforms 32 , 34 , and in particular, the control unit 10 can act to supply hydraulic fluid to the hydraulic drive cylinder 148 so that the tubular platforms 32 , 34 may be raised or lowered. Also, the control unit 10 can act to supply hydraulic fluid to the rollers on the platforms 32 , 34 so as to advance and retract the tubulars into and out of the tong assembly. Additionally, the control unit 10 will supply hydraulic pressure to the ball transfer device 153 a so that the ball transfer device 153 a is lifted and lowered during the make-up or breaking of the tubular connections as previously set-forth.
FIG. 9 is a schematic of one of the embodiments of the hydraulic system. More specifically, FIG. 9 depicts the hydraulic power unit 170 which includes the oil pump 172 , regulator 174 and the valve bank 176 . The pump 172 , regulator 174 and valve bank 176 are all commercially available from McCoy Global under the name Type 3 Bucking Unit (Power Unit & Control Console) CLEBU 1175-3. While a total of six (6) banks are shown, it is possible to use more banks or less banks as needed. FIG. 9 also shows the tong hydraulic motor 178 , the clamp cylinder 180 and the lift pipe centering guide cylinder 182 . The scissor lift cylinder units 184 a , 184 b are depicted along with the pipe roller motors 186 a , 186 b . The lift cylinders 188 a , 188 b for the ball transfer devices are also displayed on the schematic. A hydraulic splitter 190 is a gear type splitter commercially available from Haldex Barnes under the name Hydraulic Flow Divider, wherein the splitter 190 allows both of the scissor lifts to rise and lower evenly together. An hydraulic accumulator 192 absorbs hydraulic fluid and pressure fluctuations during operation of the scissor lifts.
FIG. 10 is an example graph of the torque applied by one embodiment of the present system. The graph includes the torque in foot-pounds on the vertical axis and the time on the horizontal axis. The horizontal axis depicts four time intervals that torque was applied, namely T1, T2, T3, T4. For the time intervals T1, T2, T4, the torque applied may represent approximately 5,000 foot-pounds, which is in the acceptable torque range. However, during the time interval T3, the applied torque is 10,000 foot-pounds which is above an acceptable range (note these numbers are for exemplary purposes only). Therefore, the operator may need to take corrective action as necessary. The corrective action may include inspection and/or disguarding of the tubular. Additionally, since the processor unit 160 records the torque data, a record may exist for future uses at the direction of the operator.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. 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 modular system and process for connecting a first and second tubular. The system may comprise a skid, a tong assembly operatively associated with the skid, a hydraulic power unit, operatively positioned on said skid, a spring assembly that includes spring stands, a frame containing the tong assembly, springs, rods disposed within the spring, and lanyards attached to the rods on a first end and attached to the base on a second end so that vibratory and displacement forces created during torqueing of the first tubular onto the second tubular are absorbed. The system may also include a sensor, operatively positioned on the skid, for sensing an applied torque to the first and second tubular, and generating a sensor signal.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/671,244 filed on Jul. 13, 2012, the entire disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to food processing devices, and more specifically to a rotary grater having a storage device.
2. Description of Related Art
Grating various materials such as food products has proven very useful in the preparation of many culinary dishes. Graters such as box graters and planar graters have existed for many years. In fact, the first cheese grater was invented by Francois Boullier, who developed a grater in the 1540's so that hard cheeses could still be used. In the 16 th century, there was a cheese surplus because many farmers had converted their cattle herds to dairy production in response to the current thinking of the time to avoid meat consumption. This resulted in a surplus of dairy, and the market became flooded with cheese. There was more cheese than buyers, and much of it became hard. Thus, Francois Boullier invented the cheese grater to put to use hard cheese that would otherwise be discarded. His invention became very popular in Paris in the 1540's. Unfortunately, in 1555 a drought hit Europe, drastically reducing dairy production, ending the surplus of cheese and also ending the popularity of his invention. It was not until the 1920's that an entrepreneur in Philadelphia by the name of Jeffrey Taylor once again made cheese graters popular during the great depression by allowing one to stretch the amount of cheese in a recipe. Taylor owned a cheese shop, and made his first units from shower drains with sharpened openings after reading about Boullier's invention. It was sold as the “greater”, as it made small portions of cheese appear greater.
Graters are commonly made of a metal such as stainless steel, and have perforations throughout. These perforations are commonly round or oval, and have a raised side to facilitate grating of the food product. These perforations may vary in size and number depending on the particular application. For example, cheese may be grated course or fine, and the size of the perforations will dictate the size of the grated pieces. Very small perforations may be desirable in applications such as the grating of spices such as, for example, nutmeg. The grating of other materials, such as citrus rind, may require medium to fine perforations. Typically, a well equipped kitchen will have several size graters to accommodate various culinary applications. While box and planar graters are useful, they are also labor intensive and represent a risk of skinned knuckles or fingers. Rotating graters that employ, for example, a rotating disk either driven manually or by a small electric motor, speed up the process of grating food products and reduce the risk of injury to the user.
What is needed is a rotary grater that has interchangeable blades to accommodate various grating applications and a removable handle to facilitate blade interchange.
What is also needed is a rotary grater that has a removable storage device configured so that the grated material is deposited into the removable storage device. A lid that is stored on the removable storage device when not in use is also desirable.
What is also needed is a press to apply uniform pressure to the food product while being grated and to maintain a fixed and uniform force of the food product on the cylindrical blade as the food product becomes smaller during grating operations.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a rotary grater comprising a housing formed generally as an elliptical cylinder, a cylindrical blade disposed within the housing, a handle connected to the cylindrical blade, an entry opening in the housing for receiving a material to be grated, an exit opening in the housing located below the cylindrical blade for dispensing grated material, a handle opening in the housing to facilitate connection of the handle to the cylindrical blade, a press movably connected to the housing, a lever connected to the press, and a storage device formed generally as an elliptical cylinder and removably connected to the housing for receiving and storing grated material.
The foregoing paragraph has been provided by way of introduction, and is not intended to limit the scope of the invention as described in this specification, claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by reference to the following drawings, in which like numerals refer to like elements, and in which:
FIG. 1 is a perspective view of the rotary grater with storage device;
FIG. 2 is an exploded perspective view of the rotary grater with storage device;
FIG. 3 is a top plan view of the rotary grater with storage device;
FIG. 4 is a long side plan view of the rotary grater with storage device;
FIG. 5 is a bottom plan view of the rotary grater with storage device;
FIG. 6 is a short side view of the rotary grater with storage device;
FIG. 7 is an opposing short side view of the rotary grater with storage device;
FIG. 8 is a top plan view of the handle of the rotary grater with storage device;
FIG. 9 is a side plan view of the handle of the rotary grater with storage device;
FIG. 10 is an underside plan view of the handle of the rotary grater with storage device;
FIG. 11 is a bottom plan view of the lower part of the housing of the rotary grater;
FIG. 12 is a perspective view of the lower part of the housing of the rotary grater;
FIG. 13 is a perspective view of the upper part of the housing of the rotary grater;
FIG. 14 is a top plan view of the press of the rotary grater;
FIG. 15 is a perspective view of the press of the rotary grater showing the hinge rod;
FIG. 16 is a plan view of the outside of the press of the rotary grater;
FIG. 17 is a plan view of the inside of the press of the rotary grater;
FIG. 18 is an exploded view of the storage device with lid;
FIG. 19 is a side plan view of the storage device with lid;
FIG. 20 is a perspective view of an exemplary cylindrical blade;
FIG. 21 is a side plan view of an exemplary cylindrical blade;
FIG. 22 is a side plan view of an exemplary cylindrical blade;
FIG. 23 is a side plan view of an exemplary cylindrical blade;
FIG. 24 is a top plan view of the bowtie connector receiver hub; and
FIG. 25 is an inside plan view of the bowtie connector receiver hub.
The attached figures depict various views of the rotary grater with storage device in sufficient detail to allow one skilled in the art to make and use the present invention. These figures are exemplary, and depict a preferred embodiment; however, it will be understood that there is no intent to limit the invention to the embodiment depicted herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by this specification, claims and drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A Rotary Grater With Storage Device is described and depicted by way of this specification and the attached drawings.
For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.
Referring to FIG. 1 , a perspective view of the rotary grater with storage device 100 is depicted. The rotary grater comprises a housing 101 formed generally as an elliptical cylinder. The housing 101 may be made from a material such as a plastic that is injection molded and contains features that will be further described and depicted herein. A suitable plastic is, for example, acrylonitrile butadiene styrene (ABS). While the housing 101 is formed generally as an elliptical cylinder (also known as an elliptic cylinder), other geometries such as a cylinder, a parabolic cylinder, a hyperbolic cylinder, and the like, are considered within the spirit and broad scope of the present invention. A cylindrical blade 103 is disposed within the housing. The cylindrical blade 103 is made from a metal, such as a stainless steel, and has perforations as can be seen in the drawings. The perforations may, in some embodiments of the present invention, have a raised area around one side of each perforation to facilitate grating. The cylindrical blade 103 may be stamped from a sheet of metal to provide perforations and a raised area, and then rolled into a cylinder with the ends joined together by way of welding, crimping, or the like. The cylindrical blade 103 has a hub arrangement (not shown in FIG. 1 ) to facilitate removable connection of a handle 105 to the cylindrical blade. A handle opening (not shown in FIG. 1 , see FIG. 2 ) provides for the connection of the handle 105 to the cylindrical blade 103 . The handle 105 may be made from a plastic and may have, in some embodiments of the present invention, a knob 107 . A suitable plastic for the handle 105 and the knob 107 being, for example, acrylonitrile butadiene styrene (ABS). There is also an entry opening 113 in the housing 101 for receiving material to be grated. The entry opening may be a variety of sizes and geometries. There is also an exit opening (not depicted in FIG. 1 , see FIG. 11 ) in the housing 101 located below the cylindrical blade 103 for dispensing grated material. Further depicted is a press 115 movably connected to the housing 101 . The press 115 pushes a material to be grated into the cylindrical blade 103 by way of force from a user's hand or fingers. The press 115 is movably connected to the housing 101 by way of a hinge or similar apparatus. As the material to be grated gets smaller, the press 115 moves the material to be grated closer to the cylindrical blade while protecting the user's fingers from injury. In some embodiments of the present invention there is a lever 1403 (not shown in FIG. 1 , see FIG. 14 ) connected to the press 115 to allow a user to move the press 115 either into or out of the cylindrical housing envelope. The press 115 and lever 1403 may be made from a plastic, and will be further described and depicted herein. A storage device 109 is formed generally as an elliptical cylinder, or with a geometry similar to that of the housing 101 . The storate device 109 is removably connected to the housing 101 for receiving and storing grated material. The storage device 109 may be made from a plastic and further may have a flange 117 that circumscribes the storage device 109 such that it may be retained by a flange receiver 119 that is formed into the housing 101 . A lid 111 may also be retained by the storage device 109 by way of a lid retainer 227 (depicted in FIG. 2 ) for subsequent covering of grated material that may be contained in the storage device 109 .
FIG. 2 is an exploded perspective view of the rotary grater with storage device. The lid retainer 227 can be seen as a reduced size area of the storage device 109 . Further, knurls 223 can be seen within an inner edge for retaining the lid 111 to the storage device 109 at either the top of the storage device 109 or the lid retainer 227 . The knurls 223 are features such as bumps, ridges, grooves, or the like and serve to increase the friction and binding force between the lid 111 and the storage device 109 .
Also depicted in FIG. 2 is a handle opening 221 that allows the handle 105 to couple with the cylindrical blade 103 so that the cylindrical blade can be rotated by movement of the handle 105 . The cylindrical blade 103 can also be seen with a bowtie connector receiver hub 225 that may be made of a material such as a plastic.
FIG. 3 is a top plan view of the rotary grater with storage device and FIG. 4 is a long side plan view of the rotary grater with storage device. FIG. 5 is a bottom plan view of the rotary grater with storage device where the lid 111 can be seen retained by the lid retainer 227 as further depicted in FIG. 18 . The handle 105 can be seen with the knob 107 where the knob 107 is free to rotate with respect to the handle 105 by way of a joint, socket, pin, or similar arrangement, thus allowing a user to grasp the knob 107 and rotate the handle 105 , imparting rotary motion to the cylindrical blade 103 .
FIG. 6 is a short side view of the rotary grater with storage device. The flange 117 and flange receiver 119 can be seen in cooperation to retain the storage device 109 to the housing 101 .
FIG. 7 is an opposing short side view of the rotary grater with storage device.
FIGS. 8-10 depict various views of the handle 105 and related structures.
FIG. 8 is a top plan view of the handle of the rotary grater with storage device where the knob 107 can be seen movably connected to the handle 105 .
FIG. 9 is a side plan view of the handle of the rotary grater with storage device. A bowtie connector 901 can be seen protruding from the lower part of the handle 105 . The bowtie connector provides a releasable connection from the handle 105 to the cylindrical blade 103 (not shown in FIG. 9 ). This releasable connection allows a user to easily disassemble and clean the rotary grater, and to easily and quickly change cylindrical blades.
FIG. 10 is an underside plan view of the handle of the rotary grater with storage device showing clearly the bowtie connector 901 . The bowtie connector 901 mates with the bowtie connector receiver hub 225 that is attached to the cylindrical blade 103 , as seen in FIG. 2 and subsequently in FIGS. 20-25 . The bowtie connector 901 may be made from a plastic similar to that of the handle 105 , or may be molded with the handle 105 .
The housing 101 , as depicted in FIGS. 1 and 2 , may be made from a material such as a plastic or a metal. In some embodiments of the present invention, the housing 101 comprises a lower part and an upper part that are attached together by way of an adhesive, a weld, snap fittings, screws, or the like.
FIG. 11 is a bottom plan view of the lower part of the housing of the rotary grater. An exit opening 1101 is depicted that is situated below the cylindrical blade when in use, and serves to dispense grated material to be received by the storage device 109 (see FIG. 1 ). Further, retention tabs 1103 can be seen on the bottom of the lower part of the housing that comprise bumps, ridges, grooves, or the like, and serve to retain the storage device 109 (see FIG. 1 ) by directing force to a rim or edge of the storage device 109 .
FIG. 12 is a perspective view of the lower part of the housing of the rotary grater. A lower hinge receiver 1201 can be seen for coupling to the press 115 (see FIG. 1 ). The lower hinge receiver 1201 may be, for example, molded with the lower part of the housing of the rotary grater using standard plastic injection molding techniques.
FIG. 13 is a perspective view of the upper part of the housing of the rotary grater. An upper hinge receiver 1301 can be seen for coupling to the press 115 (see FIG. 1 ). The upper hinge receiver 1301 may be, for example, molded with the upper part of the housing of the rotary grater using standard plastic injection molding techniques.
FIGS. 14-17 depict the press of the rotary cheese grater. The press 115 is made from a plastic such as, for example, acrylonitrile butadiene styrene (ABS). The press may also be referred to as a door. The press 115 generally conforms to the shape of the housing 101 .
FIG. 14 is a top plan view of the press of the rotary grater. A hinge 1401 may be connected to, or integrated or molded with, the press 115 . A lever 1403 can be seen that allows a user to move the press towards or away from the cylindrical blade 103 . A retaining edge 1405 can also be seen that acts to stop the press 115 from traveling too far outward, essentially retaining the press 115 within the confines of the housing envelope such that the material to be grated does not fall out of the rotary grater. The retaining edge 1405 may be integrated or molded with the press 115 . The retaining edge 1405 further engages with a similar retaining edge or stop on the housing to prevent unwanted travel of the press. A small bump or extension may also be present on the housing 101 to engage with retaining edge 1405 of the press 115 .
FIG. 15 is a perspective view of the press of the rotary grater showing a hinge rod 1501 . The hinge rod 1501 may be made from a metal such as stainless steel and serves to couple the hinge 1401 on the press 115 with the lower hinge receiver 1201 (see FIG. 12 ) and the upper hinge receiver 1301 (see FIG. 13 ). The hinge rod 1501 in FIG. 15 is shown in exploded perspective for clarity. For a complete understanding of the press 115 and related hardware and features, FIG. 16 is a plan view of the outside of the press of the rotary grater and FIG. 17 is a plan view of the inside of the press of the rotary grater.
The storage device 109 and lid 111 can be seen detached from the housing 101 in FIGS. 18 and 19 . FIG. 18 is an exploded view of the storage device 109 with lid 111 . The storage device 109 may be made from a plastic such as, for example, acrylonitrile butadiene styrene (ABS). The lid 111 may be made from a softer durometer plastic to allow for easy placement of the lid 111 on the storage device 109 . An example of such a plastic is ethylene-vinyl acetate (EVA). The lid 111 may, in some embodiments of the present invention, have knurls 223 that can be seen within an inner edge for retaining the lid 111 to the storage device 109 at either the top of the storage device 109 or the lid retainer 227 . The knurls are features such as bumps, ridges, grooves, or the like and serve to increase the friction and binding force between the lid 111 and the storage device 109 .
FIG. 19 is a side plan view of the storage device with lid that shows how the lid retainer 227 serves to retain the lid 111 when not in use.
FIGS. 20-23 depict various cylindrical blades with various size perforations. Smaller perforations generally produce smaller gratings, and perforation size and spacing is often times dependent on the application. For example, cheese may be grated course or fine. Chocolate may be grated in various sizes depending on the culinary application. Spices such as nutmeg are almost always grated with extremely small perforations to produce small particles of the spice so as not to overpower the food being prepared. The cylindrical blade 103 is made from a metal, such as a stainless steel, and has perforations as can be seen in the drawings. The perforations may, in some embodiments of the present invention, have a raised area around one side of each perforation to facilitate grating. The cylindrical blade 103 may be stamped from a sheet of metal to provide perforations and a raised area, and then rolled into a cylinder with the ends joined together by way of welding, crimping, or the like. The cylindrical blade 103 has a bowtie connector receiver hub 225 to facilitate removable connection of a handle 105 to the cylindrical blade. This hub arrangement will be further described by way of FIGS. 24 and 25 .
FIG. 24 is a top plan view of the bowtie connector receiver hub 225 . A hub 2401 encompasses the end of a cylindrical blade 103 and rotates within the handle opening 221 (see FIG. 2 ) when the handle 105 turns the cylindrical blade 103 . A first receiver part 2405 and a second receiver part 2407 make up a bowtie connector receiver 2403 that comprises an opening that is similar in shape to a bowtie. This bowtie connector receiver mates with the bowtie connector 901 that is attached to the handle 105 (see FIGS. 9 and 10 ). The mating of the bowtie connector 901 with the bowtie connector receiver 2403 provides for removable connection of the handle 105 to the cylindrical blade 103 .
FIG. 25 is an inside plan view of the bowtie connector receiver hub looking up through the cylindrical blade 103 . A first receiver part stop 2501 and a second receiver part stop 2503 can be seen. These stops provide a fixed point such that the handle turns the cylindrical blade 103 , and does not merely spin freely through the bowtie connector arrangement. The bowtie connector receiver hub 225 is made from a plastic such as, for example, polypropylene. A secondary hub, depicted at the opposite end of the cylindrical blade 103 from the bowtie connector receiver hub 225 , as seen in FIGS. 20-23 for example, serves to rotate within the exit opening as the handle 105 turns the cylindrical blade 103 , serving as a bearing or bushing of sorts. This secondary hub may also be made from a plastic such as, for example, polypropylene. Both hubs are attached to the cylindrical blade by an adhesive, locking tabs, crimps, or the like.
To use the Rotary Grater With Storage Device, a piece of material to be grated is placed through the entry opening 113 and the press 115 is moved inward by way of the lever 1403 so that the material to be grated makes contact with the cylindrical blade 103 . The handle 105 is rotated such that the cylindrical blade 103 in turn rotates, and grated material exits the rotary grater and enters the storage device 109 . Once a suitable amount of material is grated, the storage device 109 is removed from the housing 101 . Additional grated material may be stored in the storage device 109 and sealed with the lid 111 .
It is, therefore, apparent that there has been provided, in accordance with the various objects of the present invention, a rotary grater with storage device. While the various objects of this invention have been described in conjunction with preferred embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of this specification, claims and the attached drawings.
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A rotary grater having a removable storage device is disclosed. The rotary grater has interchangeable cylindrical blades for various grating purposes. A removable handle provides for rotational motion for the cylindrical blade to operate. The housing of the rotary grater has a movable press with a lever for applying the material to be grated to the cylindrical blade. The grated material is then dispensed from an exit opening in the housing and retained by a removable storage device.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/230,018, filed Sep. 19, 2005, the entirety of which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to messaging systems, and more particularly to electronic messaging systems.
BACKGROUND OF THE INVENTION
Today's work and home lifestyles can be very busy for many families. In many cases, individual family members may be involved in multiple activities. Oftentimes, individual family members may have very little personal interaction. In some such families, a bulletin board, chalk board or other manual messaging systems may be used to provide some means of communication between members of the household. In some households, notes may be placed on the refrigerator or other commonly used appliances. Message areas may include a place for leaving notes of interest to the entire household, such as reminders for group events or grocery lists. In some households, the message area may be divided into various sub-areas allowing messages to be easily targeted to one or more household members.
Such messaging systems are also commonly used in a variety of offices or other work spaces. For example, a bulletin board system may be used to let others in the work place know of an individual's whereabouts. A bulletin board may also be used to post important messages for employees' attention.
A problem with the above-described messaging systems in that an individual must be near the location of bulletin board to be able to post or read messages on the board. That is, conventional message systems do not provide a convenient method to manage notes posted in a shared environment from a remote location. For example, if a user is away from home when he or she desires to post a message to the bulletin board, that user would not be able to post the message until he or she returns home. By this time, the intended recipient of the message may have already departed the home, thereby missing the communication from the user. In another example, a message cannot be removed from the messaging area unless the user is physically near the messaging system. Similarly, a user cannot post a new message or update an existing messaging from a remote location.
Another problem with conventional messaging systems is that it is difficult to determine whether or not one or more of the intended recipients have read the note. For example, in conventional bulletin boards, even if a reader of a note initials the note or otherwise marks it to show it has been read, other users of the bulletin board must still physically review the board to receive the notification.
Conventional messaging systems also do not provide convenient means for creating a transportable copy of any messages posted thereon. Currently, if a user wants to take a copy of a message away from the messaging system, the user must manually copy a note onto a separate piece of paper. Alternatively, if the note was posted using a paper that may be removed from the board (e.g., pinned or taped to a bulletin board) the user may physically remove note and take the message away from the messaging system. However, if a note is removed from the message board then others members of the household or workplace will not be able to read the note.
SUMMARY OF THE INVENTION
The present invention uses a broadband-enabled internet connection to provide an always-on interface to a virtual family, group, or office bulletin board system. Family members (or, e.g., associates or co-workers) may use this shared environment to communicate with one another either locally or remotely (e.g., using any email- or other web-capable device). The system allows users to print, reply to messages, and hot link to embedded web uniform resource locators (URLs) from within a posted message.
The present invention also provides the capability to create, share and modify “common notes” (e.g., a shopping list) that can be written to or retrieved by anyone, whether in a remote location or not. Accordingly, the present invention provides systems and methods enabling a user to update the bulletin board whenever a need arises. For example, if a user is on his way home from work when he decides to stop at a grocery store, he may retrieve a current version of the shopping list by sending an email or other command to an application server. The application server responds to the request and sends a copy of the list to the user. Further, the user may send a request to update the bulletin board to reflect his intent to purchase the items from the list. In another example, a user, for example, a child, may be informed at school of some item he needs to bring to school. The child may send a message to update the shopping list with the additional item. In this manner, there is less chance of the child forgetting to inform the parents that an item is needed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing an exemplary user-interface that may be used in an embodiment of the present invention.
FIG. 2 is a schematic diagram showing an exemplary electronic bulletin board according to an embodiment of the present invention.
FIG. 3 is a schematic diagram showing an architecture that may be used to implement an embodiment of the present invention.
FIGS. 4A and 4B are exemplary tables that may be maintained in a customer database in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention comprises an “always-on” electronic bulletin board system that may be remotely manipulated by users. Remote manipulation may include, for example, reading one or more notes posted on the bulletin board, posting one or more notes to the bulletin board, deleting one or more notes from the bulletin board, acknowledging receipt of a note posted on the bulletin board, and the like. FIG. 1 shows an exemplary display device, communications center 100 , that may be used to display an electronic bulletin board according to an embodiment of the present invention. Communications center 100 may optionally include a memory, a central processing unit and computer programming logic for controlling the device. FIG. 1 shows a display of an exemplary graphical user interface for providing various communications systems via communications center 100 .
An electronic messaging system according to an embodiment of the present invention may be provided as an option, such as message center 102 on communications center 100 . Message indicators, for example indicator 104 , may be used to provide a visual alert to one or more family members that a message has been posted for their attention. As shown in FIG. 1 , message center 102 may include a separate area for each family member (or workplace user) and a collective “family” (or workplace) area. In this embodiment, a user in the household (or workplace) may access the message center (e.g., by clicking on icon 106 ) to manipulate messages in the communications center. As will be described in greater detail herein, remote users may also access the communication center to manipulate messages.
FIG. 2 shows an exemplary graphical user interface that may be displayed in embodiments of the present invention when a user clicks on icon 106 . Alternatively, the interface shown in FIG. 2 may be displayed on communications center 100 when the device is idle. For example, the bulletin board may automatically be displayed in a manner similar to that of a “screen saver” commonly used on personal computer systems. As would be apparent to one of ordinary skill in the art, other visual display layouts may be used to convey the message information to users. For example, a text-based interface may be used in embodiments of the present invention. In another example, the messages may include audio and/or video clips providing multimedia communications via the bulletin board system.
As shown in FIG. 2 , in an exemplary embodiment, messages may be posted to the bulletin board and addressed to particular members of the household (or workplace). For example, message 202 is addressed to “Billy” whereas message 204 is addressed to “Mom.” Similarly, messages may be address to “All” members of the household (or workplace) such as message 206 , or may comprise a universal message, such as grocery list 208 .
In the exemplary embodiment shown in FIG. 2 each message includes a menu bar 210 providing options for manipulating the message. Options may allow a user to reply to a message (“Reply”), print a message to a printer device attached to communications center 100 or another printer device accessible on a network (“Print”), delete a message from the display area (“Delete”), mark a message as read (“Mark”), mail a message to some other system (“Mail”), edit a message (“Edit”) and read extended messages (“More”). Other options may be provided in alternative embodiments of the present invention. Moreover, the menu of options need not be provided individually on each message. That is, a single menu may be used to manipulate selected messages. Alternatively, other user interface options may be implemented to present the menu of options to a user (e.g., “right-clicking” on a message may result in a menu being displayed).
An embodiment of the present invention also allows a user to post messages including links to web pages. For example, message 212 from “Steve” to “Jan” includes a uniform resource locator (URL) that the author wants the recipient to review. When Jane reads message 212 , she may click on the link to view the web page.
An embodiment of the present invention may include additional option buttons such as, for example, buttons 214 and 216 providing other options for the user. In this example, button 214 allows a user to create a new message to be posted on the bulletin board and button 216 allows the user to return to a main screen, such as shown in FIG. 1 .
FIG. 3 shows an architecture that may be used to implement an embodiment of the present invention. In this embodiment, the primary logic for providing a service according to the present invention is provided by application server 300 and customer database 302 . Application server 300 may be any computer system, which would typically include a central processing unit, a volatile memory and a non-volatile memory. Customer database 302 may be part of application server 300 or may be on a different computer system. In this embodiment, customer database 302 includes records mapping a user's email address to the user's bulletin board address. The database may also include an IP address associated with particular users and may include user authentication information. FIG. 4A shows an example of records 400 that may be stored in customer database 302 . The mapping provided by customer database 302 may be used in an embodiment to simplify the displayed names for a sender and recipient of a message, as described below.
In an embodiment implemented as shown in FIG. 3 , a user may post messages to the electronic bulletin board by sending an instruction via an email sent to a specified address. The email is processed by application server 300 which generates a message to send to communications center 100 . The email may be sent from any email-enabled device, including, for example, interactive pager 304 , wireless telephone 306 , wireless personal digital assistant (PDA) 308 , handheld computer 310 , computer 312 , internet appliance 314 , and the like. Moreover, as shown in FIG. 3 , the devices may transmit the email message via any standard data path to which the devices are adapted. For example, devices 304 - 310 may be adapted to transmit email via wireless voice/data network 316 . Network 316 may include one or more wireless application protocol (WAP) gateways and one or more web gateway systems. Similarly, devices 310 - 314 may transmit email via switch 318 and internet service provider (ISP) 320 . Switch 318 may be a central office (CO) switch such as those used in the public switched telephone network, or may be a softswitch used in data networks and voice-over-IP systems. ISP 320 provides connectivity to internet 322 .
Application server 300 may, for example, send the message to client gateway 108 via secure intranet 326 , firewall 324 , ISP 320 and internet 322 as shown in FIG. 3 . It would be apparent to one of ordinary skill in the art that other means of sending the message to gateway 108 may also be used. Although FIG. 3 shows only one ISP and one wireless network providing internet connectivity to each device, there may be multiple ISPs and multiple wireless network service providers as would be apparent to one of ordinary skill in the art. Similarly, there may be multiple switches serving each of devices 310 - 314 or a single switch may be used as shown in FIG. 3 .
Remote Writing (Posting) of Items to Bulletin Board
As noted above, a remote user may post an item (i.e., a message) to the bulletin board system by sending an email message to an address that is routed to application server 300 . Upon receipt of the email message, application server 300 may consult customer database 302 to determine whether or not the sender of the email is an authorized user of the electronic bulletin board. Such an authentication step is an optional procedure and may be carried out in a variety of ways. For example, customer database 302 may comprise a list of authorized sender email addresses from which it accepts bulletin board messages. Alternatively, customer database 302 may include a username and password that must be included in the email message.
In this embodiment, the sender's email message may include an addressee such as, for example, “TO: Billy@joneshome.com” and a sender's address such as, for example, “FROM: Jane@Janeswork.com.” Application server 300 looks up the addressee's domain name in column 402 in of table 400 in customer database 302 to determine the destination address, that is, an address associated with client gateway 108 at the user's home (or workplace). As shown in FIG. 4A , the destination address (column 404 ) may be expressed as any network address, such as for example, an IP address or a domain name, among others. Application server 300 may check to see whether or not the sender is authorized to post messages to an electronic bulletin board associated with this destination address. As described above, this step (if implemented) may involve a lookup of the sender's email address (column 406 ) or may involve verification of a username (column 408 ) and password (column 410 ). Alternatively, in some embodiments, open access may be allowed (i.e., application server accepts all messages received and processes them for posting to the electronic bulletin board).
Application server 300 may format the message for delivery to client gateway 108 and display on communications center 100 . In an embodiment of the present invention, customer database 302 also includes a mapping of email sending and receiving addresses to provide a more personalized messaging system. For example, customer database 302 may include a table such as table 450 shown in FIG. 4B . In this example, a message received from “Jane@Janeswork.com” is formatted for posting on the electronic bulletin board according to the recipient's address. That is, if Jane is sending a message intended for one of her children (Billy or Jane) application server 300 formats the message to identify the sender as “Mom” and the recipient by his or her first name as shown in rows 452 and 454 . However, when a message from “Jane@Janeswork.com” to “Steve@joneshome.com” is received, application server 300 formats the message to be posted to include a sender name “Jane” and a recipient name “Steve” as shown in row 456 . Similarly, a message from Jane to “all@joneshome.com” is routed to “Steve & Kids” from “Mom” as shown in row 458 .
In another embodiment of the present invention, a user may post a message to the bulletin board system by connecting to application server 300 . The connection process may be completed using any suitable network protocol, including, for example, HTTP, Telnet, and the like. Again, there may be an authentication process for verifying the user's rights to access the bulletin board system. Such authentication process may include, for example, checking a list of authorized network addresses that may connect to the server, username and password control, and the like. In this embodiment, the user may be provided a menu of options to select, for example, the sender and receiver names to use for a posted message.
Remote Reading of Bulletin Board Items
Remote retrieval or reading of content on an electronic bulletin board according to an embodiment of the present invention may be accomplished in substantially the same manner as described above. That is, for example, a user may send an email message to application server 300 requesting a download of messages from the bulletin board. In one embodiment, the user may be provided the option of only downloading those items that have not been marked read by the user. In another embodiment, the user may request a subset of messages, for example, only messages addressed to the user. In still other embodiments, the user may be able to select messages from a particular user, messages according to their posting time, or other criteria for identifying messages to be downloaded.
In an embodiment of the present invention, application server 300 maintains a copy of messages sent to client gateway 108 . In this embodiment, download requests may be processed at application server 300 without a need to contact client gateway 108 . In other embodiments, application server 300 does not maintain copies of messages posted to the bulletin board. In this embodiment, when a download request is received, application server sends a retrieval command to client gateway 108 . Client gateway 108 responds to the command and sends requested content either to application server 300 for further processing or directly to the requestor's email address.
In another embodiment of the present invention, a user may read messages or request downloads of messages by logging onto application server 300 using any suitable network protocol as described above. In this embodiment, application server 300 may include, for example, a web server configured to display the bulletin board content via a web browser application. As described above, the user may request all messages, or may select a subset of messages for retrieval.
In an embodiment, application server 300 may check the user's permission to access the bulletin board, as described above. That is, application server 300 may request the user to provide a usemame and password, or may check the requestor's email or IP address to determine whether or not the request should be honored.
Other Remote Manipulation of Bulletin Board Items
According to an embodiment of the present invention, a user may perform other remote manipulation operations on posted bulletin board items. For example, a user may request removal of an item from a bulletin board. In other embodiments, a user may remotely edit a particular message. Other remote manipulation operations that may be provided in one or more embodiments of the present invention include marking a message as read, replying to a message, changing a position of a posting on the bulletin board, copying a message, mailing a message to another email address, and the like.
In some embodiments, customer database 302 may include access levels for determining which users may perform these or other manipulation operations on one or more messages on the bulletin board. As with other embodiments described herein, the user may be requested to provide user authentication information or application server 300 may use other suitable authentication methods. Furthermore, in some embodiments, the user posting a message on the bulletin board may determine which other users may manipulate the message. For example, a user may “lock” a message to prevent others from deleting it.
Other Alternative Embodiments
In an embodiment of the present invention, special messages may be supported. For example, a special message such as grocery list 208 shown in FIG. 2 may be remotely manipulated. As used herein, grocery list 208 is a “special message” because it need not include an author (i.e., sender) name and need not include an addressee. A user may update grocery list 208 in generally the same manner as described above, except that the user may address the email to, for example, “grocery@joneshome.com.” Application server 300 may format the contents of the email to display a message as shown in FIG. 2 . Note, that because a grocery list requires no “reply”, the menu of options associated with such a message may be customized as shown in the FIG. 2 to eliminate this option. Alternatively, the system may include a “reply” option in the menu.
The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed.
Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
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An electronic bulletin board for use in a shared always-on environment wherein a user may manipulate messages from a remote location. The electronic bulletin board may be implemented via database and programming logic on an application server accessible from any network node, including wireless devices. The always-on environment may be set up on a computer or broadband internet appliance or other communications device. Remote users may perform operations such as updating an existing message, posting a new message, download messages, and the like. The bulletin board also supports shared messages designed for special purposes, for example, an electronic grocery list that is accessible from remote locations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/021,394 filed Oct. 29, 2001 and claiming a priority date of Oct. 30, 2000, now U.S. Pat. No. 6,805,218.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a motorized vehicle having left and right driving wheels independently driven by left and right electric motors, respectively.
2. Background Information
The term “working machine” is used herein in a comprehensive sense, i.e., to broadly refer to a load-carrying vehicle, a tiller, a tractor, a lawn mower, a snowplow and so on. In case of the tiller, uncultivated areas are formed at ends of an arable land where the tiller makes a 180° turn. The uncultivated areas should preferably be as small as possible. To meet this condition, the tiller is designed to have a smaller turning radius and, ideally, the tiller can make a turn while staying at the same position. Such a turn is referred to as “spot turn”. The spot turn is very useful not only for the tiller but also for other sorts of working machines because they are required to make sharp or abrupt turns frequently to avoid interference with obstacles.
Conventional techniques proposed to improve turning performance characteristics of working vehicles are disclosed in Japanese Patent Laid-open Publications Nos. 10-95360 and 6-87340.
The working vehicle disclosed in Japanese Patent Laid-open Publications Nos. 10-95360 includes a travel HST continuously variable shift mechanism and a turning HST continuously variable shift mechanism disposed in juxtaposition. The travel HST continuously variable shift mechanism is operated by a speed change lever while the turning HST continuously variable shift mechanism is operated a round-type steering handle. The disclosed working vehicle is complicated in construction because a number of links are disposed in a complicated manner below the steering handle and speed change lever. Furthermore, the side-by-side arrangement of two shift mechanisms increases the number of components of the working vehicle and makes the working vehicle expensive to manufacture.
The working machine disclosed in Japanese Patent Laid-open Publications No. 6-87340 includes a hydraulic continuous variable transmission mechanism equipped with left and right neutral valves adapted to be operated by left and right side clutch control levers provided on left and right handlebars, respectively, of the working vehicle. When the left side clutch control lever is gripped together with the left handlebar, the left neutral valve is activated to realize a clutch-off state of the continuous variable transmission mechanism. Similarly, when the right side clutch control lever is gripped together with the right handlebar, the right neutral valve is activated to realize the clutch-off state of the continuous variable transmission mechanism. With this construction, when a spot turn is to be made, the operator is required to manipulate left and right side clutch control levers with high dexterity. A similar attempt by a non-skilled operator would result in a turn of the working vehicle achieved with an increased turning radius much larger than that attained by the spot turn.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a motorized vehicle which is simple in construction but can achieve a spot turn easily and reliably.
To achieve the foregoing object, according to the present invention, there is provided a motorized vehicle comprising: a vehicle body; a left driving wheel and a right driving wheel that are rotatably mounted on the vehicle body; a left electric motor and a right electric motor that are mounted on the vehicle body for independently rotating the left and right driving wheels, respectively, at variable speeds; and an actuator for causing one of the left and right electric motors to rotate in one direction and, at the same time, causing the other of the left and right electric motors to rotate in the opposite direction, thereby ensuring that the vehicle making a turn while staying at the same position.
In one preferred form, the motorized vehicle further includes a pair of left and right handlebars extending from the vehicle body in a rearward direction of the motorized vehicle, each of the handlebars having a handgrip adapted to be gripped by the operator. The actuator comprises a left brake and a right brake that are mounted on the vehicle body for independently applying brake forces to the left and right driving wheels, respectively, and a pair of left and right turn control levers pivotally mounted to the left and right handlebars, respectively, so as to extend along the corresponding handgrips. The left and right turn control levers are operatively connected to both the left and right brakes and the left and right electric motors, respectively, such that the left and right electric motors are caused to rotate simultaneously in opposite directions based on the angular positions of the left and right turn control levers. The left and right brakes are associated with the left and right electric motors, respectively, and separately apply the brake forces to the left and right driving wheels via the left and right electric motors.
It is preferable that the left and right turn control levers are angularly movable between an initial zero-brake position and a stroke end position opposite to the zero-brake position across a full-brake position. The left and right turn control levers are operatively linked with the left and right brakes and the left and right electric motors such that when the left turn control lever moves within a first range defined between the zero-brake position and the full-brake position, the brake force applied from the left brake varies linearly with the amount of displacement of the left turn control lever, when the left turn control lever moves within a second range defined between the full-brake position and the stroke end position, the left electric motor is rotated in the reverse direction, and the right electric motor is rotated in the forward direction, when the right turn control lever moves within the first range, the brake force applied from the right brake varies linearly with the amount of displacement of the right turn control lever, and when the right turn control lever moves within the second range, the right electric motor is rotated in the reverse direction, and the left electric motor is rotated in the forward direction.
In another preferred form, the actuator comprises a left spot turn switch operatively connected to the left and right electric motors and manually operable to cause the left electric motor to rotate in the reverse direction and the right electric motor to rotate in the forward direction, and a right spot turn switch operatively connected to the left and right electric motors and manually operable to cause the right electric motor to rotate in the reverse direction and the left electric motor to rotate in the forward direction. The motorized vehicle may further include an operator control panel mounted to the vehicle body in which instance, the left and right spot turn switches are provided on the operator control panel.
The motorized vehicle may further include a pair of left and right crawler belts driven by the left and right driving wheels.
BRIEF DESCRIPTION OF THE DRAWINGS
Certain preferred embodiments of the present invention will hereinafter be described in detail, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a plan view of a motorized vehicle according to a first embodiment of the present invention;
FIG. 2A is a diagrammatical view showing the operation of an accelerator lever of the motorized vehicle;
FIG. 2B is a graph showing the relationship between the output from an accelerator potentiometer and the position of the accelerator lever;
FIG. 3 is a side view showing a brake control lever serving also as a turn control lever of the motorized vehicle;
FIG. 4A is a diagrammatical view showing the operation of a brake potentiometer taken in conjunction with the position of the turn control lever;
FIG. 4B is a graph showing the relationship between the output from the brake potentiometer and position of the turn control lever;
FIG. 5 is a pictorial block diagram showing a control system of the motorized vehicle;
FIG. 6 is a flowchart showing a series of operations achieved by the control system when the vehicle makes a spot turn;
FIGS. 7A to 7C are diagrammatical views illustrative of the manner in which the vehicle makes a sport turn;
FIGS. 8A and 8B are diagrammatical views illustrative of the manner in which the vehicle makes a normal pivot turn;
FIG. 9 is a plan view of a motorized vehicle according to a second embodiment of the present invention;
FIG. 10A is a diagrammatical view showing the operation of a brake potentiometer taken in conjunction with the position of a brake control lever;
FIG. 10B is a graph showing the relationship between the output from the brake potentiometer and position of the brake control lever;
FIG. 11 is a pictorial block diagram showing a control system of the motorized vehicle shown in FIG. 9 ;
FIG. 12 is a flowchart showing a series of operations achieved by the control system when the vehicle of FIG. 9 makes a spot turn;
FIGS. 13A to 13C are diagrammatical views illustrative of the manner in which the vehicle shown in FIG. 9 makes a sport turn;
FIG. 14 is a side view of a snowplow embodying the present invention;
FIG. 15 is a plan view of the snowplow; and
FIG. 16 is a diagrammatical, partly perspective view showing a control system of the snowplow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in plan view a motorized vehicle 10 according to a first embodiment of the present invention, the vehicle 10 taking the form of a walk-behind motorized crawler cart. The motorized crawler cart 10 generally comprises a vehicle frame or body 11 , batteries 12 mounted on the vehicle body 11 , left and right electric motors 13 L, 13 R powered with the batteries 12 , left and right driving axles 14 L, 14 R rotatably mounted on the vehicle frame 11 and independently driven by the left and right electric motors 13 L, 13 R, respectively, left and right driving wheels 15 L, 15 R attached to an end of the left and right driving axles 14 L, 14 R, respectively, left and right crawler belts 16 L, 16 R each stretched between the driving wheel 15 L, 15 R and a driven wheel 15 ′L, 15 ′R and driven by the driving wheel 15 L, 15 R, and left and right brakes 17 L, 17 R for independently applying a braking force to the left and right driving wheels 15 L, 15 R, respectively. In the illustrated embodiment, the left and right brakes 17 L, 17 R are associated with the left and right electric motors 13 L, 13 R, respectively, for independently braking the motors 13 L, 13 R to vary the speeds of the left and right driving wheels 15 L, 15 R. The driven wheels 15 ′L, 15 ′R are rotatably mounted on opposite ends of a front axle 14 ′ rotatably mounted on the vehicle body 11 .
The vehicle 10 further has a load-carrying platform 20 mounted on the vehicle body 11 , an operator control panel 21 mounted to a rear end of the load-carrying platform 20 , and left and right operation handlebars 30 L, 30 R extending from a rear portion of the operator control panel 21 obliquely upward in a rearward direction of the motorized crawler cart 10 . The handlebars 30 L, 30 R may be so arranged to extend from the vehicle body 11 or the platform 20 . The operator control panel 21 is provided with an accelerator lever 22 .
The operation handlebars 30 L, 30 R have handgrips 25 L, 25 R at free ends thereof for being gripped with hands of the operator. Left and right turn control levers 23 L, 23 R attached to the left and left handlebars 30 L, 30 R so as to extend along the left and right handgrips 25 L, 25 R, respectively. The turn control levers 23 L, 23 R are manually operated to control operation of the corresponding electric motors 13 L, 13 R and the brakes 17 L, 17 R in a manner as described below.
The operator manipulates levers and buttons including the accelerator lever 22 on the operator control panel 21 and the turn control levers 23 L, 23 R while walking behind the vehicle 10 so as to move the vehicle forward or backward, turn the vehicle leftward or rightward, and stop the vehicle.
A control unit 24 is disposed inside the operator control panel 21 and controls operation of the electric motors 13 L, 13 R and the left and right brakes 17 L, 17 R based on the positions of the accelerator lever 22 and turn control levers 23 L, 23 R. The brakes 17 L, 17 R may be an electromagnetic brake, a hydraulic brake, a mechanical brake, regenerative brake and so on.
The accelerator lever 22 is manually actuated to control the direction and speed of movement of the vehicle 10 . The accelerator lever 22 is normally disposed in a neutral position where the vehicle is stopped. The position of the acceleration lever 22 is monitored by an accelerator potentiometer 26 shown in FIG. 2A . The output from the accelerator potentiometer 26 varies linearly with the amount of angular displacement of the accelerator lever 22 , as indicated by a graph shown in FIG. 2B . In the illustrated embodiment, the output from the accelerator potentiometer 26 is set to vary within a range from 0 to 5.0 volts (V). A maximum forward speed of the vehicle is achieved when the output from the accelerator potentiometer 26 is +5.0 V. A maximum backward vehicle speed is achieved when the accelerator potentiometer output is 0 volt. The vehicle is stopped when the accelerator potentiometer output is 2.5 V.
FIG. 3 shows a free end portion of the operation handlebar 30 L, 30 R including the handgrip 25 L, 25 R. The turn control lever 23 L, 23 R is pivotally connected by a hinge pin 31 L, 31 R to the handlebar 30 L, 30 R so as to extend along the handgrip 25 L, 25 R. The turn control lever 23 L, 23 R is firmly connected to one end of an actuator arm 32 L, 32 R of a brake potentiometer 27 a , 27 b so that the actuator 32 L, 32 R angularly moves or turns in unison with the turn control lever 25 L, 25 R. The brake potentiometer 27 L, 27 R is designed such that the output from the brake potentiometer 27 a , 27 b varies linearly with the amount of angular displacement of the actuator arm 32 L, 32 R and turn control lever 23 L, 23 R. As shown in FIG. 3 , the turn control lever 23 L, 23 R is angularly movable between an initial zero-brake position (first position) P 1 indicated by the solid line and a stroke end position (second position) P 2 indicated by two-dot chain line through a full-brake position (third position) P 3 indicated by the dashed line. The turn control lever 23 L, 23 R is normally disposed in the solid-lined zero-brake position P 1 by the force of a return spring 33 L, 33 R.
FIG. 4A shows a range of angular movement of the actuator arm 32 L, 32 R of the brake potentiometer 27 L, 27 R, which corresponds to the range of movement of the turn control lever 23 L, 23 R shown in FIG. 3 . As shown in FIG. 4 , the actuator arm 32 L, 32 R is angularly movable between the first position (zero-brake position) P 1 and the second position (stroke end position) P 2 through the third position (full-brake position) P 3 . The output from the brake potentiometer 27 L, 27 R varies linearly with the position of the actuator arm 32 L, 32 R and turn control lever 23 L, 23 R, as indicated by a graph shown in FIG. 4B . In the illustrated embodiment, the output from the brake potentiometer 27 L, 27 R is set to vary within a range from 0 to 5.0 volts (V). When the turn control lever 23 L, 23 R is in the initial zero-brake position P 1 , the output from the brake potentiometer is nil. When the turn control lever 23 L, 23 R is in the stoke end position P 3 , the output from the brake potentiometer is 5.0 V. And when the turn control lever 23 L, 23 R is in the intermediate full-brake position P 2 , the output from the brake potentiometer is Vm volts, where Vm is greater than 0 and smaller than 5.0. The output voltage Vm may be 1.5, 2.0 or 2.5 volts.
As shown in FIGS. 4A and 4B , when the turn control lever 23 L, 23 R (i.e., the actuator arm 32 L, 32 R) moves within a range defined between the zero-brake position P 1 and the full-brake position P 3 , brake control operation is achieved. On the other hand, when the turn control lever 23 L, 23 R (actuator arm 32 L, 32 R) moves within a range defined between the full-brake position P 3 and the stroke end position P 2 , turn control operation is achieved.
FIG. 5 shows a control system of the motorized vehicle 10 . As shown in this figure, the accelerator potentiometer 26 and the left and right brake potentiometers 27 L, 27 R are electrically connected to the control unit 24 . Also connected to the control unit 24 is a vehicle speed sensor 34 for detecting the speed of the vehicle 10 . The control unit 24 is electrically connected to the left and right brakes 17 L, 17 R via left and right brake drivers 28 L, 28 R, respectively, for controlling operation of the brakes 17 L, 17 R based on the position of the corresponding turn control levers 23 L, 23 R in a manner described below. Similarly, the control unit 24 is electrically connected to the left and right electric motors 13 L, 13 R via left and right motor drivers 29 L, 29 R, respectively, for controlling operation of the motors 13 L, 13 R based on the position of the accelerator lever 22 in a manner described below. In a practical sense, the brake drivers 28 L, 28 R and the motor drivers 29 L, 29 R are formed as a part of the control unit 24 .
When the left turn control lever 23 L is manipulated or otherwise pulled by the operator, the left brake potentiometer 27 L generates an output signal BKLV corresponding in magnitude to the amount of angular displacement of the turn control lever 23 L. Upon receipt of the output signal BKLV from the brake potentiometer 27 L, the controller 24 sends a command signal to the left brake driver 28 L so that the left brake 17 L is driven to apply to the left driving wheel 15 L a brake force corresponding to the position of the left turn control lever 23 L. When the left turn control lever 23 L (i.e., the actuator arm 32 L of the left brake potentiometer 27 L) is in the brake control range defined between the zero-brake position P 1 and the full-brake position P 3 ( FIGS. 4A and 4B ), brake control operation is achieved, in which the brake force applied from the left brake 17 L to the left driving wheel 15 L varies linearly with the amount of angular displacement of the left turn control lever 23 L.
Similarly, when the right turn control lever 23 R is manipulated or otherwise pulled by the operator, the right brake potentiometer 27 R generates an output signal BKRV corresponding in magnitude to the amount of angular displacement of the turn control lever 23 R. Upon receipt of the output signal BKRV from the brake potentiometer 27 R, the controller 24 sends a command signal to the right brake driver 28 R so that the right brake 17 L is driven to apply to the right driving wheel 15 R a brake force corresponding to the position of the right turn control lever 23 R. When the right turn control lever 23 R (i.e., the actuator arm 32 R of the right brake potentiometer 27 R) is in the brake control range defined between the zero-brake position P 1 and the full-brake position P 3 ( FIGS. 4A and 4B ), brake control operation is achieved, in which the brake force applied from the right brake 17 R to the right driving wheel 15 R varies linearly with the amount of angular displacement of the right turn control lever 23 R.
When the accelerator lever 22 is actuated or otherwise tilted by the operator, the accelerator potentiometer 26 generates an output signal ACCV corresponding in magnitude to the amount of angular displacement of the accelerator lever 22 . Upon receipt of the output signal ACCV from the accelerator potentiometer 26 , the controller 24 sends a command signal to the left and right motor drivers 29 L, 29 R so that the left and right electric motors 13 L, 13 R rotate the corresponding driving wheels 15 L, 15 R in the forward or backward direction at a speed corresponding to the position of the accelerator lever 22 . Thus, the vehicle (crawler cart) with crawler belts 16 L, 16 R independently driven by the driving wheels 15 L, 15 R moves in the forward or backward direction at the desired speed.
When the left or right turn control lever 23 L, 23 R is pulled to approach the handgrip 25 L, 25 R across the full-brake position P 2 ( FIGS. 4A and 4B ), turn control operation is achieved under the control of the control unit 24 so as to ensure that the vehicle makes a turn while staying at the same position (spot turn). The turn control operation will be described with reference to a flowchart shown in FIG. 6 .
At a first step ST 01 , a judgment is made to determine as to whether or not the output signal BKLV from the left brake potentiometer 27 L ( FIG. 5 ) is greater than Vm ( FIG. 4B ). When the result of judgment is “YES” (BKLV>Vm), this means that the left turn control lever 23 L is disposed in the turn control range defined between the full-brake position P 3 and the stroke end position P 2 ( FIGS. 3 and 4A ). The control then goes on to a step ST 02 . Alternately, when the result of judgment is “NO” (BKLV,≦Vm), the control moves to a step ST 07 .
At the step ST 02 , the output signal V from the vehicle speed sensor 34 ( FIG. 5 ) is monitored so as to determine whether or not the vehicle speed V is not more than V 0 where V 0 represents the vehicle being at halt or moving at a slow speed which allows the vehicle to make an abrupt turn. When the result of judgment is “YES” (V<V 0 ), the control advances to a step ST 04 . Alternately when the judgment result is “NO” (V≧V 0 ), the control moves to a step ST 03 .
At the step ST 03 , slowdown control is achieved in which the control unit 24 ( FIG. 5 ) controls the electric motors 13 L, 13 R via the motor drivers 29 L, 29 R so as to slow down the rotational speed of the driving wheels 15 L, 15 R. This operation continues until the vehicle speed V is below V 0 .
At the step ST 04 , the left and right brakes 17 L, 17 R ( FIG. 5 ) are released or de-activated to allow rotation of the left and right driving wheels 15 L, 15 R. After the step ST 04 , the control goes on to a step ST 05 .
The step ST 05 is achieved on condition that VKLV>Vm and V<V 0 (that is, the left turn control lever 23 L is in the turn control range defined between the full-brake position P 3 and the stroke end position P 2 , and the vehicle is stopped or moving at a slow speed which allow the vehicle to make an abrupt turn). At the step ST 05 , the left electric motor 13 L ( FIG. 5 ) is rotated in the reverse direction and, at the same time, the right electric motor 13 R is rotated in the forward direction. The term “forward direction” is used to refer to a direction to move the vehicle forward, and the term “reverse direction” is used to refer to a direction to move the vehicle backward. By thus driving the left and right electric motors 13 L, 13 R simultaneously in opposite directions, the vehicle starts to make an abrupt turn in the leftward direction while staying at the same position (spot turn).
When the vehicle has turned leftward through a desired angle (180 degrees, for example), the operator releases the left turn control lever 23 L, allowing the lever 23 L to return to its initial zero-brake position P 1 ( FIGS. 3 and 4B ). This causes the output BKLV from the left brake potentiometer 27 L to go down to or below Vm (BKLV≦Vm). This condition is detected at a step ST 06 whereupon the control comes to an end and operation of the vehicle returns to a regular operation mode.
At the step ST 07 , which follows the “NO” state at the preceding step ST 01 , a judgment is made to determine as to whether or not the output signal BKRV from the right brake potentiometer 27 R ( FIG. 5 ) is greater than Vm ( FIG. 4B ). When the result of judgment is “YES” (BKRV>Vm), the control advances to a step ST 08 . Alternately, when the judgment result is “NO”(BKRV≦Vm), this means that either lever 23 L, 23 R (actuator arm 32 L, 32 R of the brake potentiometer 27 L, 27 R) is not in the turn control range defined between the full-brake position P 3 and the stroke end position P 2 . Accordingly, the control is terminated.
At the step ST 08 , following the “YES” state in the preceding step ST 07 , the output signal V from the vehicle speed sensor 34 ( FIG. 5 ) is compared with V 0 so as to determine whether or not V<V 0 . When the comparison result is “YES” (V<V 0 ), the control advances to a step ST 10 . Alternately when the comparison result is “NO” (V≧V 0 ), the control moves to a step ST 09 .
At the step ST 09 , slowdown control is achieved in which the control unit 24 ( FIG. 5 ) controls the electric motors 13 L, 13 R via the motor drivers 29 L, 29 R so as to slow down the rotational speed of the driving wheels 15 L, 15 R. This operation continues until the vehicle speed V is below V 0 .
At the step ST 10 , the left and right brakes 17 L, 17 R ( FIG. 5 ) are released or de-activated to allow rotation of the left and right driving wheels 15 L, 15 R. After the step ST 10 , the control goes on to a step ST 11 .
The step ST 11 is achieved on condition that VKRV>Vm and V<V 0 (that is, the right turn control lever 23 R is in the turn control range defined between the full-brake position P 3 and the stroke end position P 2 , and the vehicle is stopped or moving at a slow speed which allows the vehicle to make an abrupt turn). At the step ST 11 , the right electric motor 13 R ( FIG. 5 ) is rotated in the reverse direction and, at the same time, the left electric motor 13 L is rotated in the forward direction. As a result of simultaneous driving of the left and right electric motors 13 L, 13 R in opposite directions, the vehicle starts to make an abrupt turn in the rightward direction while staying at the same position (spot turn).
When the vehicle has turned rightward through a desired angle (180 degrees, for example), the operator releases the right turn control lever 23 R, allowing the lever 23 R to return to its initial zero-brake position P 1 ( FIGS. 3 and 4B ). This causes the output BKRV from the right brake potentiometer 27 R to go down to or below Vm (BKRV≦Vm). This condition is detected at a step ST 12 where-upon the control is terminated and operation of the vehicle returns to the regular operation mode.
The speed of the electric motors 13 L, 13 R achieved at the steps ST 05 and ST 11 may be either fixed at a predetermined value, or alternately variable. In the latter case, the motor speed is set to be proportional to the output ACCV from the accelerator potentiometer 26 (corresponding to the position of the accelerator lever 22 ). By thus setting the motor speed, the vehicle can make a spot turn at the same speed as a preceding working operation which the vehicle has done.
FIGS. 7A to 7C are illustrative of the manner in which the vehicle makes a spot turn in the rightward direction through an angle of 180 degrees. In these figures, the left turn control lever is not shown for the purpose of illustration. When the right turn control lever 23 R is manipulated or otherwise pulled so as to approach the handgrip 25 R across the full-brake position P 2 ( FIG. 3 ), the left electric motor 13 L is driven to rotate in the forward direction and, at the same time, the right electric motor 13 R is driven to rotate in the reverse direction. This means that the left crawler belt 16 L is driven to run or travel in the forward direction, while the right crawler belt 16 R is driven to run or travel in the backward direction. As a result of simultaneous running of the left and right crawler belts 16 L, 16 R in the forward and backward directions, respectively, the vehicle 10 starts to turn rightward about a center G 1 common to the left and right crawler belts 16 L, 16 R, with a turning radius R 1 equal to the distance from the turning center G 1 to a front left corner of the load-carrying platform 20 , as shown in FIG. 7A .
Continuing operation of the left and right motors 13 L, 13 R will place the vehicle 10 to a position shown in FIG. 7B where the vehicle 10 has turned about the center G 1 in the rightward direction through an angle of 90 degrees. As the turning operation further continues, the vehicle 10 completes a 180° turn while staying at the same position, as shown in FIG. 7C . Then the operator releases the right turn control lever 23 to thereby terminate the spot turn operation. A spot turn in the leftward direction can be achieved in the same manner as described above by pulling the left turn control lever 23 L until it assumes a position located within the turn control range defined between the full-brake position P 3 and the stroke end position P 2 shown in FIGS. 3 and 4B .
For comparative purposes, description will be made to a normal pivot turn operation of the vehicle 10 with reference to FIGS. 8A and 8B . When a right turn of the vehicle 10 is desired, the right turn control lever 23 R is pulled to assume the full-brake position P 3 ( FIGS. 3 and 4B ) or a position immediately before the full-brake position P 3 , whereupon by the effect of a maximum brake force applied from the right brake 17 R to the right driving wheel 15 R, the right crawler belt 16 R is stopped. In this instance, since the left crawler belt 16 L continues its running in the forward direction, the vehicle 10 starts to turn rightward about a turning center G 2 located at a longitudinal center of the right crawler belt 16 R, with a turning radius R 2 equal to the distance from the turning center G 2 to the front left corner of the platform 20 , as shown in FIG. 8B .
As the turning operation further continues, the vehicle 10 completes a 180° turn about the turning center G 2 . A comparative review of FIGS. 7C and 8B indicates that a turning area in a circle drawn with the turning radius R 1 achieved by the spot turn operation ( FIG. 7C ) is much smaller than that in a circle drawn with the turning radius R 2 achieved by the normal pivot turn operation ( FIG. 8B ). This proves that the spot turn is optimum to minimize the turning area of the vehicle 10 .
When the direction of travel of the vehicle 10 is to be adjusted, the left or the right turn control lever 23 L, 23 R is lightly pulled to create a speed difference between the left and right crawler belts 16 L, 16 R due to a brake force applied from the left or right brake 17 L, 17 R to the corresponding driving wheel 15 L, 15 R. Thus, the vehicle starts to make a gradual turn in a desired direction. When a rapid direction change is needed, the left or right turn control lever 23 L, 23 R is pulled to an increased extent. In this instance, when the turn control lever 23 L, 23 R is in the brake full-brake position P 3 , the normal pivot turn will be achieved in the same manner as described above with reference to FIGS. 8A and 8B . Alternatively, when the turn lever 23 L, 23 R is in the turn control region defined between the full-brake position P 3 and the stroke end position P 2 , the spot turn will be achieved in the same manner as described above with reference to FIGS. 7A to 7C .
It will readily be understood that by merely manipulating the turn control levers 23 L, 23 R in an appropriate manner, the vehicle can make a gradual turn, a normal pivot turn or a spot turn. The turn control levers 23 L, 23 R double in function as brake control levers to achieve gradual turns and a normal pivot turn, and also as a spot-turn initiating levers to achieve a spot turn. This obviates the need for the provision of a separate lever used exclusively for achieving different sorts of turn. The motorized vehicle is relatively simple in construction and can easily be operated even by an un-skilled operator.
FIG. 9 shows a motorized vehicle 10 a taking the form of a walk-behind motorized crawler cart according to a second embodiment of the present invention. The vehicle 10 a is structurally and operationally the same as the vehicle 10 of the first embodiment shown in FIG. 1 , with the exception that the left and right turn control levers 23 L, 23 R serve only as brake control levers, and left and right spot turn switches 35 L, 35 R are provided separately to achieve a spot turn. Due to this similarly, these parts which are identical to those shown in FIG. 1 are designated by the same reference characters and further description thereof can, therefore, be omitted to avoid duplicate description.
As shown in FIG. 9 , the left and right spot turn switches 35 L, 35 R are provided on an operator control panel 21 and electrically connected to a control unit 24 disposed inside the operator control panel 21 . The left and right turn control levers 23 L, 23 R (hereinafter referred to as brake control levers) are electrically connected to the control unit 24 via left and right brake potentiometers 27 L, 27 R ( FIGS. 10A and 11 ). The potentiometers 27 L, 29 L each have an actuator arm 32 L, 32 R ( FIG. 10A ) directly connected to the corresponding brake control lever 23 L, 23 R.
As understood from FIG. 10A , the brake control levers 23 L, 23 R (i.e., the actuator arms 32 L, 32 R of the brake potentiometers 27 L, 27 R) are angularly movable between an initial zero-brake position (first position) P 1 and a full-brake position (second position) P 2 . The output from the brake potentiometer 27 L, 27 R varies linearly with the position of the actuator arm 32 L, 32 R (i.e., the position of the brake control lever 23 L, 23 R), as indicated by a graph shown in FIG. 10B . In the illustrated embodiment, the output from the brake potentiometer 27 L, 27 R is set to vary within a range from 0 to 5.0 volts (V). When the brake control lever 23 L, 23 R is in the initial zero-brake position P 1 , the output from the brake potentiometer is nil. When the turn control lever 23 L, 23 R is in the full-brake position P 2 , the output from the brake potentiometer is 5.0 V. In terms of the output, the full-brake position P 2 in this position corresponds to the stroke end position P 2 of the first embodiment shown in FIG. 4B .
FIG. 11 shows a control system of the motorized vehicle 10 a . The control system structurally differs from the control system of the first embodiment shown in FIG. 5 in that the spot turn switches 35 L, 35 R are provided separately from the brake control levers (turn control levers) 23 L, 23 R. Due to this similarity, these parts which are identical to those shown in FIG. 5 are designated by the same reference characters, and no further description thereof is needed.
With the control system arranged as shown in FIG. 11 , when the left brake control lever 23 L is manipulated or otherwise pulled by the operator, the left brake potentiometer 27 L generates an output signal BKLV corresponding in magnitude to the amount of angular displacement of the brake control lever 23 L. Upon receipt of the output signal BKLV from the brake potentiometer 27 L, the controller 24 sends a command signal to the left brake driver 28 L so that the left brake 17 L is driven to apply to the left electric motor 13 L a brake force corresponding to the position of the left brake control lever 23 L. By thus braking the electric motor 13 L, the rotating speed of the left driving wheel 15 L decreases linearly with the amount of displacement of the left brake control lever 23 L. When the brake control lever 23 L is pulled so as to assume the full-brake position P 2 ( FIG. 10A ), a maximum brake force is applied from the left brake 17 L to the left motor 13 L, thereby stopping rotation of the left motor 13 L. Thus, the left driving wheel 15 L is stopped. Similarly, when the right brake control lever 23 R is manipulated or otherwise pulled by the operator, the control unit 24 controls operation of the right brake 17 R via the right brake driver 28 R so that the right motor 13 R is braked with a brake force variable linearly with the output BKRV from the right brake potentiometer 27 R. When the right brake control lever 23 R is in the full-brake position P 2 ( FIG. 10A ), the output BKRV from the right brake potentiometer 27 R has a maximum value. This makes the right motor 13 R to stop rotation by the effect of a maximum brake force applied from the right brake 17 R.
When the accelerator lever 22 is actuated or otherwise tilted by the operator, the accelerator potentiometer 26 generates an output signal ACCV corresponding in magnitude to the amount of angular displacement of the accelerator lever 22 . Upon receipt of the output signal ACCV from the accelerator potentiometer 26 , the controller 24 sends a command signal to the left and right motor drivers 29 L, 29 R so that the left and right electric motors 13 L, 13 R rotate the corresponding driving wheels 15 L, 15 R in the forward or backward direction at a speed corresponding to the position of the accelerator lever 22 . Thus, the vehicle (crawler cart) with crawler belts 16 L, 16 R independently driven by the driving wheels 15 L, 15 R moves in the forward or backward direction at the desired speed.
When the left or right spot turn switch 35 L, 35 R is activated, turn control operation is achieved under the control of the control unit 24 so as to ensure that the vehicle makes a turn while staying at the same direction (spot). The turn control operation will be described with reference to a flowchart shown in FIG. 12 .
At a first step ST 01 , a judgment is made to determine as to whether or not the left spot turn switch 35 L is in the “ON” state. When the result of judgment is “YES”, the control then goes on to a step ST 02 . Alternately, when the judgment result is “NO”, the control moves to a step ST 06 .
At the step ST 02 , the output signal V from the vehicle speed sensor 34 ( FIG. 11 ) is monitored so as to determine whether or not the vehicle speed V is not more than V 0 where V 0 represents the vehicle being at halt or moving at a slow speed which allows the vehicle to make an abrupt turn. When the judgment result is “YES” (V<V 0 ), the control advances to a step ST 04 . Alternately when the judgment result is “NO” (V≧V 0 ), the control moves to a step ST 03 .
At the step ST 03 , slowdown control is achieved in which the control unit 24 ( FIG. 11 ) controls the electric motors 13 L, 13 R via the motor drivers 29 L, 29 R so as to slow down the rotational speed of the driving wheels 15 L, 15 R. This operation continues until the vehicle speed V is below V 0 .
The step ST 04 is achieved on condition that VKLV>Vm and V<V 0 (that is, the left spot turn switch 35 L is in the “ON” state, and the vehicle is stopped or moving at a slow speed which allows the vehicle to make an abrupt turn). At the step ST 04 , the left electric motor 13 L ( FIG. 11 ) is rotated in the reverse direction and, at the same time, the right electric motor 13 R is rotated in the forward direction. By thus driving the left and right electric-motors 13 L, 13 R simultaneously in opposite directions, the vehicle starts to make an abrupt turn in the leftward direction while staying at the same position (spot turn).
When the vehicle has turned leftward through a desired angle (180 degrees, for example), the operator deactivates the left spot turn switch 35 L, causing the output BKLV from the left brake potentiometer 27 L to go down to or below Vm (BKLV≦Vm). This condition is detected at a step ST 05 , and upon detention of this condition, the control comes to an end and operation of the vehicle returns to a regular operation mode.
At the step ST 06 , which follows the “NO” state at the preceding step ST 01 , a judgment is made to determine as to whether or not the right spot turn switch 35 R is in the “ON” state. When the result of judgment is “YES”, the control advances to a step ST 07 . Alternately, when the judgment result is “NO”, this means that either switch 35 L, 35 R is not activated. Accordingly, the control is terminated.
At the step ST 07 , following the “YES” state in the preceding step ST 06 , the output signal V from the vehicle speed sensor 34 ( FIG. 11 ) is compared with V 0 so as to determine whether or not V<V 0 . When the comparison result is “YES” (V<V 0 ), the control advances to a step ST 09 . Alternately when the comparison result is “NO” (V≧V 0 ), the control moves to a step ST 08 .
At the step ST 08 , slowdown control is achieved in which the control unit 24 ( FIG. 11 ) controls the electric motors 13 L, 13 R via the motor drivers 29 L, 29 R so as to slow down the rotational speed of the driving wheels 15 L, 15 R. This operation continues until the vehicle speed V is below V 0 .
The step ST 09 is achieved on condition that VKRV>Vm and V<V 0 (that is, the right spot turn switch 35 R is in the “ON” state, and the vehicle is stopped or moving at a slow speed which allows the vehicle to make an abrupt turn). At the step ST 09 , the right electric motor 13 R ( FIG. 11 ) is rotated in the reverse direction and, at the same time, the left electric motor 13 L is rotated in the forward direction. As a result of simultaneous driving of the left and right electric motors 13 L, 13 R in opposite directions, the vehicle starts to make an abrupt turn in the rightward direction while staying at the same position (spot turn).
When the vehicle has turned rightward through a desired angle (180 degrees, for example), the operator deactivates the right spot turn switch 35 R, causing the output BKRV from the right brake potentiometer 27 R to go down to or below Vm (BKRV≦Vm). This condition is detected at a step ST 010 , and upon detention of this condition, the control is terminated operation of the vehicle returns to a regular operation mode.
The speed of the electric motors 13 L, 13 R achieved at the steps ST 04 and ST 09 may be either fixed at a predetermined value, or alternately variable. In the latter case, the motor speed is set to be proportional to the output ACCV from the accelerator potentiometer 26 ( FIG. 11 ) By thus setting the motor speed, the vehicle can make a spot turn at the same speed as a preceding working operation which the vehicle has done.
FIGS. 13A to 13C are illustrative of the manner in which the vehicle 10 a makes a spot turn in the rightward direction through an angle of 180 degrees. In these figures, the brake control levers are not shown for the purpose of illustration. When the right spot turn switch 35 R is activated, the left electric motor 13 L is driven to rotate in the forward direction and, at the same time, the right electric motor 13 R is driven to rotate in the reverse direction. This means that the left crawler belt 16 L is driven to run or travel in the forward direction, while the right crawler belt 16 R is driven to run or travel in the backward direction. As a result of simultaneous running of the left and right crawler belts 16 L, 16 R in the forward and backward directions, respectively, the vehicle 10 a starts to turn rightward about a center G common to the left and right crawler belts 16 L, 16 R, with a turning radius R equal to the distance from the turning center G to a front left corner of the load-carrying platform 20 , as shown in FIG. 13A .
Continuing operation of the left and right motors 13 L, 13 R will place the vehicle 10 a to a position shown in FIG. 13B where the vehicle 10 has turned about the turning center G in the rightward direction through an angle of 90 degrees. As the turning operation further continues, the vehicle 10 a completes a 180° turn while staying at the same position, as shown in FIG. 13C . Then the operator deactivates the right spot turn switch 35 R to thereby terminate the spot turn operation. A spot turn in the leftward direction can be achieved in the same manner as described above by activating the left spot turn switch 35 L.
The spot turn switches 35 L, 35 R may be comprised of a push button switch, a self-hold push-push switch, a self-hold toggle switch, or a self-hold dial switch. Though not shown, these switches 35 L, 35 R may be mounted to the left and right handlebars 30 L, 30 R adjacent to the handgrips 25 , 25 R.
FIGS. 14 and 15 show a walk-behind self-propelled crawler snowplow 40 embodying the present invention. The snowplow 40 generally comprises a propelling frame 42 carrying thereon left and right crawler belts 41 L, a vehicle frame 45 carrying thereon a snowplow mechanism 43 and an engine (prime motor) 44 for driving the snowplow mechanism 43 , a frame lift mechanism 46 operable to lift a front end portion of the vehicle frame 45 up and down relative to the propelling frame 42 , and a pair of left and right operation handlebars 47 L and 47 R extending from a rear portion of the propelling frame 42 obliquely upward in a rearward direction of the snowplow 40 . The propelling frame 42 and the vehicle frame 45 jointly form a vehicle body 49 .
The left and right crawler belts 41 L, 41 R are driven by left and right electric motors 71 L, 71 R, respectively. The crawler belts 41 L, 41 R are each trained around a driving wheel 72 L, 72 R and an idler wheel 73 L, 73 R. The driving wheel 72 L, 72 R is disposed on a rear side of the crawler belt 41 L, 41 R, and the idler wheel 73 L, 73 R is disposed on a front side of the crawler belt 41 L, 41 R.
The snowplow mechanism 43 has an auger 43 a , a blower 43 b and a discharge duct 43 c that are mounted to a front portion of the vehicle frame 45 . In operation, the auger 43 a rotates to cut snow away from a road, for example, and feed the cut mass of snow to the blower 43 b which blows out the snow through the discharge duct 43 c to a position far distant from the snowplow 40 .
The operation handlebars 47 L, 47 R are adapted to be gripped by a human operator (not shown) walking behind the snowplow 40 in order to maneuver the snowplow 40 . An operator control panel 51 , a control unit 52 and batteries 53 are arranged in a vertical space defined between the handlebars 47 L, 47 R and they are mounted to the handlebars 47 L, 47 R in the order named when viewed from the top to the bottom of FIG. 14 .
The operation handlebars 47 L, 47 R each have a handgrip 48 L, 48 R at the distal end (free end) thereof. The left handlebar 47 L has a parking brake lever 54 disposed in close proximity to the handgrip 48 L. The parking brake lever 54 is of the deadman lever type and is adapted to be gripped by the operator together with the left handgrip 48 L. When gripped, the parking brake lever 54 turns about a pivot pin 54 a in a direction toward the handgrip 48 L. With this movement of the parking brake lever 54 , a brake switch 55 ( FIG. 16 ) is turned on, thereby releasing a brake on the driving wheels 72 L, 72 R. The left and right handlebars 14 L, 47 R further have turn control levers 56 L, 56 R associated with the respective handgrips 48 L, 48 R.
The crawler snowplow 40 of the foregoing construction is self-propelled by the crawler belts 41 L, 41 R driven by the electric motors 71 L, 71 R and is also maneuvered by the human operator walking behind the snowplow 40 while gripping the handlebars 47 L, 47 R.
In the crawler snowplow 40 , a generator driving pulley 75 is attached to an output shaft 65 of the engine 44 . The diving pulley 75 is connected by an endless belt 77 to a generator driven pulley 76 mounted to the shaft of a generator 69 . Thus, rotation of the engine output shaft 65 is transmitted via the belt 77 to the generator 69 . That is, when the engine 44 is running, the generator 69 is driven via the belt drive 75 – 77 so that the batteries 53 ( FIG. 14 ) are charged with electric current supplied from the generator 69 .
A second driving pulley 67 a is coupled via an electromagnetic clutch 66 to the output shaft 65 of the engine 44 , and a second driven pulley 68 b is connected to one end of a rotating shaft 68 a . The second driving and driven pulleys 67 a , 68 b are connected by a second endless belt 67 b . The rotating shaft 68 a is connected to a central shaft of the auger 43 a via a worm gear speed reducing mechanism (not designated). The rotating shaft 68 a is also connected to the blower 43 b . While the engine 44 is running, the auger 43 a and blower 43 b are drivable through the second belt drive 67 a , 67 b , 68 b when the electromagnetic clutch 66 is in the engaged state.
The operator control panel 51 has a lift control lever 60 a for controlling operation of the frame lift mechanism 46 ( FIG. 14 ), a duct control lever 60 b for changing direction of the discharge duct 43 c , an accelerator lever 22 for controlling the direction and speed of travel of the snowplow 40 , and a throttle lever 64 for controlling the speed of the engine 44 . The operator control panel 51 further has a clutch switch 59 disposed adjacent to the right operation handlebar 47 R. The clutch switch 59 is a normally open contact switch and adapted to be turned on and off to achieve on-off control of the electromagnetic clutch 66 .
As shown in FIG. 16 , the left and right turn control levers 56 L, 56 R each have an integral pivot pin 56 a by means of which the lever 56 L, 56 R is pivotally mounted to the corresponding handlebar 47 L, 47 R. The pivot pin 56 a serves also as a rotating shaft of a rotary type brake potentiometer 57 L, 57 R which is associated with the turn control lever 56 L, 56 R to monitor the position of the turn control lever 56 L, 56 R. The brake potentiometer 57 L, 57 R are electrically connected to the control unit 52 . Left and right brakes 74 L, 74 R are associated with the left and right motors 71 L, 71 R, respectively, for independently applying a brake force to the corresponding motors 71 L, 71 R. The Left and right brakes 74 L, 74 R are driven by left and right brake drivers 58 L, 58 R under the control of the control unit 52 based on the amount of angular displacement of the turn control levers 56 L, 56 R detected by the brake potentiometers 57 L, 57 R. The accelerator lever 22 is electrically connected to the control unit 52 via an accelerator potentiometer 26 . The left and right motors 71 L, 71 R are driven by left and right motor drivers 29 L, 29 R under the control of the control unit 52 based on the amount of angular displacement of the accelerator lever 22 detected by the accelerator potentiometer 26 . The operation of the accelerator lever 22 and turn control levers 56 L, 56 R are identical to the operation of those 22 , 23 L, 23 R described above with reference to the first embodiment shown in FIGS. 1–8 , and further description thereof can be omitted.
It will be appreciated from the foregoing description that by virtue of the left and right turn control levers mounted to the left and right handlebars so as to extend along the left and right handgrips, the operator can manipulate the turn control levers while keeping a grip on the handgrips. This enables the operator to steer the motorized vehicle stably and reliably in a desired direction. Furthermore, the turn control levers can be easily manipulated with operator's fingers of the operator. This will lessen the load on the operator.
The present disclosure relates to the subject matter of Japanese Patent Applications Nos. 2000-331554, 2000-331561 and 2001-134689, filed Oct. 30, 2000, Oct. 30, 2000 and May 1, 2001, respectively, the disclosures of which are expressly incorporated herein by reference in their entirety.
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A motorized vehicle has a vehicle body, at least a pair of wheels mounted on the vehicle body for undergoing rotation to cause the motorized vehicle to undergo travelling, and a pair of electric motors each mounted on the vehicle body to selectively undergo forward and reverse rotation to rotationally drive a respective one of the wheels. A first switch is connected to the electric motors so that operation of the first switch causes the electric motors to undergo rotation simultaneously in opposite directions to turn the motorized vehicle in a first direction while the motorized vehicle does not undergo travelling. A second switch is connected to the electric motors so that operation of the second switch causes the electric motors to undergo rotation simultaneously in opposite directions to turn the motorized vehicle in a second direction opposite to the first direction while the motorized vehicle does not undergo travelling.
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TECHNICAL FIELD
[0001] This application relates generally to software systems and more particularly to a software system for loading software on demand.
BACKGROUND OF THE INVENTION
[0002] Computer systems often involve downloading applications and data from a server system for use on a client system. The applications or data may be downloaded only once and then stored on the client computer or they may be downloaded each time the application or data is used. In present application download systems, the client computer initiates a launch mechanism for a desired application, and the compressed bits for the entire application are streamed down from the server and onto the client system. The bits are then decompressed, installed, and executed. Such systems allow no overlap between download time and the execution. The client computer waits until the entire application has been downloaded before beginning execution of the program. Also, a client computer utilizes only about twenty percent of an application's total size during a typical user scenario. Thus, about eighty percent of the downloaded application code and data is unnecessary. While applications are typically cached after they are initially downloaded, the first time download wastes significant bandwidth resources. Also, the time for starting up many applications is extremely long for clients without high-speed connections to servers.
[0003] Some systems have used a process called paging, in which an application is split into pages of equal size and each page is downloaded as it is needed by the application. However, such systems often require download of code and/or data that is unnecessary because it happens to be on the same page as the requested code or data. This again wastes bandwidth resources and time. It may also have adverse effects on the operation of the application because the downloaded pages are not arranged in a logical manner.
SUMMARY OF THE INVENTION
[0004] In accordance with the present invention, the above and other problems are solved by supplying portions of program code or program data of a computer program as the portions are needed by the program. The portions are defined in accordance with the logic of the computer program. The portions are then removed from the computer program to produce an application skeleton. Rather than downloading and running the entire program on a computing system, the computing system runs the smaller program skeleton. The computing system generally downloads the portions of the computer program and inserts them into the skeleton, as they are needed.
[0005] In accordance with other aspects, the present invention relates to a method of preparing a computer program for operation in a computer supply system that supplies portions, or program units, of program code or program data of the computer program as the program needs the portions. The method includes defining a program unit of the program and removing the program unit from the program, thereby producing a program skeleton that is missing the program unit. The method further includes inserting instructions in place of the program unit in the program skeleton. The instructions are operative to request the program unit when the program skeleton encounters the instructions.
[0006] In accordance with still other aspects, the present invention relates to an information structure stored on a computer-readable medium. The information structure includes a program skeleton of a program. The program skeleton is missing a funclet of the program, but includes a placeholder in place of the funclet. The program skeleton additionally includes instructions in place of the funclet. The instructions are operative to request the funclet when the program skeleton encounters the instructions.
[0007] The invention may be implemented as a computer process, a computing system or as an article of manufacture such as a computer program product or computer readable media. The computer program product may be a computer storage media readable by a computer system and encoding a computer program of instructions for executing a computer process. The computer program product may also be a propagated signal on a carrier readable by a computing system and encoding a computer program of instructions for executing a computer process.
[0008] These and various other features as well as advantages, which characterize the present invention, will be apparent from a reading of the following detailed description and a review of the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates an operational flow for preparing an application for use with a loading process according to an embodiment of the present invention.
[0010] FIG. 2 illustrates a computing system, such as a system that can be used for the preparation operation of FIG. 1 .
[0011] FIG. 3 illustrates a portion of an application, showing how that portion could be divided into funclets according to an embodiment of the present invention.
[0012] FIG. 4 illustrates an operational flow of three funclet divisions of an original program and the corresponding features of the resulting program skeleton.
[0013] FIG. 5 illustrates an operational flow for preparing an application for use with a loading process according to an embodiment of the present invention.
[0014] FIG. 6 illustrates the optimize and define funclets operation of FIG. 5 in more detail.
[0015] FIG. 7 illustrates the seed operation of FIG. 6 in more detail.
[0016] FIG. 8 illustrates the accumulate operation of FIG. 6 in more detail.
[0017] FIG. 9 illustrates the place global data blocks operation of FIG. 6 in more detail.
[0018] FIG. 10 illustrates the filter operation of FIG. 6 in more detail.
[0019] FIG. 11 illustrates the generate skeleton and convert program to data operations of FIG. 5 in more detail.
[0020] FIG. 12 illustrates the operation of “to” and “from” flags in accordance with an embodiment of the present invention.
[0021] FIG. 13 illustrates the insert housekeeping structure operation of FIG. 5 in more detail.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The logical operations of the various embodiments of the present invention are implemented (1) as a sequence of computer implemented acts or program modules running on a computing system and/or (2) as interconnected machine logic circuits or circuit modules within the computing system. The implementation is a matter of choice dependent on the performance requirements of the computing system implementing the invention. Accordingly, the logical operations making up the embodiments of the present invention described herein are referred to variously as operations, structural devices, acts or modules. It will be recognized by one skilled in the art that these operations, structural devices, acts and modules may be implemented in software, in firmware, in special purpose digital logic, and any combination thereof without deviating from the spirit and scope of the present invention as recited within the claims attached hereto.
[0023] An embodiment of the present invention separates portions of operational code or data of a computer program to be downloaded into program units referred to herein as “funclets.” Funclets are preferably defined in accordance with the logic of a particular program so as to avoid downloading unneeded code or data and to optimize the performance of the program on the client system. Rather than downloading an entire program from a server system to a client system, a program skeleton is downloaded and the funclets from the program are downloaded as they are needed by the program, as described below.
[0024] Referring now to FIG. 1 , before an application program is used with a software on demand system, an original application 10 is processed in a binary preparation operation 12 . The binary preparation operation 12 receives the original application 10 and yields an application skeleton 20 and funclets 34 , all corresponding to the original application 10 . The application skeleton 20 is based on the original application 10 , but is missing the funclets 34 . The computing system runs the application skeleton 20 and uses an LDRRT (loader run time) module to get the funclets 34 as they are needed by the application skeleton 20 . Running the application skeleton 20 and downloading the funclets 34 is described in more detail in United States Patent Application Serial No. (Atty. Docket No. MS172057.1/40062.191US01) entitled “Software on Demand System,” which is filed on even date with the present application and is incorporated herein by reference. The funclets 34 are preferably defined in accordance with the logic of the original application 10 , as described more fully below.
[0025] Computer systems such as a computer system 100 shown in FIG. 2 may be used to perform the binary preparation operation 12 , to run the application skeleton 20 , and to download the funclets 34 . In its most basic configuration, computing system 100 is illustrated in FIG. 2 by dashed line 106 encompassing the processor 102 and the memory 104 . Additionally, system 100 may also include additional storage (removable and/or non-removable) including, but not limited to, magnetic or optical disks or tape. Such additional storage is illustrated in FIG. 2 by removable storage 108 and non-removable storage 110 . Computer storage media, such as memory 104 , removable storage 108 or non-removable storage 110 includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, information or data structures, program modules or other data. Memory 104 , removable storage 108 and non-removable storage 110 are all examples of computer storage media. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by system 100 . Any such computer storage media may be part of system 100 . Depending on the configuration and type of computing device, memory 104 may be volatile, non-volatile or some combination of the two.
[0026] System 100 may also contain communications connection(s) 112 that allow the device to communicate with other devices. Additionally, system 100 may have input device(s) 114 such as a keyboard, mouse, pen, voice input device, touch input device, etc. Output device(s) 116 such as a display, speakers, printer, etc. may also be included. All these devices are well known in the art and need not be discussed at length here.
[0027] Computer system 100 typically includes at least some form of computer readable media. Computer readable media can be any available media that can be accessed by system 100 . By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Communication media typically embodies computer readable instructions, information or data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.
[0028] Each funclet 34 preferably has only a single entry point so that each funclet will have only a single corresponding binary stub. However, each funclet 34 may have multiple exit points, and in some situations it may be preferable for funclets to have multiple entry points, for example to facilitate making larger funclets. FIG. 3 illustrates a portion 240 of the process flow of the original application 10 . An entry operation 242 calls a query operation 244 , such as an “IF” operation. The query operation 244 may call either a first post-query operation 246 or a second post-query operation 248 . Upon completion, the active post-query operation 246 , 248 calls a common return operation 250 . As is shown, the query operation 244 and the first post-query operation 246 may be combined into a first funclet 260 because it is highly likely that entry into the query operation 244 will result in a call to the first post-query operation 246 based on the logic of the application 10 . The second post-query operation 248 defines a second funclet 262 , and the return operation 250 defines a third funclet 264 . By thus defining the funclets according to the process flow of the original application 10 , the downloading of unnecessary data or code is minimized. Note that the second post-query operation 248 and the return operation 250 would preferably not be included in a single funclet because the resulting funclet would have two entry points (one from the query operation 244 into the second post-query operation 248 and another from the first post-query operation 248 into the return operation 250 ). More specific operations for thus defining funclets are described in more detail below.
[0029] Referring now to FIG. 4 , the original application 10 includes the first funclet 260 , the second funclet 262 , and the third funclet 264 . The binary preparation operation 12 yields the application skeleton 20 , which is stored in an information structure on a computer readable medium. Specifically, the binary preparation operation 12 replaces the first funclet 260 , the second funclet 262 , and the third funclet 264 from the original application 230 with a first binary stub 270 , a second binary stub 272 , and a third binary stub 274 , respectively. In a preferred embodiment, each binary stub 270 , 272 , 274 includes a call to the LDRRT module and a placeholder, which preferably includes unused space filled with zeros to replace the missing funclet 260 , 262 , 264 , respectively.
[0030] Referring now to FIG. 5 , the operational flow of the binary preparation operation 12 will be described in more detail. The original application 10 and profile data 310 are input into an optimize and define funclets operation 312 . The profile data 310 includes information regarding the operation of the original application 10 . The profile data 310 is preferably compiled by monitoring the operation of the original application 10 during several user sequences that are designed to simulate the typical use of the original application 10 by end users. Included within the profile data 310 is information regarding the frequency with which particular blocks of code or data are used during a typical user scenario. The optimize and define funclets operation 312 preferably determines an optimum configuration of the application for use in a software on demand system. Among other things, the optimize and define funclets operation 312 defines the funclets 34 . The optimize and define funclets operation 312 will be described in more detail below.
[0031] In a preferred embodiment, a generate skeleton operation 316 produces the basic structure of the application skeleton 20 , while a convert program to data operation 318 produces the funclets 34 . Both the generate skeleton operation 316 and the convert program to data operation 318 operate in accordance with the configuration determinations made by the optimize and define funclets operation 312 , as described below.
[0032] The funclets 34 that are output from the convert program to data operation 318 are preferably compressed by compress operation 320 . The compression and decompression of the funclets 34 is described in more detail in U.S. patent application Ser. No. ______ entitled “Temporally Ordered Binary Search Method and System,” which is filed on even date with the present application and is incorporated herein by reference. The compressed funclets 34 are placed in an LDN (Loader.net) file or storage space 322 , preferably on a server computer system.
[0033] The basic structure of the application skeleton 20 is output from the generate skeleton operation 316 to the insert housekeeping structure operation 324 , which places housekeeping structure and a link to the LDRRT module in the application skeleton 20 . The housekeeping structure and the LDRRT link allow the application skeleton 20 to properly communicate with the LDRRT module and request the funclets 34 as they are needed. An emit skeleton binary operation 326 then formats the application skeleton 20 so that it is executable by a computer operating system. Preferably, the application skeleton 20 and the LDRRT module are then supplied to a client computer system.
[0034] Referring now to FIG. 6 , the optimize and define funclets operation 312 from FIG. 5 will be described in more detail. Upon beginning the operation at start 340 , a define blocks operation 342 defines procedure blocks and data blocks of the original application 10 . Each procedure block preferably includes a single entry point and a single exit point. The data blocks each preferably include a natural data group, such as an integer, an alphanumeric structure or an array of structures. An unprocessed procedures query operation 344 determines whether more procedure blocks remain to be processed by a procedure contain code query operation 346 . If the unprocessed procedures query operation 344 determines that procedure blocks remain to be processed, then the procedure contain code query operation 346 pulls a procedure block and determines whether it contains any code. If the procedure block is determined to contain no code, then it is deemed a data block and is inserted with other data blocks in a place data in global data cloud operation 348 . The unprocessed procedures query operation 344 then determines again whether any unprocessed procedures remain.
[0035] Once all procedure blocks are processed by the procedure contain code query 346 , the unprocessed procedures query operation 344 determines that no unprocessed procedures remain. A seed operation 350 then defines certain procedure blocks as funclets or seeds, as will be described in more detail below. An accumulate operation 352 then adds to the funclets defined in the seed operation 350 by inserting more procedure blocks within the funclets and by defining more procedure blocks as new funclets. A place global data block 354 places data blocks in funclets that have already been defined and defines data blocks as new funclets. In filter operation 356 , certain funclets are removed from the list of funclets if they do not meet predetermined requirements. With the funclets defined, the optimize flow within funclets operation 358 defines an arrangement of data blocks within each funclet that will optimize performance within the funclet. The optimize and define funclets operation 312 terminates at end operation 360 .
[0036] Referring to FIG. 7 , the seed operation 350 from FIG. 6 begins at start operation 366 and the more blocks query operation 368 determines whether any procedure blocks remain that have not been processed by the seed operation 350 . If more blocks remain, a call target query operation 370 pulls the highest priority unprocessed block and determines whether that block is a call target of another procedure. Priority of blocks is determined by the most heavily favored path through the original application 10 , as indicated by the profile data 310 . Thus, the highest priority block is the one most frequently encountered during the user scenarios that produced the profile data 310 , and the lowest priority block is the one least frequently encountered during the user scenarios that produced the profile data 310 . Thus, more frequently encountered blocks are preferably processed before less frequently encountered blocks.
[0037] If the call target query operation 370 determines that the block is a call target of another procedure, then start new funclet operation 372 defines a new funclet with the block. In other words, a new funclet is defined that initially includes only the block that was determined to be a call target. If the call target query operation 370 determines that the block is not a call target of another procedure, then an outside direct reference query operation 374 determines whether the block is directly referenced from outside that block's parent procedure. If the direct reference query operation 374 determines that the block is directly referenced from outside the parent procedure, then start new funclet operation 372 defines a new funclet with the block. Thus, all blocks that are either call targets of another procedure or that are directly referenced by outside the parent procedure are defined as funclets or seeds in start new funclet operation 372 .
[0038] If the outside direct reference query operation 374 determines that the block is not directly referenced from outside the parent procedure, then live query operation 376 determines whether the block is dynamically live or dynamically dead, as indicated by the profile data 310 . A dynamically dead block is a block that is substantially likely to never be needed by the application skeleton 20 during operation. In a preferred embodiment, a dynamically dead block is one that was not encountered during the user scenarios that produced the profile data 310 . A dynamically live block is simply a block that is not dynamically dead.
[0039] If the live query operation 376 determines that the block is dynamically live, a dead block reference query operation 378 determines whether the dynamically live block is referenced from a dynamically dead block. If the dynamically live block is referenced from a dynamically dead block, then the start new funclet operation 372 defines the live block as a new funclet. If the dynamically live block is not referenced from a dynamically dead block, then the block is not defined as a funclet in seed operation 350 and the more blocks query operation 368 determines whether any blocks remain to be processed by the seed operation 350 .
[0040] If the live query operation 376 determines that the block is dynamically dead, a live block reference query operation 380 determines whether the dynamically dead block is referenced from a dynamically live block. If the dynamically dead block is referenced from a dynamically live block, then the start new funclet operation 372 defines the dead block as a new funclet. If the dynamically dead block is not referenced from a dynamically live block, then the block is not defined as a funclet in seed operation 350 and the more blocks query operation 368 determines whether any blocks remain to be processed by the seed operation 350 .
[0041] Thus, the seed operation 350 defines a block as a new funclet in start new funclet operation 372 if the block is either a dynamically live block referenced by a dynamically dead block or a dynamically dead block referenced by a dynamically live block. In this way, the optimize and define funclets operation 312 is able to separate dynamically live blocks and dynamically dead blocks into separate funclets. This is typically desirable because it is highly unlikely that the dynamically dead blocks would ever need to be downloaded. Note that in some situations, such as where a dynamically dead block is very small and cannot be combined with other dynamically dead blocks into a funclet, it may be desirable to combine dynamically live and dead blocks into a single funclet.
[0042] After all blocks have been processed by the seed operation 350 , the more blocks query operation 368 determines that no more blocks remain to be processed, and end operation 382 terminates the seed operation 350 .
[0043] Referring now to FIG. 8 , after the seed operation 350 is complete, the accumulate operation 352 from FIG. 6 begins at start operation 410 . A more unplaced blocks query operation 412 determines whether any procedure blocks remain to be placed into funclets by the accumulate operation 352 . If the more unplaced blocks query operation 412 determines that more blocks remain to be processed by the accumulate operation 352 , then a compute references from funclets operation 414 computes the references from existing funclets to the remaining unplaced blocks. Additionally, a compute references among unplaced blocks operation 416 computes the references between the remaining unplaced blocks. A single-funclet-and-no-procedure-reference query operation 418 then determines whether any unplaced blocks are referenced by exactly one funclet and are not referenced by any other unplaced blocks. If at least one unplaced block is referenced by only one funclet and no other unplaced blocks, then the insert procedure block operation 420 includes the highest priority block that meets this criteria in the definition of the funclet that references the block.
[0044] By inserting such referenced blocks, the funclets can include several blocks and still have only one entry point into the funclet. It is desirable to have larger funclets because larger funclets can be more effectively compressed and downloaded. However, it is desirable to have each funclet include only a single entry point so that each funclet will have only one corresponding binary stub. This improves the performance of the application when running the application skeleton 20 . This is illustrated by the funclet 260 in FIG. 3 , which includes the query operation or block 244 and the first post-query operation or block 246 . Note that if the query operation 244 alone were an existing funclet, then the first post-query operation 246 would be an unplaced block that was referenced by only one funclet and no other unplaced blocks. By including such a block in the funclet, the resulting funclet 260 still includes only a single entry point.
[0045] Referring back to FIG. 8 , if no unplaced blocks are referenced by only one funclet and no other unplaced blocks, then a single funclet reference query operation 422 determines whether the highest priority unplaced block is referenced by only one funclet. If the highest priority unplaced block is referenced by only one funclet, even if it is also referenced by other unplaced blocks, then that highest priority block is included within the definition of the referencing funclet in the insert procedure block operation 420 . Note that this may produce a funclet having more than one entry point because the resulting funclet will have an existing funclet entry point and will also have an entry point into the newly inserted block. However, the benefits of creating larger funclets in this manner have been found to generally outweigh the drawbacks of the rare multiple entry point funclets that may be created. In fact, in some situations multiple entry point funclets may be more desirable than single entry point funclets.
[0046] If no unplaced blocks are referenced by only one funclet as determined by the single funclet reference query operation 422 , then start new funclet operation 424 defines the highest priority unplaced block as a new funclet. After a block is included in the definition of an existing funclet in the insert procedure block operation 420 or a new funclet is defined in the start new funclet operation 424 , the unplaced blocks query operation 412 again determines whether any procedure blocks remain to be placed in funclets by the accumulate operation 352 .
[0047] Thus, the accumulate operation 352 places all procedure blocks in funclets by either placing them in existing funclets or by defining them as new funclets.
[0048] Referring now to FIG. 9 , the place global data blocks operation 354 begins at a start operation 430 . A more unplaced global data query 432 determines whether any unplaced blocks of global data or data blocks (i.e., blocks that contain data and no code) remain. If unplaced data blocks remain, then a single funclet and no data reference query operation 434 determines whether any unplaced data blocks are referenced by exactly one funclet and are not referenced by any unplaced data blocks.
[0049] If at least one unplaced data block is referenced by exactly one funclet and no unplaced data blocks, then the insert data block operation 436 includes the highest priority unplaced data block within the funclet referencing that data block.
[0050] If the single-funclet-and-no-data-reference query operation 434 determines that no unplaced data blocks are referenced by only one funclet and are not referenced by any unplaced data blocks, then the start new funclet operation 438 defines the highest priority unplaced data block as a new funclet. A compute references operation 440 then computes the references from the funclets to any remaining unplaced data blocks.
[0051] After the insert data block operation 436 or the compute references operation 440 , the unplaced global data query operation 432 again determines whether any unplaced data blocks remain. After all data blocks have been included within funclet definitions, the unplaced global data query operation 432 determines that no unplaced data blocks remain and end operation 442 terminates the place global data blocks operation 354 . Thus, the place global data blocks operation 354 includes all data blocks within funclet definitions by either including them within existing funclets or by defining them as new funclets.
[0052] Thus, the seed operation 350 , the accumulate operation 352 , and the place global data blocks operation 354 define funclets that cumulatively include all procedure blocks and all data blocks. The funclets are preferably not actually created by the seed operation 350 , the accumulate operation 352 , and the place global data blocks operation 354 . Rather, the seed operation 350 , the accumulate operation 352 , and the place global data blocks operation 354 create a list of the defined funclets. The generate skeleton operation 316 and the convert program to data operation 318 , which are discussed in more detail below with reference to FIG. 11 , use the list of defined funclets to create the actual funclets 34 and the application skeleton 20 .
[0053] Referring now to FIG. 10 , the filter operation 356 from FIG. 6 begins at a start operation 450 . A compute references among funclets operation 452 computes the references between the defined funclets. A more funclets query operation 454 then determines whether any funclets remain to be processed by the filter operation 356 . If funclets remain to be processed, then a too big query operation determines whether a particular unprocessed funclet is too big to be effectively compressed and downloaded. The actual maximum funclet size will depend on the particular application and on the particular download system characteristics. If the funclet is too big, then the remove from list operation 458 removes the funclet from the list of funclets. Thus, the data and/or code of the funclet will be included in the application skeleton 20 .
[0054] If the too big query operation 456 determines that the funclet is not too big, then a too small query operation 462 determines whether the funclet is too small for the benefits of the funclet to outweigh the drawbacks of including the funclet. The benefits of including a small funclet may be minimal because of its size. Thus the benefits may be outweighed by the drawbacks, which include the time to process requests for the funclet and to download the funclet during use. The optimum actual minimum funclet size will depend on the particular application and the download system characteristics. If the funclet is too small, then the remove from list operation 458 removes the funclet from the list of funclets. Thus, the too big query operation 456 and the too small query operation 462 together assure that each funclet is within a predetermined funclet size range.
[0055] If the too small query operation 462 determines that the funclet is not too small, then the too many funclet references query operation 464 determines whether the funclet includes so many references to other funclets that the drawbacks of processing those references and the fix-ups described below outweigh the benefits of including the funclet. Again, the maximum number of references to other funclets will depend on the particular application and the download system characteristics. It may also depend on the benefits of including the funclet, which could depend on the characteristics of the particular funclet, such as the size of the funclet. If the too many funclet references query operation 464 determines that the funclet has too may references to other funclets, then the remove from list operation 458 removes the funclet from the list of funclets.
[0056] If the too many funclet references query operation 464 determines that the funclet does not include too many references to other funclets, then an application entry point query operation 466 determines whether the funclet includes the entry point for the entire application. The entry point for the entire application is preferably included in the application skeleton 20 , not in a funclet. Thus, if the funclet includes the entry point for the entire application, the remove from list query operation 458 removes the funclet from the list of funclets.
[0057] If the application entry point query operation 466 determines that the funclet does not include the application entry point, then a data referenced by non-funclets query operation 468 determines whether the funclet includes data that is referenced by non-funclets. Such data and the defined funclets including such data are preferably included within the application skeleton 20 . Thus, if the funclet includes data that is referenced by non-funclets, then the remove from list operation 458 removes the funclet from the list of funclets.
[0058] After the funclet is removed from the list of funclets by the remove from list operation 458 or the data referenced by non-funclets query operation 468 determines that the funclet does not include data referenced by non-funclets, then the compute references among funclets operation 452 again computes the references between the funclets and the more funclets query operation 454 determines whether more funclets remain to be filtered by the filter operation 356 . After the filter operation 356 filters all the funclets, the more funclets query operation 454 determines that no funclets remain to be filtered and the filter operation 356 terminates at end operation 470 .
[0059] Referring back to FIG. 6 , the optimize flow within funclets operation 358 preferably arranges the code and data within the funclets according to the most favored path through the application as indicated by the profile data 310 . Thus, blocks that are more likely to be encountered are grouped together within each funclet to improve performance of the funclet after it has been supplied to the application skeleton 20 . This optimization may be performed in a manner similar to the optimization of procedures that have not been included in funclets.
[0060] Referring now to FIG. 11 , the generate skeleton operation 316 and the convert program to data operation 318 of FIG. 5 will be described in more detail. The generate skeleton operation 316 begins at start operation 510 , and an unprocessed funclets query operation 512 determines whether more funclets remain to be processed by the generate skeleton operation 316 .
[0061] If more funclets remain to be processed by the generate skeleton operation 316 , then a remove and save operation 514 removes the funclet code and/or data from the original application 10 and saves a copy of the original funclet code and/or data. The replace funclet with placeholder operation 516 then reserves the space where the funclet code and/or data was removed, preferably by inserting zeros in that space. Finally, the insert stub instructions operation 518 inserts stub instructions that will call the LDRRT module to request the missing funclet when the stub instructions are encountered while running the application skeleton 20 . The combined stub instructions and placeholder are referred to herein as a binary stub. The unprocessed funclets query operation 512 then determines whether more funclets remain to be processed by the generate skeleton operation 316 . The generate skeleton operation 316 thus produces an application skeleton 320 that includes binary stubs in place of missing funclets.
[0062] After the generate skeleton operation 316 processes all the funclets, a more unprocessed funclets query operation 524 of the convert program to data operation 318 determines whether funclets remain to be processed by the convert program to data operation 318 . If unprocessed funclets remain, then a get final address operation 526 gets the final address for the references from the funclet to other parts of the application, including references to other funclets. In so doing, the final address operation 526 must assure that each reference includes enough space or memory. For example, a jump command that only needs to go a short distance may need less space than a jump command that must go a longer distance. For example, in an x86 platform jump commands that need to jump short distances in memory typically only need to include 3 bytes, while jump commands that need to jump relatively long distances in memory typically require 5 bytes. Thus, in an x86 platform all jumps to other funclets preferably include 5 bytes because the other funclets may be located long distances from the referring jump command in memory. Likewise, jumps that must go long distances within funclets may also need to be 5 bytes. Of course, other platforms may require different numbers of bytes.
[0063] The copy code bytes operation 528 copies the funclet code and data bytes into the funclet. The funclet code and data bytes were previously saved by the remove and save operation 514 of the generate skeleton operation 316 .
[0064] An add fix-ups operation 530 adds fix-ups or relocations to the funclet. The add fix-ups operation 530 determines where to apply a relocation by determining where a reference within the funclet points to a target that will be modified by the binary preparation operation 12 . The add fix-ups operation 530 also determines what the relocation is pointing to and what type of relocation is needed. Referring now to FIG. 12 , the effects of two types of fix-ups, a “to” flag 532 and a “from” flag 534 , are illustrated. In FIG. 12 , the from flag 534 refers to the offset 536 between the beginning of a first funclet or “BAR” 538 and the referenced code 540 . The to flag 532 includes a simple call to another funclet or “FOO” 542 . Thus, the relocation may be a to flag such as 532 or a from flag such as 534 . Note that in either case, the relocation or fix-up is needed because the referenced funclet will be in a different place in memory after being supplied to the application skeleton 20 than it would have been in the original application 10 .
[0065] Referring back to FIG. 11 , after the add fix-ups operation 530 , the unprocessed funclets operation 524 determines whether more unprocessed funclets remain to be processed by the generate skeleton operation 318 . After the generate skeleton operation 318 processes all the funclets, then the generate skeleton operation 318 terminates at end operation 546 .
[0066] Referring now to FIG. 13 , the insert housekeeping structure operation 324 from FIG. 5 inserts several components into the application skeleton 20 that enable the application skeleton 20 to operate properly in a software on demand system. In insert application context id operation 550 , an application context identification is placed in the application skeleton 20 . Each funclet request from the application skeleton 20 will include the application context identification, which is used to match the request with the corresponding LDN 322 . The application context identification and a funclet identification from the requesting binary stub enable the software on demand system to locate the requested funclet. Additionally, an insert server name operation 554 preferably includes a computer system identification of the computer system where the LDN 322 is stored to aid the software on demand system in locating requested funclets. The computer system identification is preferably the name of the server that includes the corresponding LDN 322 .
[0067] A modify application header operation 556 modifies the application header of the application skeleton 20 . A typical application header includes housekeeping information that is supplied to the operating system. When an application is started, the application header typically gives the operating system the entry point for the application and the operating system gives control to the application. The header of the application skeleton 20 is modified so that each time the application skeleton 20 executes, the application calls the corresponding LDRRT module and allows the LDRRT module to initialize before going to the original application entry point.
[0068] An insert compressor/decompressor list operation 558 places in the application skeleton 20 a list of the compressors used to compress each funclet and the corresponding decompressors that should be used to decompress each funclet. The compressor/decompressor pair list is especially important where multiple compressors are used to compress the funclets. This may be done where different funclets can be more effectively compressed using different compressors. The list allows each funclet to be decompressed by the decompressor corresponding to the compressor used to compress the funclet.
[0069] In insert number of funclets operation 560 , the number of funclets 34 is placed in the application skeleton 20 . This number may be used by the LDRRT module to produce an optimum configuration during initialization. Additionally, an insert “from” references to LDRRT operation 562 includes in the application skeleton the offset distance from the beginning of the LDRRT module to the referenced code or data within the LDRRT module for all references. Such “from” references enable the references to properly point to the desired code or data with the LDRRT module, even if the LDRRT module is loaded into different places in memory with each use of the LDRRT module.
[0070] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made therein without departing from the spirit and scope of the invention.
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A method prepares a computer program for operation in a computer supply system that supplies portions, or program units, of program code or program data of the computer program as the program needs the portions. The method includes defining a program unit of the program and removing the program unit from the program, thereby producing a program skeleton that is missing the program unit. The method further includes inserting instructions in place of the program unit in the program skeleton. The instructions are operative to request the program unit when the program skeleton encounters the instructions. An information structure includes a program skeleton of a program. The program skeleton is missing a funclet of the program, but includes a placeholder in place of the funclet. The program skeleton additionally includes instructions in place of the funclet. The instructions are operative to request the funclet when the program skeleton encounters the instructions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application (under 35 U.S.C. §371) of PCT/EP2008/060114, filed Aug. 1, 2008, which claims benefit of German application 10 2007 037522.2, filed Aug. 9, 2007.
BACKGROUND OF THE INVENTION
The present invention relates to disperse azo dyes in which a phenacyl ester is linked to the chromophore. Dyes comprising this structural element are already known and are described for example in WO05/056690.
BRIEF SUMMARY OF THE INVENTION
It has now been found that disperse azo dyes in which the phenacyl ester is substituted by a further phenyl or phenoxy radical have outstanding properties and that dyeings prepared therewith are notable for good washfastnesses and outstanding sublimation fastnesses. More particularly, such dyeings meet the special requirements of industrial laundering, where textiles are exposed to high temperatures after the wash cycle.
We have found that, surprisingly, despite their relatively high molecular weight, the dyes of the present invention go readily onto polyester and polyester blend fabrics.
The present invention provides dyes of the general formula (I)
where
D is the residue of a diazo component; R 1 is hydrogen, (C 1 -C 6 )-alkyl, (C 1 -C 4 )-alkoxy, hydroxyl, halogen, —NHCHO, —NHCO(C 1 -C 6 )-alkyl or —NHSO 2 (C 1 -C 6 )-alkyl; R 2 is hydrogen, (C 1 -C 6 )-alkyl, (C 1 -C 4 )-alkoxy or halogen; R 3 is hydrogen, (C 1 -C 6 )-alkyl, substituted (C 1 -C 6 )-alkyl, (C 3 -C 4 )-alkenyl or substituted (C 3 -C 4 )-alkenyl; or R 2 and R 3 combine to form the radical —C*H(CH 3 )CH 2 C(CH 3 ) 2 —, where the carbon atom marked * is attached to the phenyl nucleus; R 4 is hydrogen or (C 1 -C 6 )-alkyl; R 5 is hydrogen or (C 1 -C 6 )-alkyl; R 6 is hydrogen or (C 1 -C 6 )-alkyl; X is phenyl, thiophenyl, sulfonylphenyl or phenoxy; n is 0, 1, or 2; and m is 0 or 1.
DETAILED DESCRIPTION OF THE INVENTION
Residues D of a diazo component are in particular the residues customary in the field of disperse dyes and known to one skilled in the art.
Preferably, D
represents a group of the formula (IIa)
where
T 1 and T 2 are independently hydrogen, halogen, (C 1 -C 4 )-alkyl, (C 1 -C 4 )-alkoxy, cyano, —SO 2 (C 1 -C 4 )-alkyl or nitro; and T 4 and T 3 are independently hydrogen, halogen, trifluoromethyl, cyano, —SO 2 CH 3 , —SCN or nitro;
with the proviso that at least one of T 1 , T 2 , T 3 and T 4 is not hydrogen; or represents a group of the formula (IIb)
where
T 5 and T 5′ are independently hydrogen or halogen; and T 6 is hydrogen, —SO 2 CH 3 , —SCN, (C 1 -C 4 )-alkoxy, halogen, cyano or nitro;
with the proviso that at least one of T 5 , T 5′ and T 6 is not hydrogen; or represents a group of the formula (IIc)
where
T 12 is hydrogen or halogen;
or represents a group of the formula (IId)
where
T 7 is nitro, —CHO, —COCH 3 , cyano or a group of the formula
where T 10 is hydrogen, halogen, nitro or cyano;
T 8 is hydrogen, (C 1 -C 6 )-alkyl or halogen; and T 9 is nitro, cyano, —COCH 3 or —COOT 11 ; where T 11 is (C 1 -C 4 )-alkyl; or represents a group of the formula (IIe)
where T 7 and T 8 are each as defined above;
or represents a group of the formula (IIf)
where T 13 is phenyl or (C 1 -C 4 )-alkylthio;
or represents a group of the formula (IIg)
where T 14 is cyano or —COCH 3 or —COOT 11 , where T 11 is (C 1 -C 4 )-alkyl; and T 15 is phenyl or (C 1 -C 4 )-alkyl;
or represents a group of the formula (IIh)
where T 14 is as defined above and T 16 is (C 1 -C 4 )-alkyl;
or represents a group of the formula (IIi)
where T 17 is cyanomethyl, benzyl or allyl;
or represents a group of the formula (IIj)
(C 1 -C 6 )-Alkyl groups R 1 to R 7 may be straight chain or branched and are for example methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, tert-butyl, n-pentyl or n-hexyl. Analogous considerations apply to (C 1 -C 6 )-alkoxy.
Substituted (C 1 -C 6 )-alkyl groups R 3 are substituted in particular by 1 to 3 substituents selected from the group consisting of halogen, cyano, hydroxyl, (C 1 -C 6 )-alkoxy, —COO(C 1 -C 6 )-alkyl, —OCOO(C 1 -C 6 )-alkyl and —OCO(C 1 -C 6 )-alkyl.
A (C 3 -C 4 )-alkenyl group R 3 is in particular allyl.
Halogen is preferably chlorine or bromine.
R 1 is preferably hydrogen, chlorine, methyl, ethyl, hydroxyl, methoxy, ethoxy, acetylamine, propionylamino, methylsulfonylamino or ethylsulfonylamino. R 2 is preferably hydrogen, chlorine, methyl, ethyl, methoxy or ethoxy. R 3 is preferably hydrogen, methyl, ethyl, propyl, butyl, methoxyethyl, cyanoethyl, C 2 H 4 OCOCH 3 , C 2 H 4 OCOC 2 H 5 , C 2 H 4 COOCH 3 , C 2 H 4 COOC 2 H 5 or allyl. R 4 , R 5 and R 6 are each preferably methyl or hydrogen, more preferably hydrogen. X is preferably phenyl or phenoxy and more preferably phenyl. n is preferably 0 or 1, more preferably 0. m is preferably 1. m+n is preferably 1.
Preferred dyes of the present invention conform to the general formula (Ia)
where T 1 to T 4 , R 1 to R 6 , m and n are each as defined above.
Particularly preferred dyes of this type according to the present invention conform to the general formula (Iaa)
where
T 1 is nitro; T 3 is hydrogen, cyano, chlorine or bromine; T 4 is hydrogen, cyano, nitro, chlorine, bromine or trifluoromethyl; R 1 is hydrogen, hydroxyl, methyl, acetylamino or propionylamino; R 2 is hydrogen, chlorine, methyl or methoxy; R 3 is hydrogen, methyl, ethyl, butyl or allyl.
Further preferred dyes of the present invention conform to the general formula (Ib)
where T 1 to T 4 , R 1 to R 6 , m and n are each as defined above.
Particularly preferred dyes of this type according to the present invention conform to the general formula (Iba)
where
T 1 is nitro; T 3 is hydrogen, cyano, chlorine or bromine; T 4 is hydrogen, cyano, nitro, chlorine, bromine or trifluoromethyl; R 1 is hydrogen, hydroxyl, methyl, acetylamino or propionylamino; R 2 is hydrogen, chlorine, methyl or methoxy; R 3 is hydrogen, methyl, ethyl, butyl or allyl.
The dyes of the general formula (I) according to the present invention can be prepared by methods known to one skilled in the art. For instance, a compound of the general formula (III)
D-NH 2 (III)
where D is as defined above, is diazotized and coupled onto a compound of the general formula (IV)
where R 1 to R 6 , X, m and n are each as defined above.
The compounds of the general formula (III) are generally diazotized in a known manner, for example with sodium nitrite in an acidic aqueous medium, for example in an aqueous medium rendered acidic with hydrochloric acid or sulfuric acid, or with nitrosylsulfuric acid in dilute sulfuric acid, phosphoric acid or a mixture of acetic and propionic acids. The preferred temperature range is between 0° C. and 15° C.
The diazotized compounds are generally likewise coupled onto the compounds of the general formula (IV) in a known manner, for example in an acidic, aqueous, aqueous-organic or organic medium, with particular advantage at temperatures below 10° C. Acids used are in particular sulfuric acid, acetic acid or propionic acid.
The compounds of the general formulae (III) and (IV) are known and can be prepared by known methods.
The dyes of the general formula (I) according to the present invention are outstandingly useful for dyeing and printing hydrophobic materials in that the dyeings and prints obtained are notable for level shades and high service fastnesses. Deserving of emphasis are good washfastnesses, in particular those in combination with very good sublimation fastnesses.
It has further been determined that the disperse dyes of the present invention are outstandingly useful for the continuous dyeing of polyester-cotton blends as used for workwear for example. The wetfastnesses achieved, in particular according to the “Hoechst combination test” which is particularly relevant for this application and wherein the dyed material is exposed to temperatures of 190° C. for 5 minutes before the ISO 105-C05 test, are outstanding.
The present invention thus also provides for the use of the dyes of the general formula I for dyeing and printing hydrophobic materials, and processes for dyeing or printing such materials in conventional procedures which utilize as colorants one or more dyes of the general formula (I) according to the present invention.
The hydrophobic materials mentioned can be of synthetic or cellulosic origin. Hydrophobic materials contemplated include for example secondary cellulose acetate, cellulose triacetate, polyamides and, in particular, macromolecular polyesters. Materials composed of macromolecular polyester are in particular those based on polyethylene glycol terephthalates.
The hydrophobic synthetic materials may be in the form of sheet- or thread-shaped structures and may have been processed for example into yarns or woven or knit textile fabrics. Preference is given to fibrous textile materials, which can also be present in the form of microfibers for example.
The dyeing in accordance with the use according to the present invention can be effected in a conventional manner, preferably from an aqueous dispersion, if appropriate in the presence of carriers, between 80 to about 110° C. by the exhaust method or by the HT method in a dyeing autoclave at 110 to 140° C., and also by the so-called thermofix method in which the fabric is padded with the dyeing liquor and subsequently fixed/set at about 180 to 230° C.
Printing of the materials mentioned can be carried out in a manner known per se by incorporating the dyes of the general formula (I) of the present invention in a print paste and treating the fabric printed therewith at temperatures between 180 to 230° C. with HT steam, high-pressure steam or dry heat, if appropriate in the presence of a carrier, to fix the dye.
The dyes of the general formula (I) of the present invention shall be in a very fine state of subdivision when they are used in dyeing liquors, padding liquors or print pastes.
The dyes are converted into the fine state of subdivision in a conventional manner by slurrying the as-fabricated dye together with dispersants in a liquid medium, preferably in water, and subjecting the mixture to the action of shearing forces to mechanically comminute the original dye particles to such an extent that an optimal specific surface area is achieved and sedimentation of the dye is minimized. This is accomplished in suitable mills, such as ball or sand mills. The particle size of the dyes is generally between 0.5 and 5 μm and preferably equal to about 1 μm.
The dispersants used in the milling operation can be nonionic or anionic. Nonionic dispersants include for example reaction products of alkylene oxides, for example ethylene oxide or propylene oxide, with alkylatable compounds, for example fatty alcohols, fatty amines, fatty acids, phenols, alkylphenols and carboxamides. Anionic dispersants are for example lignosulfonates, alkyl- or alkylarylsulfonates or alkylaryl polyglycol ether sulfates.
The dye preparations thus obtained shall be pourable for most applications. Accordingly, the dye and dispersant content is limited in these cases. In general, the dispersions are adjusted to a dye content up to 50 percent by weight and a dispersant content up to about 25 percent by weight. For economic reasons, dye contents are in most cases not below 15 percent by weight.
The dispersions may also contain still further auxiliaries, for example those which act as oxidizing agents, for example sodium m-nitrobenzenesulfonate, or fungicidal agents, for example sodium o-phenylphenoxide and sodium pentachlorophenoxide, and particularly so-called “acid donors”, examples being butyrolactone, monochloroacetamide, sodium chloroacetate, sodium dichloroacetate, the sodium salt of 3-chloropropionic acid, monosulfate esters such as lauryl sulfate for example, and also sulfuric esters of ethoxylated and propoxylated alcohols, for example butylglycol sulfate.
The dye dispersions thus obtained are very advantageous for making up dyeing liquors and print pastes.
There are certain fields of use where powder formulations are preferred. These powders comprise the dye, dispersants and other auxiliaries, for example wetting, oxidizing, preserving and dustproofing agents and the abovementioned “acid donors”.
A preferred method of making pulverulent preparations of dye consists in stripping the above-described liquid dye dispersions of their liquid, for example by vacuum drying, freeze drying, by drying on drum dryers, but preferably by spray drying.
The dyeing liquors are made by diluting the requisite amounts of the above-described dye formulations with the dyeing medium, preferably water, such that a liquor ratio of 5:1 to 50:1 is obtained for dyeing. In addition, it is generally customary to include further dyeing auxiliaries, such as dispersing, wetting and fixing auxiliaries, in the liquors. Organic and inorganic acids such as acetic acid, succinic acid, boric acid or phosphoric acid are included to set a pH in the range from 4 to 5, preferably 4.5. It is advantageous to buffer the pH setting and to add a sufficient amount of a buffering system. The acetic acid/sodium acetate system is an example of an advantageous buffering system.
To use the dye or dye mixture in textile printing, the requisite amounts of the abovementioned dye formulations are kneaded in a conventional manner together with thickeners, for example alkali metal alginates or the like, and if appropriate further additives, for example fixation accelerants, wetting agents and oxidizing agents, to give print pastes.
The present invention also provides inks for digital textile printing by the ink jet process, comprising a present invention dye of the general formula (I).
The inks of the present invention are preferably aqueous and comprise one or more of the present invention's dyes of the general formula (I), for example in amounts of 0.1% to 50% by weight, preferably in amounts of 1% to 30% by weight and more preferably in amounts of 1% to 15% by weight based on the total weight of the ink. They further comprise in particular from 0.1% to 20% by weight of a dispersant. Suitable dispersants are known to one skilled in the art, are commercially available and include for example sulfonated or sulfomethylated lignins, condensation products of aromatic sulfonic acids and formaldehyde, condensation products of substituted or unsubstituted phenol and formaldehyde, polyacrylates and corresponding copolymers, modified polyurethanes and reaction products of alkylene oxides with alkylatable compounds, for example fatty alcohols, fatty amines, fatty acids, carboxamides and substituted or unsubstituted phenols.
The inks of the present invention may further comprise customary additives, for example viscosity moderators to set viscosities in the range from 1.5 to 40.0 mPas in a temperature range of 20 to 50° C. Preferred inks have a viscosity in the range from 1.5 to 20 mPas and particularly preferred inks have a viscosity in the range from 1.5 to 15 mPas.
Useful viscosity moderators include rheological additives, for example polyvinyl-caprolactam, polyvinylpyrrolidone and also their copolymers, polyetherpolyol, associative thickeners, polyureas, sodium alginates, modified galactomannans, polyetherurea, polyurethane and nonionic cellulose ethers.
By way of further additives, the inks of the present invention may include surface-active substances to set surface tensions in the range from 20 to 65 mN/m, which are if appropriate adapted depending on the process used (thermal or piezo technology). Useful surface-active substances include for example surfactants of any kind, preferably nonionic surfactants, butyldiglycol and 1,2 hexanediol.
The inks may further include customary additives, for example chemical species to inhibit fungal and bacterial growth in amounts from 0.01% to 1% by weight based on the total weight of the ink.
The inks of the present invention can be prepared in conventional manner by mixing the components in water.
Example 1
66.2 g of 6-bromo-2,4-dinitroaniline are suspended in 185 ml of acetic acid at room temperature. 7.5 ml of sulfuric acid (96%) are added with slight cooling. 45 ml of nitrosylsulfuric acid (40%) are added dropwise at 15-20° C. The mixture is subsequently stirred at 15-20° C. for one hour. The diazonium salt solution thus obtained is added dropwise to a mixture of 111.6 g of 2-biphenyl-4-yl-2-oxoethyl 3-(5-acetylamino-2-methoxyphenylamino)propionate, 1 l of acetone and 10 g of urea at 5-10° C. in the course of one hour. This is followed by stirring for one hour, diluting with 500 ml of water, filtering off with suction, washing with water and drying to leave 86g of the dye of the formula (Iab)
(λ max [DMF]=594 nm) which produces blue shades having good washfastnesses and sublimation fastnesses on polyester.
Example 2
51.6 g of 2-chloro-4-nitroaniline are stirred up with 100 ml of water and 85 ml of hydrochloric acid (30%) at room temperature for 18 hours. After additions of 160 g of ice, 40 ml of nitrite solution (53 g/l) are added over 1-2 minutes. The mixture is subsequently stirred at not more than 5° C. for 2 hours and excess nitrite is subsequently destroyed with amidosulfonic acid. The diazonium salt solution thus obtained is added dropwise to a solution of 116.3 g of 2-biphenyl-4-yl-2-oxoethyl 3-(ethylphenylamino)propionate in 1.4 l of acetone at 0-5° C. in the course of an hour.
The mixture is subsequently stirred at 5-10° C. for 18 hours and poured onto 6.5 l of water. The precipitate is filtered off with suction, washed with water and dried to leave 167 g of the dye of the formula (Iac)
(λ max [DMF]=514 nm) which produces red shades having good washfastnesses and excellent sublimation fastnesses on polyester.
Example 3
14.3 g of 2-biphenyl-4-yl-2-oxoethyl 3-{[3-acetylamino-4-(2-bromo-4,6-dinitrophenylazo)phenyl]ethylamino}propionate and 1.9 g of copper(I) cyanide are stirred in 80 ml of N-methylpyrrolidone at 100° C. for 2 hours. After cooling, 250 ml of methanol are added dropwise to the batch. The precipitate is filtered off with suction, and washed with a little methanol and water. The water-moist solid is stirred in 150 ml of hydrochloric acid (10%) for one hour, filtered off with suction and washed with water. Drying under reduced pressure leaves 8.8 g of the dye of the formula (Iad)
(λ max [DMF]=602 nm) which dyes polyester in brilliant blue shades and has good washfastnesses and excellent sublimation fastnesses.
The compounds of Examples 4 to 45 in Table 1 were prepared similarly to the processes described in Examples 1 to 3.
TABLE 1
λ max (nm)
Example
T 1
T 2
T 3
T 4
R 1
R 2
R 3
R 4
R 5
n
m
X
DMF
4
NO 2
H
Br
NO 2
NHCOCH 3
OCH 3
CH 2 CH 3
H
H
0
1
C 6 H 5
604
5
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
CH 2 CH 3
H
H
0
1
C 6 H 5
604
6
NO 2
H
H
NO 2
NHCOCH 3
OCH 3
CH 2 CH 3
H
H
0
1
C 6 H 5
582
7
NO 2
H
Br
NO 2
NHCOCH 3
OCH 3
CH 2 CH 3
H
H
0
0
C 6 H 5
590
8
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
H
H
H
2
0
C 6 H 5
600
9
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
CH 2 CH═CH 2
H
H
0
1
C 6 H 5
598
10
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
CH 3
H
H
0
1
C 6 H 5
600
11
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
H
H
H
0
1
C 6 H 5
594
12
NO 2
H
Br
NO 2
NHCOCH 3
OCH 3
H
H
H
0
1
OC 6 H 5
594
13
NO 2
H
Cl
NO 2
NHCOC 2 H 5
OCH 3
H
H
H
0
1
C 6 H 5
594
14
NO 2
H
Br
CN
NHCOCH 3
OCH 3
H
H
H
0
1
C 6 H 5
624
15
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
H
CH 3
H
0
1
C 6 H 5
596
16
NO 2
H
Cl
NO 2
NHCOCH 3
OCH 3
H
H
CH 3
0
1
C 6 H 5
592
17
NO 2
H
H
NO 2
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
548
18
NO 2
H
Cl
NO 2
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
560
19
NO 2
H
CN
NO 2
NHCOCH 3
H
CH 2 CH 3
H
H
0
0
C 6 H 5
584
20
NO 2
H
Br
NO 2
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
558
21
NO 2
H
H
CN
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
552
22
NO 2
H
Br
CN
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
584
23
NO 2
H
H
Cl
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
534
24
NO 2
H
H
Cl
NHCOCH 3
H
n-butyl
H
H
0
1
C 6 H 5
534
25
NO 2
H
H
H
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
514
26
NO 2
H
H
H
NHCOCH 3
Cl
H
H
H
0
1
C 6 H 5
450
27
NO 2
H
H
CN
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
548
28
NO 2
H
H
Cl
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
524
29
NO 2
H
Cl
Cl
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
462
30
NO 2
H
Br
Cl
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
460
31
NO 2
H
CN
CN
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
598
32
NO 2
H
CN
CN
CH 3
H
n-butyl
H
H
0
1
C 6 H 5
600
33
NO 2
H
Br
CN
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
560
34
NO 2
H
H
CN
H
H
CH 2 CH 3
H
H
0
1
C 6 H 5
536
35
NO 2
H
H
CN
H
H
n-propyl
H
H
0
1
C 6 H 5
538
36
NO 2
H
Cl
Cl
H
H
CH 2 CH 3
H
H
0
1
C 6 H 5
442
37
NO 2
H
Br
Cl
H
H
CH 2 CH 3
H
H
0
1
C 6 H 5
440
38
NO 2
H
H
H
H
H
CH 2 CH 3
H
H
0
1
C 6 H 5
488
39
NO 2
H
H
H
H
H
CH 2 CH 3
H
H
0
0
C 6 H 5
476
40
NO 2
H
H
CN
H
H
CH 2 CH 3
H
H
0
0
C 6 H 5
522
41
NO 2
H
H
Cl
H
H
CH 2 CH 3
H
H
0
1
OC 6 H 5
514
42
NO 2
H
H
H
H
Cl
H
H
H
0
1
C 6 H 5
452
43
NO 2
Cl
H
Cl
H
H
CH 2 CH 3
H
H
0
1
C 6 H 5
510
44
H
NO 2
H
H
CH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
452
45
CH 3
H
CN
CN
NHCOCH 3
H
CH 2 CH 3
H
H
0
1
C 6 H 5
532
Example 46
6.5 g of 3-amino-5-nitrobenzisothiazole are introduced into a mixture of 16.6 ml of sulfuric acid (96%) and 6 ml of phosphoric acid (85%). Then, 6.9 ml of nitrosylsulfuric acid (40%) are added dropwise at 10 to 15° C. The mixture is subsequently stirred at 10 to 15° C. for 4 hours. The diazonium salt solution thus obtained is expeditiously added dropwise to a mixture of 12.9 g of 2-biphenyl-4-yl-2-oxoethyl 3-(ethylphenyl-amino)propionate, 250 ml of acetone, 1.7 g of urea at 0-5° C. This is followed by stirring at room temperature overnight, filtering off with suction and washing with methanol and then with water and drying to leave 13.7 g of the dye of the formula (Ibb)
(λ max [DMF]=604 nm) which dyes polyester in blue shades and has very good washfastnesses and sublimation fastnesses.
The compounds of Examples 47 to 55 in Table 2 were prepared similarly to the process described in Example 46.
TABLE 2
Example
D
R 1
R 2
R 3
X
λ max [DMF]
47
H
H
CH 2 CH 3
C 6 H 5
650
48
H
H
CH 3
C 6 H 5
602
49
CH 3
H
CH 2 CH 3
C 6 H 5
618
50
NHCOCH 3
Cl
H
C 6 H 5
594
51
NHCOCH 3
H
CH 2 CH 3
C 6 H 5
594
52
NHCOCH 3
H
CH 2 CH 3
C 6 H 5
642
53
HNCOCH 3
H
CH 2 CH 3
C 6 H 5
648
54
CH 3
H
CH 2 CH 3
C 6 H 5
520
55
NHCOCH 3
OCH 3
CH 2 C 6 H 5
C 6 H 5
600
Example 56
A textile fabric consisting of polyester is padded with a liquor consisting of 50 g/l of 8% sodium alginate solution, 100 g/l of 8-12% carob flour ether solution and 5 g/l of monosodium phosphate in water and then dried. The wet pickup is 70%.
The textile thus pretreated is then printed with an aqueous ink prepared in accordance with the procedure described above and containing
3.5% of the dye of Example 1,
2.5% of Disperbyk 190 dispersant,
30% of 1,5-pentanediol,
5% of diethylene glycol monomethyl ether,
0.01% of Mergal K9N biocide, and
58.99% of water
using a drop-on-demand (piezo) ink jet print head. The print is fully dried. Fixing is effected by means of superheated steam at 175° C. for 7 minutes. The print is subsequently subjected to an alkaline reduction clear, rinsed warm and then dried.
|
The invention provides for a dye of the formula (I)
where
D is the residue of a diazo component;
R 1 is hydrogen, (C 1 -C 6 )-alkyl, (C 1 -C 4 )-alkoxy, hydroxyl, halogen, —NHCHO, —NHCO(C 1 -C 6 )-alkyl or —NHSO 2 (C 1 -C 6 )-alkyl; R 2 is hydrogen, (C 1 -C 6 )-alkyl, (C 1 -C 4 )-alkoxy or halogen; R 3 is hydrogen, (C 1 -C 6 )-alkyl, substituted (C 1 -C 6 )-alkyl, (C 3 -C 4 )-alkenyl or substituted (C 3 -C 4 )-alkenyl or R 2 and R 3 combine to form the radical —C*H(CH 3 )CH 2 C(CH 3 ) 2 —, where the carbon atom marked * is attached to the phenyl nucleus; R 4 is hydrogen or (C 1 -C 6 )-alkyl; R 5 is hydrogen or (C 1 -C 6 )-alkyl; R 6 is hydrogen or (C 1 -C 6 )-alkyl; X is phenyl, thiophenyl, sulfonylphenyl or phenoxy; n is 0, 1, or 2; and m is 0 or 1. The invention is also related to the process of using the dye and the process of preparing the dye.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electrical connectors and, more particularly, to a coding system to allow connection of connectors to each other only upon having a matched configuration.
2. Prior Art
U.S Pat. No. 5,041,025 to Haitmanek discloses a multi-positionable key for interconnectable components. U.S. Pat. No. 3,426,315 to DeTar discloses electrical connectors with studs adapted to mate with each other having thirty-six different matching positions. U.S. Pat. No. 5,044,994 to Van Woensel discloses a connector assembly with various different types of mating coding elements. U.S. Pat. No. 4,925,400 to Blair et al. discloses the use of an octagonal keying element on a mother board and corresponding keying elements on a module connector.
One of the problems encountered with keying and coding systems in the prior art is that most of them are not easily configurable. Another problem is that such prior art systems occupy excessive space making connectors significantly larger than otherwise would be necessary. Another problem is that with systems, such as disclosed in U.S. Pat. No. 5,044,994, that provide many different configurations, the large variety of coding elements increases inventory and manufacturing costs.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention an electrical connector is provided comprising a housing, electrical contacts mounted to the housing, and a coding module connected to the housing. The coding module comprises a frame and at least two keys. The frame is connected to the housing with a window with each key. The windows are oriented towards a path of insertion with a second connector. Each key has a keying section located in one of the windows thereby blocking a portion of each window. The keying sections are suitably positioned in the windows to provide a plurality of different blocked window patterns.
In accordance with another embodiment of the present invention an electrical connector coder is provided comprising a frame and a key. The frame has a key receiving area and means for connecting the frame to a first electrical connector. The key has a mounting base and an off-center polarizing section. The key is positionable in the frame at a variety of orientations in the key receiving area such that the off-center polarizing section occupies a predetermined portion of the key receiving area. The key and the key receiving area are adapted to allow connection of the first electrical connector with a second electrical connector having a second coder upon the keys of the two coders being cooperatingly matched to align adjacent each other, but otherwise prevent connection of the two electrical connectors to each other.
In accordance with another embodiment of the present invention an electrical connector assembly is provided comprising a first connector, a second connector, a first coder module, and a second coder module. The second connector is adapted to electrically and mechanically connect to the first connector. The first coder module is connected to the first connector and comprises a first frame and at least two first keys. The second coder module is connected to the second connector and comprises a second frame and at least two second keys. The second frame has a window for each of the second keys. The second keys are located at least partially in the windows and are positionable at a variety of orientations in the windows to provide a variety of different blocked window configurations wherein the first and second connectors can be connected to each other with the first keys located in the windows adjacent the second keys when the first and second keys are cooperatingly arranged, but otherwise prevents connection of the connectors to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is an exploded perspective view of a connector assembly incorporating features of the present invention.
FIG. 2 is a cross sectional view of the coding sections of the electrical plug and socket shown in FIG. 1.
FIG. 3 is a diagrammatical view of the 16 possible window/code configurations of the coding sections shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown an exploded perspective view of a connector assembly 10 incorporating features of the present invention. The assembly 10 generally comprises an electrical plug connector 12 and an electrical socket connector 14. The assembly 10, in the embodiment shown, is for a three phase power connection. However, the present invention could be used for any suitable type of connection where coding is desired or required. In addition, any suitable size, shape or type of elements or materials could be used to practice the present invention.
The plug 12, in the embodiment shown, is part of a cable assembly 16. The cable assembly 16 has a cable 18 with three electrical conductors therein. The plug 12 has a housing 20, three contacts 22, 23, 24, and a coding module 26. The housing 20 has a front end 28 with three contact receiving areas having the contacts 22-24 located therein. Latches 30 are provided on the lateral sides of the housing 20 to latch the plug 12 with the socket 14. In the embodiment shown, the front end 28 has two slots 32, 33 to form a peninsula or mounting post 34 having the contact 23 therein and, forming an area for receiving the coding module 26 as further understood below. The rear end of the peninsula 34 has recessed areas 36, 37 that function as latches for snap locks on the coding module 26.
The plug coding module 26 generally comprises a frame 38 and two keys 40, 41. The frame 38 has a main receiving area 42, two key windows 44, 45, and two snap-lock latches 46 at the sides of the frame. The sides of the frame 38 are suitably sized to fit into the housing slots 32, 33. The main receiving area 42 is suitably sized and shaped to receive the peninsula 34 therein. The snap-lock latches 46 are adapted to snap into the recessed areas 36, 37 when the module 26 is connected to the housing 20. In the embodiment shown, the module 26 can be connected to the housing 20 in two orientations; either the orientation shown in FIG. 1 or an upside-down orientation from that shown in FIG. 1. When the module 26 is connected to the housing 20 its front face is flush with the front face of the housing front 28. Its bottom face is also flush with the bottom of the housing. Once the frame 2 is connected to the housing 20, it is not removable because the snap-lock latches 46 are then hidden. However, in an alternate embodiment, the frame 26 may be removable.
Referring also to FIG. 2, the keys 40 and 41 are substantially identical to each other and each comprises a base 48 and an off-center keying section 50. The base 48 is slightly larger then the size of the front of the key windows 44, 45. The key windows 44, 45 are substantially identical and have a square cross-sectional shape. A rear portion 52 of each window 44, 45 has an area suitably sized and shaped to receive a base 48 and sandwich the base against the housing 20. In this manner, the keys 40 and 41 can be stably and fixedly positioned in the frame 38. As noted above, the keys each have an off-center keying section 50. In the embodiment shown, the section 50 has a rectangular cross-sectional shape equal to about one-half the cross-sectional area of one of the windows 44, 45. However, any suitably shaped windows and keys could be provided. In addition, more or less then a two key/window configuration could be provided. In the embodiment shown, each of the keys is positionable into one window in four different orientations; each orientation being 90° different along the longitudinal axis of the window. As can be seen with reference to FIG. 3, because the sections 50 only occupying about half of each window, various blocked window patterns or configurations can be provided. Because there are two key/window coding sections, there are sixteen possible code configurations. Open window areas 53 are thus provided to receive keys from the socket 14 as further understood below.
The socket 14, in the embodiment shown, has a housing 54, three contacts 56, 57, 58, and a coding module 60. The housing 54 has a receiving area 62 for receiving the front 28 of the plug 12. The contacts 56-58 are male contacts adapted to be received in the female contacts 22-24 of the plug 12. Of course, in an alternate embodiment, the plug 12 could have male contacts and the socket 14 could have female contacts. The housing 54 has two lateral side holes 64 for receiving retention locks (not shown). The retension locks are used with the latches 30 to fixedly, but removably latch the plug 12 to the socket 14. However, any suitable type of latching system could be used. In the embodiment shown, the receiving area 62 has an upper area 66 with two recesses 68, 69 and snap-lock areas 70. The socket coding module 60 generally comprises a frame 72 and two keys 74, 75. The keys 74, 75 are substantially identical to the keys 40, 41 and, thus, each comprise a base 48 and an off-center keying section 50. The frame 72 has two lateral snap-lock legs 76 and two windows 78, 79. The legs 76 are adapted to project into areas 70 in the housing 54 to snap-lock the frame 72 to the housing 54.
In the embodiment shown, the windows 78, 79 are slightly smaller than the bases 48 such that the frame 72 can retain the bases 48 of the keys 74, 75 in the recesses 68, 69. The off-center keying section 50 of the keys 74, 75 projects through the windows 78, 79 and extends out in front of the frame 72 a predetermined distance. The windows 78, 79 are substantially the same square cross-sectional size as the windows 44, 45. The off-center keying sections 50 of the keys 74, 75 have rectangular shapes and each one of the keys 74, 75 is adapted to be orientated at four different orientations on the housing 54. Therefore, similar to the plug coding module 26, the socket coding module 60 can provide sixteen window/key configurations similar to those shown in FIG. 3. In a preferred embodiment, once the frame 72 is attached to the housing 54, the frame cannot be removed to thereby permanently set the coding configuration of the socket 14. However, in an alternate embodiment, the frame 72 may be removable to thereby allow the coding configuration to be altered or reconfigured if necessary.
The primary purpose of the present invention is to allow electrical connectors to be coded to thereby prevent unmatched connectors from being connected to each other. In the present invention, this is accomplished by the use of configurable coding modules that are connected to the connectors. By use of configurable coding modules, manufacturing and inventory costs are reduced while nonetheless providing numberous coding configurations. FIG. 3 has several of the coding configurations lettered for indentification and description proposes. In the event the socket 14 has the code configuration A, the plug 12 must have the code configuration C in order for the plug to be connectable to the socket. If the two code configurations did not cooperatively match, the keys 40, 41 and 74, 75 would hit each other and thereby prevent connection of the plug 12 to the socket 14. Thus, the code configuration A would only match the code configuration C; not any of the other code configurations shown. Likewise, the code configuration B would only match the code configuration D; not any of the other code configurations shown. When the plug and socket are connected to each other, the key sections 50 of the keys 74, 75 project into the open windows areas 53 of the windows 44, 45.
Although the single embodiment shown in the drawings has been described in detail above, various alternatives are easily envisioned. The keys 40, 41 and 74, 75 could have any suitable shape. The windows 44, 45 and 78, 79 could have any suitable shape. More than two key/window sections could be provided for each connector. Each key could have more or less than four orientations. The frames and keys can be suitably configured such that the keys are fixed to the frames prior to connection of the modules to the connectors. Any suitable type of means to fixedly mount the keys to the frames could be provided.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the spirit of the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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Coding modules are connected to an electrical plug and an electrical socket to control whether or not the plug and socket can be connected to each other. Each module has a frame and two keys connected to their frames. The keys are selectively positionable on the frames to provide at least sixteen different key configurations for each module. The modules are snap-lock connected to the electrical plug and socket such that the module key configurations must be arranged in a complementary fashion before the plug and socket can be connected to each other.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 07/683,974 by the same inventor and assignee herein, filed Apr. 11, 1991, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to coin handling machines, and specifically to coin handling machines with rotating coin bowls.
Referring to FIG. 1, shown is a plan view of a conventional coin handling machine having a coin bowl 10 which may be at an angle to horizontal and is typically rotated. Coins are typically loaded into the machine through a fixed coin hopper 20 and fall gravitationally, or are pushed into the coin bowl. (Coin 12a is shown leaving the coin bowl, while coin 12b is shown lodged in a coin receiving space.) The coins form a tumbling coin mass and coin lifters 14 attached to a rotating drum wheel disk 16 help direct coins through coin receiving holes 17 of the drum wheel disk when the coin level is low and into the space between the back side of the drum wheel disk and a stationary surface which is parallel and spaced from the drum wheel disk. The drum wheel disk forms the bottom of the coin bowl 10 and carries ejector pins 19 on its back side which direct the coins to an exit chute 18. A coin stripper 22, mounted on a stationary back surface 24 and positioned behind the drum wheel disk, engages an edge of a coin as it is pushed along by the ejector pins and directs the coins into chute 18 and out of the machine. The coins impinge on a coin stripper edge 22a, which is usually a hard steel or plastic surface. Ejector pins 19 exert forces on the coins which act both parallel and perpendicular to the coin stripper edge. A hub 25 on the back side of drum wheel disk 16 may also be included to help guide the flow of coins toward coin holes 17.
Other coin handling machines which operate along the lines discussed above are known. U.S. Pat. No. Reissue No. 28,557 shows a disk dispensing apparatus. U.S. Pat. No. 902,067 (Froberg) discloses a rotating coin receiver designed to receive a mass of coins, preferably inclined so that the coins slide toward a lower portion of the coin receiver, where openings allow the coins to be driven out of the receiver by reciprocating slides. Similarly, U.S. Pat. No. 918,273 (Brewster) discloses a coin counter having a plurality of coin separating disks which rotate around a spindle and in which a hopper rotates via a hand wheel crank. U.S. Pat. No. 1,080,533 (Bach) discloses a rotating coin hopper, but coins are guided only by rotation of the hopper. Other relevant patents include U.S. Pat. No. 1,095,981, which shows a lifting plate for discharging coins; U.S. Pat. No. 3,757,805, which shows an annular ring which defines an adjustable space for coins of different thicknesses; U.S. Pat. Nos. 4,557,282 and 4,620,559, which disclose rotating coin hoppers; and U.S. Pat. No. 4,570,655 which shows coin guides.
Most prior art coin handling machines suffer frequent failures which take them out of service. Failures are typically due to a coin wedging against a stationary coin bowl ring or other surface which is stationary or relatively slower moving. Other failures typically occur because of improper or lack of adequate agitation of the coin mass by the rotating drum wheel disk and the coin lifters attached to the drum wheel disk, inadequate guidance of the coins as they are moved toward the discharge chute, or the accumulation of "coin dust" in these machines, with no apparent way of removing it.
SUMMARY OF THE INVENTION
In accordance with the present invention, a coin handling machine is provided for sequentially dispensing individual coins from a coin mass. The machine includes a frame, a stationary back plate assembly mounted to the frame and having a face which is angularly inclined relative to the vertical, and a disk parallel to and spaced from the stationary back plate assembly for defining a generally annular coin moving space between the disk and the stationary back plate assembly. The disk generally includes a plurality of circumferentially spaced coin-receiving holes of a diameter sufficient to permit passage of the coin from a side of the disk facing away from the stationary back plate assembly into the coin moving space. One novel feature is a set of coin pushers associated with each coin hole, the pushers being radially spaced and the stationary back plate assembly including a plurality of spaced-apart circular grooves positioned and formed to coincide with the positions of the coin pushers. The coin pushers extend from the disk into the associated grooves of the back plate, with the leading edges of the pushers in the direction of rotation of the disk trailing the associated coin hole in the disk. As the pushers move coins along an arcuate path through the space as the disk is rotated, a stripper means traversing the arcuate path intercepts the coins, thereafter moving them transversely to the direction of rotation of the disk from the space to a coin discharge area which is beyond a periphery of the disk. Preferred embodiments include those wherein the radially innermost of each set of pushers is closest to the associated coin hole in the disk and the radially outermost pusher is furthest removed from the associated coin hole in the disk so that the forces applied by the pushers to a coin engaged by the stripper means act generally in the direction of the transverse movement of a coin to the discharge area.
Another aspect of the invention includes a pressure pad located proximate to and upstream of the stripper means in the direction of disk rotation, the pressure pad being movably mounted to the stationary back plate assembly and including means for biasing the pressure pad toward the disk which gently presses a coin overlying the pad against the disk to thereby stabilize the coin in the space immediately prior to its engagement by the stripper means.
Further aspects of the invention will become apparent from the description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art apparatus presented to illustrate the state of the art;
FIG. 2 is a side elevation and section of a coin handling machine constructed in accordance with the present invention;
FIG. 3 is an elevation, with parts broken away, of the coin handling machine shown in FIG. 2 and is taken on line 3--3 of FIG. 2;
FIG. 4 is a section taken on line 4--4 of FIG. 3, and shows how the pressure pad holds a coin against the back side of the drum wheel disk;
FIG. 5 is a section taken along line 5--5 of FIG. 3 showing an embodiment of an assembly allowing the adjustment of the separation between the stationary back plate assembly and the drum wheel disk;
FIG. 6 shows an exploded perspective view of a second embodiment of the stationary back plate assembly, pressure pad, and coin guide;
FIG. 7 shows an embodiment of a pressure pad wherein the pad comprises two individual pressure pads; and
FIG. 8 shows a perspective view of the coin handling machine having a baffle plate useful for high coin levels, reducing the effective weight of the coin mass and thus the strain on the means for rotating the drum wheel disk.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 2 and 3 (similar reference numerals are used throughout FIGS. 2-8), a coin handling machine 2 constructed in accordance with the present invention generally comprises an upright frame 4 adapted to be supported on a flat surface (not separately shown) which has an inclined face 6 to which a stationary back plate assembly 8 is secured. (As used herein the term "stationary" means not rotating, with axial movement allowable.) A drive motor 10 is mounted to the frame on the side of face 6 opposite from the back plate assembly and it includes a shaft 12 which protrudes through an appropriate bore in the back plate assembly. A drum wheel disk 14, mounted to the free end of the motor shaft for rotation therewith, is spaced from the stationary back plate assembly, as is further discussed below, and includes a central hub 48 and a plurality of circumferentially spaced-apart coin receiving holes 17 of a diameter sufficient to permit passage of the coins being handled by the machine. A cylindrical drum 18 is attached to the disk along its periphery and rotates with the disk when driven by the motor. Cylindrical drum 18 and disk 14 rotate in a counterclockwise fashion as designated by the arrow ω (FIG. 3), although it will be appreciated by those skilled in the art that clockwise rotation may be used with associated changes in the structure in the coin handling machine. A coin hopper 19, which may be made of molded plastic material, is attached to the back plate assembly, surrounds the disk and the cylinder drum and holds a mass of coins (not shown).
Referring specifically to FIG. 3, this figure shows a section taken along the line 3--3 of FIG. 2. A coin stripper 20 is disposed in a suitably shaped recess of the back plate assembly 8 with threaded bolts 22, for example. The stripper includes a coin stripping edge 24 which protrudes from surface 26 of the back plate assembly, that is, it protrudes into a space 28 between disk 14 and back plate assembly 8. (See FIG. 4, a section taken along the line 4--4 of FIG. 3.) The coin stripping edge extends transversely (but not radially) to the direction of rotation of the disk from the vicinity of disk hub 48 toward the periphery of the back plate assembly and a coin discharge area 30 where coins are introduced into a suitable coin chute (not shown) for delivery to a desired coin pay-out location (not shown).
Just upstream (in the counterclockwise direction of rotation of drum wheel disk 14 of the stripper 20 is a pressure pad 32 which gently biases a coin 33 (shown in FIG. 4) toward the back side of drum wheel disk 14. In the preferred embodiment of the invention, the stationary back plate assembly 8 is formed of a stationary back plate 34 and a stationary ring 36 secured, for example, bolted thereto. The stationary ring includes a cutout 38 shaped to slidably receive the pressure pad to that it can move in the cutout in a direction perpendicular to the faces of the stationary ring. One or more springs 40 anchored in bores 42 in the back plate bias the pressure pad toward drum wheel disk 14, thereby pressing coin 33 against the back side of the disk, as is best illustrated in FIG. 4, and stabilizing it. Pressure pad 32 may be in two or more parts, as shown in FIG. 7, or may be one solid plate, the choice depending on whether a staged coin exit is to be achieved or not.
The back side of drum wheel disk 14 includes a set of circularly arcuate, radially spaced-apart, rib-shaped coin pushers 44 which project into correspondingly shaped and arranged, circular, spaced-apart grooves 46 in stationary ring 36. A set of such pushers trails (in the direction of disk rotation) each coin receiving hole 17 in the disk to form a pocket for a coin which is recessed from hole 17. It is the function of the pushers to move any coin in space 28 through the space and toward stripper 20 as the disk is rotated while the coin is retained in the pocket.
As perhaps better seen in the section of FIG. 5, taken along the line 5--5 of FIG. 3, coin pushers 44 track in the stationary ring grooves 46 in stationary ring 36. Thus, as drum wheel disk 14 rotates as shown in FIG. 3, coins deposited in coin holes 17 and lodged in coin receiving space 28 will be moved toward pressure pad 32 by coin pushers 44. As the drum wheel disk is rotated in the counterclockwise fashion, the pushers exert a force on the coins which tends to move the coins tangentially toward the drum wheel disk periphery. Upstream of coin stripper 20 and pressure pad 32 and generally near the top of stationary ring 36 is a pivotally mounted coin guide 64, as shown in FIGS. 3, 4, and 6, which stabilizes and directs the coin in space 28 towards hub 48 before the coin encounters the pressure pad 32 and contacts coin stripping edge 24. Coin guide 64 in effect exerts a force which counteracts the tendency of the coin to move tangentially toward the periphery of the drum wheel disk.
Referring to FIGS. 3 and 4, as the coins approach coin stripper 20 they are stabilized by pressure pad 32. Pressure pad 32 is located strategically above, i.e., just upstream of coin stripping edge 24 and it gently presses the coin against the back side of the disk, thereby eliminating any play and looseness of the coin in the space and preventing a coin from gravitationally and uncontrollably dropping onto the coin stripping edge 24. Pressure pad 32 ensures the positive guidance of the coin and its controlled advance through space 28 as it is being pushed by pushers 44 of the rotating drum wheel disk.
The stripper edge 24 is defined by stripper ribs 25 (FIG. 3) on coin stripper 20 and they are spaced apart to accommodate coin pushers 44 on the back side of drum wheel disk 14. Once the coin contacts stripper edge 24 its motion is redirected by the edge while the pushers continue to apply a moving force to the coin to advance it transversely to the direction of rotation along the stripper edge and out of space 28 toward coin discharge area 30. As the coin moves along the stripper edge, the coin periphery is engaged by successively radially more outward pushers of the set. The geometry of the coin periphery, the stripper edge and the pushers of the set are such that the contact point between the coin periphery and the pushers remain in the general vicinity of the centerline of the coin which is parallel to the stripper edge 24. This minimizes the force component applied by the pushers to the coin which acts transverse, i.e. relatively perpendicular to the stripper edge.
The increasingly trailing position of the leading edges of the radially more outward pushers facilitates this reduction of the transverse force component. The small force which presses the coin against the stripper edge 24 minimizes wear and tear of the edge, the pushers, and the coins. It also reduces the generation of undesirable coin dust within the machine.
Referring now to FIG. 3, stationary ring 36 has the same number of spaced-apart grooves 46 as there are coin pushers 44 on drum wheel disk 14. Spaced-apart grooves 46 also serve the function of collecting "coin dust" which is generated by the coin mass as it tumbles in the coin bowl. Such "coin dust" typically includes metal shavings from coins, fibers, paper fragments and other assorted dirt and rubbed off particles which may be detrimental to the smooth operation of the coin handling machine. To remove the coin dust from the machine, stationary ring 36 preferably has one or more through-holes 80 at spaced apart locations in the grooves. Coin dust eventually accumulates in the grooves and is swept by the moving pushers 44 to the holes where it drops out of the machine.
Referring to FIG. 5, a modification of the apparatus allows the separation between stationary ring 36 and drum wheel disk 14 to be adjusted for handling coins of different thicknesses with the same machine. For this purpose an adjustable nut and screw assembly 52 is attached (e.g. welded) to back plate 34, having a main separation adjustment screw 54 and a spring 62. One or more adjusting springs 56 support stationary ring 36 in a firm but elastic manner on the back plate 34. A bolt and washer assembly 60 connects adjustable nut and screw assembly 52 to stationary ring 36. When main adjustment screw 54 is rotated clockwise by hand or with a suitable tool the separation between the back surface of drum wheel disk 14 and front surface of stationary ring 36 is decreased as the stationary ring moves axially toward the disk, with the opposite rotation of screw 54 effecting an increase in separation.
Referring now to FIG. 6, there is shown an exploded perspective view of the stationary back plate assembly, pressure pad, and coin guide. Coin guide 64 is pivotally mounted to the stationary ring 36 with a pivot defined by a pin 70 and a journal 72. A spring 66 which is anchored in bores 68, 69 in the back plate and the coin guide, respectively, biases coin guide 64 toward the center of ring 36.
Referring to FIGS. 4 and 6, an embodiment of pressure pad 32 is shown which is shaped to help position a coin properly relative to the stripper edge. The pressure pad includes a first surface 35 facing the drum wheel disk which is substantially parallel thereto, and a second surface 37 which is contiguous with and located in the direction of disk rotation upstream of the first surface 35. Second surface 37 slopes away from the disk in a direction opposite to the direction of disk rotation to facilitate the engagement of the coin by the pressure pad 32 as the coin is advanced toward the stripper edge 24. Springs 40 urge the pressure pad or pads through aperture 38 in ring 36 against the backside of disk 14 or, when a coin overlies the pad, against the coin, thereby urging the coin against the back side of the disk to stabilize it as it continues to move toward engagement with the stripper edge.
In addition to stabilizing the coins moving over the pressure pad, the pad, when no coin is present, rests flush against the back side of the disk and for that purpose it includes grooves which are shaped and positioned to correspond to the grooves in ring 36 so that the pushers on the back side of the disk can move therethrough. When the pad is flush against the back side of the disk, it prevents the entry of a fresh coin from the hopper into a coin opening 17 located upstream but in the vicinity of the stripper edge. If a coin were permitted to enter the opening at such a location, it might only partially enter space 28 between the disk and the back plate and remain partially in the opening, with one part of the coin in the space between the disk and the back plate and the other part on the hopper side of the disk. If the inner part of such a coin were permitted to contact the stripper edge, the coin would become wedged between the edge and the coin opening 17 in the disk. This would arrest the rotation of the disk and render the entire machine inoperative. Biasing the pressure pad 32 flush against the back side of the disk prevents such an occurrence.
FIG. 7 shows another embodiment of a pressure pad 32 comprising in two parts 32a and 32b. The advantage of having the configuration and number of pads as shown in FIG. 7 is that it may be shaped to extend a substantial length across the coin stripping edge 24 of coin stripper 20. This enhances the control over and guidance of the coin as it approaches and then moves along the stripper edge.
Referring to FIG. 8, in another embodiment the hopper 19 of the coin handling machine of the present invention includes a baffle plate 82 attached (e.g., welded or bolted) to the inside of the hopper 19, e.g., at 83. The baffle plate covers a major portion of the side of disk 14 facing the interior of the hopper and includes a cutout 85, in the lower portion of the baffle plate, which is defined by an upright, generally vertical edge 87 and an upper, horizontal edge 89. The baffle plate prevents a substantial and, depending on the height of the coin mass, even a major part of the coins from contacting the rotating disk, thereby reducing wear and tear, friction and, surprisingly, facilitating the pickup of fresh coins in coin holes 17 of the disk. Coin lifters 91 (see FIG. 3) in the form of small blocks bolted to the periphery of disk 14 may be provided for agitating the coin mass overlying cutout 85 in the baffle plate to facilitate the positioning of coins in each coin opening 17 as it passes the cutout and moves towards coin stripper 20. The coin lifter has a height less than the spacing between the disk and baffle plate 82 to prevent any interference between them.
The hub, drum wheel disk, and cylindrical coin bowl may be made out of any material which can withstand the physical conditions existing in the hopper. Since the hopper will usually handle metal coins, materials of construction typically include various steels and steel alloys. Thermoplastics, such as TEFLON®, may also be used, as well as thermo-setting compression molded resins such as phenol-formaldehyde-type resins. Coin guide 64 can be fabricated using either metal or high-wear plastic. Preferably steel with a high surface hardness is used. Pressure pad 32 is preferably made of either metal or high-wear resistant plastic and may be fabricated by methods well known in the art, such as simple injection molding of a thermoplastic such as nylon or TEFLON®.
Turning now to the operation of the coin handling machine of the present invention, and referring to the drawings, coins are initially placed inside hopper 19 and motor 10 is energized to rotate disk 14. As coin openings 17 sweep past cutout 85 in baffle plate 82, coins drop into coin opening 17 and become positioned in annular space 28 between the disk and the back plate 34. Pushers 44 advance the coins as the disk rotates towards stripper 20. The coins will typically move radially outward toward and frequently into engagement with skirt 50 of the disk which forms the peripheral boundary for annular space 28.
When a given coin reaches coin guide 64, in the typical, inclined installation of the machine shown in FIG. 2 at the top of the back plate, the spring loaded guide urges the coin radially inward toward and into engagement with hub 48. At this time the spring biased pressure pad 32 engages the side of the coin facing the back plate and urges the coin against the back side of the disk, thereby stabilizing it and preventing the coin from uncontrollably moving, e.g., gravitationally dropping downwardly onto stripper edge 24. Instead, the coin is moved by pushers 44 and once it engages the stripper edge, its direction of movement changes and its motion continues along the stripper edge until the coin is entirely outside the annular space 28 between the disk and the back plate and in coin discharge area 30 for further movement toward a payout location (not shown).
It has been surprisingly shown that the apparatus of the present invention not only reduces static friction within the rotating coin bowl and reduces failure due to static friction, but improves the flow of coins through the hopper, which is to a large extent due to the reduction of static friction between coins and stationary or slow moving parts of the hopper, and stabilization of the coins in the coin receiving space as they approach the coin stripper and exit the coin handling machine.
The features described herein in accordance with the invention can also be retrofitted into existing machines to improve coin flow and reduce hopper failures.
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An improved coin handling machine of the type having a rotating coin bowl and coin stripper is presented which allows a coin to be stabilized prior to exiting the machine, reducing jamming of the machine and subsequent maintenance. Improvements include the provision of a set of coin pushers on the underside of the drum wheel disk, a coin guide for helping the coins remain in their respective coin receiving spaces and one or more pressure pads placed strategically above the coin stripper for discharging the coins out of the machine, the pressure pad(s) preventing the coins from gravitationally dropping over the coin stripper as the coins move toward the coin exit chute.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application 61/087,963, filed Aug. 11, 2008 and U.S. Provisional Application No. 61/142,838, titled “Sidecar for Peak Power System” filed on Jan. 6, 2009, both entire disclosures of which are hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention relate generally to Energy Management and Control Systems (EMCS).
2. Description of the Related Art
Conventional Energy Management and Control Systems are not totally integrated into the fabric of the control panels and wiring at the circuit level. Many times, clamp-on CT's are brought into a facility and the circuits are monitored for a few days to characterize typical energy usage, then all the equipment and instrumentation is removed before the “Fire Marshal” arrives. The conventional methods have such a “rats nest” of wiring and instrumentation hanging out of the panels that it would never pass the “Fire Marshal” inspection.
Conventional Energy Management and Control Systems do not do first and second derivatives and utilize historical graphs and graphs of similar equipment to anticipate equipment abnormalities and potential failures.
Conventional Energy Management and Control Systems are largely localized at a specific location. There is no means for comparing the energy consumption patterns of a piece of equipment at one location to the same or similar type of equipment at another location.
Conventional Energy Management and Control Systems relays require continuous energy to hold them in certain positions. A Normally Open (NO) relay requires continuous energy to keep it closed. A Normally Closed (NC) relay requires continuous energy to keep it open.
There is a need for a relay that doesn't waste energy that will hold in any position without consuming outside energy. The instant invention accomplishes all these goals.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a highly integrated, innocuous (almost invisible) energy management and control system hardware and software, which operates continuously 24/7/365 and may be monitored and controlled over the Internet from virtually anywhere in the world. It silently monitors and alerts humans only when there's a problem that it can't handle.
Another object of the present invention is to provide virtually continuous, monitoring and analysis of energy consuming equipment and detecting early warning signs of increasing energy use or potential failure.
Another object of the present invention is to be able to actively remotely control energy usage and thermostats via the internet, (e.g. in case someone leaves an Air Conditoner on after hours).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIGS. 1 a and 2 b depict a prior art image of an existing three phase circuit breaker, specifically in which FIG. 1 a is a Prior Art Circuit Breaker as front view 100 and further in which FIG. 1 b is a Prior Art LFD Current Limiter 110 .
FIG. 2 : The PeakPower System Components illustrates the components of the system including the PeakPower Central Server, PeakPower Gateway Cellular WAN Module, PeakPower Commander Device, Temperature- Pressure- Humidity Sensor, Gas Sensor, Liquid Sensor, Wireless Thermostat, Operational Software and various user terminals (Laptop, tablet, Cell Phone, etc.) depicted at the various elements 200 PeakPower commander in a clear enclosure, 210 standard off the shelf 3-phase breaker, 220 PeakPower Gateway cellular WAN module, 230 PeakPower main server, 240 PeakPower software, 250 computers, PDAs, cell phones, tablets for monitoring local or remote in which colors indicate level of alert, 260 sensor for gas usage sends data to gateway wired or wireless, uses battery or AC power, 270 sensor for water usage, sends data to gateway wired or wireless, uses battery or AC power, 280 Sensor for temperature, humidity and pressure, sends data to gateway wired or wireless, uses battery or AC power, and 290 wireless thermostat receives commands and sends status via gateway over Internet to server, uses battery or AC power.
FIG. 3 : PeakPower Commander in Clear Case Installed beside Circuit Breaker, shows how the PeakPower Commander Sensor and communications unit mounts next to an existing Circuit Breaker as depicted at the various elements 300 PeakPower, 310 Three Phase Power wires go straight through insulation and all in which contact is not required, 320 Three CTs one for each phase: Black, Blue, and Red, 330 Electrolytic capacitors mounted on PCB, and 340 showing screws for securing each power wire once they are routed through.
FIG. 4 : Photograph, PeakPower Commander Front View, shows the components and CT's on the front of the PeakPower Commander unit as depicted at elements 400 depicting Current Transformers (CTs).
FIG. 5 : The Current Transformer (CT) used as a standard current measuring device
FIG. 6 : The CT used to extract power during the intervals when it's not measuring, so that it supplies power to the PeakPower Commander Device.
FIG. 7 : One or more of the CT's may be used for communications over the power line(s), This figure illustrates the Transmit mode.
FIG. 8 : One or more of the CT's may be used for communications over the power line(s), figure illustrates the Receive mode.
FIG. 9 : Voltage versus Current Zero Crossings at element 900 depicting Zero crossing for Voltage and Current that are 180 degrees out of phase, showing how the PeakPower commander communicates near zero crossings using the CT that it measures current with.
FIG. 10 : The PeakPower Commander Board Schematic, illustrating one of the preferred embodiments.
FIG. 11 is a mechanical drawing of the preferred embodiment #2 of the Multi-Stable Relay according to the present invention.
FIG. 12 is a bottom view of the preferred embodiment #2 of the Multi-Stable Relay
FIG. 13 is a side view of the preferred embodiment #2 of the Multi-Stable Relay
FIG. 14 is a photograph of the sub-GigaHertz wireless module used for local communications between Gateway and Sensors.
FIG. 15 is the “PeakPower System—Power Monitoring Architecture”. This is a high level diagram that doesn't include the entire host of monitoring devices (e.g. Temperature, Pressure, Humidity, Gas Flow, Liquid Flow, Thermostats etc.) This is just to give a high level communications overview to show how some of the key pieces of the system fit together and communicate in a power monitoring application.
DETAILED DESCRIPTION OF THE INVENTION
The following sets forth a detailed description of a mode for carrying out the invention. The description is intended to be illustrative of the invention and should not be taken to be limiting.
The PeakPower Management and Control System is organized as a hierarchical system (see FIG. 15 ). It is comprised of a Central Server at the top which manages and controls several Gateways at several different locations.
FIG. 15 illustrates a basic PeakPower System for a Power Monitoring application. This is a high level diagram of the key pieces for Power Monitoring. This includes a Gateway device at each location to gather and manage the data at that site and forward that data up to the main server(s) for further processing, analysis and closed loop control. This diagram doesn't include the entire host of monitoring devices (e.g. Temperature, Pressure, Humidity, Gas Flow, Liquid Flow, Thermostats etc.). Please refer to FIG. 2 for details. This is just a high level communications architecture overview to show how some of the key pieces of the system fit together and communicate in a power monitoring application.
Note that equipment power usage characteristics anf curves on a piece of equipment in Location 1 may be analyzed and correlated with the patterns observed on the same type equipment in Location 2 or Location n and adjusted for environmental conditions, to determine if it's outside a preset “corridor” of operation. If so, an ALERT or an ALARM will be set dependent on how far outside limits it is or how rapidly (derivative) it's proceeding to go out of limits.
FIG. 2 is a system block diagram of the PeakPower Management and Control Apparatus that includes sensors, relays, acquisition, processing and analysis software and operational user interface. The sensors monitor power in the power lines, they also derive all the power required to drive the monitor module apparatus from the power lines they are monitoring. Said modules also communicate over said power lines all without making physical contact with said power lines.
The Power Management and Control Software [ 240 ] performs statistical analysis on all signals including first and second derivatives and compares it to data acquired on previous dates and times as well as comparing it to manufacturers specs as well as data from the same model of equipment in other locations to detect early warning signs of potential failures or anomalies in the power used by this equipment versus other same or similar equipment in order to optimize energy use.
The Power Management and Control User Interface shown replicated on the Computer, Cell Phone and PDA in [ 250 ] uses a priority pop-up scheme to pop-up the most critical alert or alarm item out of the group currently being monitored to bring instant attention to it (Border colored Red is a Critical ALARM) (Border colored Yellow is a warning ALERT) (Border colored Green means it's within limits), and give the operator timely data to make critical decisions instantly. There is a set of Red, Yellow, Green indicators (like idiot lights) across the top (or bottom) of the screen where the overall status of all entities being monitors is viewable at a glance. The Red once always pop to the upper left corner and sound the buzzer.
If multiple ALARMS occur they propagate to the right upper corner then the lower left corner then finally the lower right corner if four alarms occur before they can be corrected and return to green status. After the screen is full, the idiot lights at the top are used to manage further red and yellow ALARMS and ALERTS. As the ALARMS or ALERTS are corrected, they return to GREEN.
Embodiments of the present disclosure describe a PeakPower System, which includes the Peak Power Commander Sensor Module. The Peak Power System provides local and/or remote control of various aspects of device operation (e.g., power, security, etc.) for commercial, industrial and/or residential applications. In some embodiments, the Peak Power System may monitor temperature and reset a thermostat, turn on/off an air conditioning or refrigeration unit, etc.
The Peak Power System is described in detail in U.S. Provisional Application No. 61/087,963, titled “Peak Power System” filed on Aug. 11, 2008, the entire disclosure of which is hereby incorporated by reference.
A Sidecar embodiment of the “Peak Power System” is described in detail in U.S. Provisional Application No. 61/142,838, titled “Sidecar for Peak Power System” filed on Jan. 6, 2009, the entire disclosure of which is hereby incorporated by reference. The “Sidecar” has since been renamed, “PeakPwr Commander”, hereinafter referred to as “PeakPower CMDR”.
The present disclosure implements the Peak Power System's energy sensor through a PeakPower CMDR device that may be coupled, e.g., installed, beside a conventional circuit breaker such as, but not limited to, an Eaton (Cutler-Hammer) ED and FD type of circuit breaker, see, e.g., FIG. 1 a . In other embodiments, the PeakPower CMDR may be configured to couple with other circuit breakers. The PeakPower CMDR is a somewhat similar form factor to the LFD Current Limiter shown in FIG. 1 b . Although, the PeakPower CMDR makes no physical connection to any of the wires, except the wires pass directly through the hole(s) in the PeakPower CMDR (insulation and all in some cases) with no screws required, because the wire is not physically attached to the PeakPower CMDR.
The PeakPower CMDR may have three phases and the board mounts in the case so that the wires go straight through the three current sensors and out the other side. There is no physical electrical connection or physical connection required. The sensing and communications are all done via current Transformers (CT's). Even the power to drive the PeakPower CMDR is extracted through these CT's. For instance, FIG. 6 depicts element 600 , in which the CT is alternately switched (Using very low R DS ON FET's) to build up power to power the PeakPower Commander Module using Low V f Schottky diodes and further in which The CT supplies power to the PeakPower Commander Device.
The PeakPower CMDR may communicate through the wires it's monitoring or it may communicate through the Sub-GigaHertz wireless module that plugs onto the tear of the main board. Refer to FIG. 14 in which an RF Module (433 MHz or 900 MHz) is depicted having thereupon elements 1400 of a chip antenna, 1401 of a crystal oscillator, 1402 of a CC 1101 Transceiver, 1403 of a connector to connect to a main board or to a battery, and element 1404 of an MSP430 processor with a temperature sensor. Note, this module has a space to plug in the temperature and humidity sensors so that the same module can be used as the Temperature/Pressure/Humidity sensor, simply by connecting a battery to it and placing it in a separate enclosure.
The pressure sensor is a Pegasus MPL115A MEMS type sensor (very tiny).
Referring to FIG. 3 , in this embodiment, there are three current transducers (CT) mounted on the Printed Circuit Board (PCB) in a row. The three Wires are momentarily disconnected from the breaker, then routed through the three CT's and back into the Breaker like they normally go, and the screws in the Breaker are used to secure the Wires as usual.
FIGS. 3 and 4 show perspective views of a circuit breaker with the PeakPower CMDR coupled thereto in accordance with some embodiments. The housing of the PeakPower CMDR is shown as semitransparent in FIG. 3 and is not shown in FIG. 4 .
One key element of the PeakPower CMDR is the communications methodology. The PeakPower CMDR utilizes the Current Transformer(s) [CT] for communications, obviating the need for physically connecting to the wire(s)
A key novelty of this technique is that the current and voltage on the Wire(s) is 90 degrees out of phase. See FIG. 9 for an illustration of this relationship. In prior art techniques (e.g. X-10) the communications must occur at or near the Voltage zero crossing when the voltage in the line is at a low ebb. The PeakPower CMDR, however, is more flexible. Since it utilizes a “Current” Transformer to communicate, it can also transmit and receive when the Line Voltage is at or near its MAXIMUM, because that's when the Current is near zero. The PeakPower CMDR typically sends or receives high frequency pulses during a preset narrow window of time relative to a cycle (typically 50 Hz or 60 Hz). Also, the position of the pulse(s) within this window may be further interpreted to yield even more data bits per cycle.
The liquid and gas flowmeters in the preferred embodiment ( FIG. 2 ) may use similar Doppler technology, or Magnetic-Inductive or Coriolis type sensor pickups. The small wall-wart attached to it contains the sub GigaHertz wireless module or it can optionally communicate via Power Line Controller (PLC). For instance, FIG. 5 depicts element 500 , in which the Current Transformer (CT) measures current via the magnetic field generated when the current passes through it, and further in which the Current Transformer (CT) is used as a current measuring device.
FIG. 10 illustrates a circuit schematic of the PeakPower CMDR as set forth at element PCB 123 of FIG. 10 depicting the PeakPower Commander Board Schematic, in accordance with some embodiments. This shows how the two CT's on the left (L 1 and L 2 ) are full wave rectified (when they are not being sampled) in order to extract power to power the device. They normally sample once every 15 to 30 seconds for only a few milliseconds.
The instant invention solves the problems of prior art relays too. The Multi-Stable Relay consumes much less (near zero) energy. The only energy required is a minimal amount of energy (a pulse) to change the relay from one state to another.
The Power Management and Control relays in FIGS. 11 , 12 and 13 are novel requiring zero electrical energy to remain enabled or disabled, referred to as a Permanent Magnet Multi-pole, Multi-Throw Relay that has a magnetic detent at every throw position requiring no electrical energy to be applied to keep it closed or open as the case may be.
This “Control” portion of this PEAKPOWER ENERGY MANAGEMENT AND CONTROL SYSTEM is referred to as a Multi-Stable Magnetic Relay Multi-stable relay method and apparatus for switching electrical power with zero holding current, For instance, FIG. 7 depicts element 700 , in which one or more of the CTs may be switched (e.g., using very low R DS ON FETs) to use it as a communications device for transmitting and receiving. FIG. 7 thus depicts one implementation for the transmit side of the PeakPower Commander Board. According to FIG. 7 , one or more of the CTs may be used for communications over the power line(s) in transmit mode.
This method and apparatus for switching power, requires no activation or hold current once it's switched to any state. Any detent state is held by permanent magnet force and requires zero current to hold the relay in any detent state position. For instance, FIG. 8 depicts element 800 , in which one or more of the CTs may be switched (e.g., using very low R DS ON FETs) to use it as a communications device for transmitting and receiving. FIG. 8 thus depicts one implementation for the receive side of the PeakPower Commander Board. According to FIG. 8 , one or more of the CTs may be used for communications over the power line(s) in receive mode.
The Relay Preferred Embodiment #1 is as disclosed in the Provisional Application Ser. No. 61/087,963 filed Aug. 11, 2008 which is included in its entirety by reference
Preferred embodiment #2: This preferred embodiment is a simple form, a Single Pole Double Throw (SPDT) version in FIG. 11
The enclosure case [ 1100 ] is plastic and could be polycarbonate, ABS, acrylic, etc. There are five connector pins [ 1110 ] in this embodiment which make electrical contact to the Printed Circuit Board (PCB) usually via a connector socket that is soldered down onto the PCB when it's manufactured.
FIG. 12 is a bottom view of the Multi-Stable Relay showing the five connector pins. These pins are typically fairly large in order to minimize losses when high currents are passing through. The Main Voltage/Current Input/Output Pin [ 1200 ] is where the main input current/voltage or output current/voltage either enters or exits. It's bi-directional.
The Voltage/Current Input/Output Pin- 1 [ 1210 ] is where one input current/voltage or one output current/voltage either enters or exits. This pin is also referred to as NOC- 1 which means “Normally Open or Closed”. This is to distinguish it from prior art which is either NO or NC. This pin is also bi-directional.
The Voltage/Current Input/Output Pin- 2 [ 1230 ] is where a second input current/voltage or one output current/voltage either enters or exits. This pin is also referred to as NOC- 2 . This pin is also bi-directional.
The Control Pins, Control Pulse- 1 [ 1220 ] and Control Pulse- 2 [ 1240 ] are where the activation switching signal is applied.
When [ 1240 ] is held at Ground potential and a 20 msec 12 Volt pulse is applied to [ 1220 ] the Relay goes to STATE 1 where MAIN [ 1200 ] is connected to [ 1210 ]. And it stays in that state consuming no detention until an opposite polarity pulse is received.
i.e. When [ 1220 ] is held at Ground potential and a 20 msec 12 Volt pulse is applied to [ 240 ] the Relay goes to STATE 2 where MAIN [ 1200 ] is connected to [ 1230 ].
And it stays in that state consuming no detention power until an opposite polarity pulse is received.
In FIG. 3 In order to move the torsion beam conductor [ 1370 ] over to the left side and activate current flow between pins [ 1200 ] and [ 1210 ], the control pin [ 1220 ] is momentarily switched to Ground and a 12 VDC pulse is applied to pin [ 1240 ] for 20 msec. The pulse goes through both inductor coils.
The momentary magnetic field generated in the two coils pushes the magnet(s) to the left. Actually the Left Coil [element 1370 on the Left] attracts the North pole of the magnet(s) and [element 1370 on the Right] repels the South pole so that the magnet “sticks” to the left ferromagnetic screw, causing the osculating contact [ 1310 ] to make solid contact with [ 1300 ], the Voltage/Current Input/Output Pin- 1 Static Contact and current flows with no further activation or detent current required. Elements 1310 Voltage/Current input/output NOC- 1 Osculating contact, 1320 Reciprocating Magnet(s) Left and Right, 1330 screw or rivet made of slightly ferrous material detent to attract and hold reciprocating magnet(s) left and right, 1340 planar support bar, left and right, 1350 left to right support stiffener, 1360 Torsion beam electrical conductor main voltage/current input/output, 1380 voltage/current input/output- 2 NOC- 2 static contact, and 1390 voltage/current input/output- 2 NOC- 2 osculating contact are further depicted.
In order to flip the Relay to Position 2 on the right simply reverse the process by momentarily holding pin [ 1240 ] to Ground and applying a 12 VDC pulse for 20 msec to pin [ 1220 ].
An alternative method for flipping the relay is to tie one of the Control pins to ground either [ 1220 ] or [ 1240 ] and pulse the other pin with +12 VDC then −12 VDC alternately to flip it back and forth.
This Multi-Stable Relay [FIGS. 11 , 12 , 13 ] is one of the key elements in providing Control in this EMC System. They are normally equipped with a sub-GigaHertz wireless unit so that the Gateway [ 220 ] can turn them on and off based on normal preset cycles or problem conditions or due to commands received over the Internet.
In FIG. 2 , [ 1290 ] is the Wireless Thermostat which is another one of the key control elements of this Energy Management and Control System. This Thermostat contains a sub-GigaHertz wireless Tx/Rx radio and is controlled directly through the wireless radio in the Gateway Module [ 220 ]. The Gateway Module [ 220 ] is connected to the PeakPower Server [ 230 ] via the Internet (lightning bolts) either wired or wirelessly via Cellular wireless (e.g. 3 G) radio. So the end user or Energy Management person is able to change the thermostat from virtually anywhere in the world!
While particular embodiments of the present invention have been shown and described, it will be recognized to those skilled in the art that, based upon the teachings herein, further changes and modifications may be made without departing from this invention and its broader aspects, and thus, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention.
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An integrated Energy Management and/or Control System method and apparatus that continually monitors power consumption on each piece of equipment 24/7 and performs detailed analyses of energy consumption curves including derivatives and compares data to historical data on the same equipment as well as going online and acquiring manufacturers specs and comparing to that as well as the same model number equipment in the same or other locations, in order to detect anomalies, abnormal energy consumption or provide early warning of equipment failures.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part application of U.S. patent application Ser. No. 10/037,207, filed Jan. 7, 2002, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of oxygen bottle carrying apparatus, particularly for individuals who have difficulty breathing and, in particular, to an oxygen bottle carrier that can be attached for use to an orthopedic appliance, such as a walker or a wheelchair.
BACKGROUND OF THE INVENTION
[0003] Many patients and, in particular, elderly patients, have breathing disorders that necessitate the use of oxygen. In certain extreme cases, the patient must have oxygen for breathing available at all times and, in particular, when the patient is exerting him or herself, as for example, when walking. Oxygen bottle caddies on wheels are presently available for transporting oxygen bottles. However, these devices require the use of one of the patient's hands to propel the bottle, thus rending them impractical for use when the patient must also use a walker to get about. Attempts to mount an oxygen bottle upon a walker have been proven to be less than satisfactory because the bottle typically renders the walker unstable and extremely difficult to manage. This, in turn, can pose a dangerous situation for an elderly or weak patient which can lead to a potentially damaging fall.
[0004] Alternately, patients who cannot walk utilize wheelchairs to get from place to place. There are known oxygen bottle carriers that are designed specifically for use with such appliances, such as described in U.S. Pat. No. 5,288,001. However, there are associated problems with such carriers. For example, typically the extremely flexible fabric carrier sack must first be placed on the floor or other surface in a non-use position in order to push the oxygen bottle into the confines thereof. That is to say, it is extremely difficult, if not impossible for one person to load the bottle into the carrier in the use position on the wheelchair or walker. This is disadvantageous, particularly when attempting, for example, in trying to replace an empty bottle. In addition, there are also associated problems in attempting to attach the caddy to the wheelchair or other appliance in an effectively balanced manner. Still further, there are issues concerning whether the top of the bottle is effectively secured, for example, if the carrier were to fall, given the dangerous circumstances surrounding a pressurized oxygen bottle.
SUMMARY OF THE INVENTION
[0005] It is, therefore, a primary object of the present invention to improve oxygen bottle carriers in an effort to overcome the above-noted deficiences of the prior art.
[0006] It is a further primary object of the present invention to provide for the safety of patients who require the use of both oxygen and a walker or other appliance, such as a wheelchair, when moving from place to place.
[0007] It is a still further object of the present invention to mount an oxygen bottle upon a walker or other appliance in a stable condition that will not impede the user's ability to safely control the walker.
[0008] It is still a further object of the present invention to provide a carrier for an oxygen bottle that permits same to more effectively support an oxygen bottle in the instance the carrier should fall. In addition, the carrier, can preferably include convenient means for supporting additional items and storage.
[0009] These and other objects of the present invention are attained by a carrier for supporting an oxygen bottle, said carrier including an open-top flexible container having at least a pair of stabilizing straps are attached to the container, said straps being securable to lateral portions of said applicance to prevent the container and thus the oxygen bottle from moving out of the commonly shared frame with the wheels.
BRIEF DESCRIPTION OF THE DRAWING
[0010] For a better understanding of these and other objects of the present invention, reference will be made to the following detailed description of the invention which is to be read in association with the accompanying drawings wherein:
[0011] [0011]FIG. 1 is a front perspective view of a walker having an oxygen bottle carrier made in accordance with a first embodiment of the present invention;
[0012] [0012]FIG. 2 is a partial sectional view taken along lines 2 - 2 in FIG. 1;
[0013] [0013]FIG. 3 is a further partial sectional view taken along lines 3 - 3 in FIG. 2;
[0014] [0014]FIG. 4 is an enlarged rear perspective view of the walker and carrier of FIGS. 1 - 3 ;
[0015] [0015]FIG. 5 is a rear perspective view of an oxygen bottle carrier made in accordance with a second preferred embodiment of the present invention, the carrier being used in conjunction with a wheelchair;
[0016] [0016]FIG. 6 is a partial top view of the oxygen bottle carrier of FIG. 5; and
[0017] [0017]FIG. 7 is a partial enlarged top view of the carrier of FIGS. 5 and 6 with the upper retaining portion of the bag removed for purposes of clarity.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following discussion relates to certain preferred embodiments of an oxygen bottle carrier that is made in accordance with the present invention and used in conjunction with certain orthopedic applicances. It should be readily apparent that certain modifications and variations will be available to one of sufficient skill in the field, after consulting the teachings provided herein.
[0019] With regard to the first embodiment, and turning now to FIG. 1, there is illustrated a walker, generally referenced 10 , that includes an oxygen bottle carrier made in accordance with the present invention. The walker 10 is of typical construction and includes a pair of side frames 12 and 13 . Each side frame 12 , 13 is of similar construction and includes a vertically disposed front leg 15 and a vertically disposed rear bar 16 . A horizontally disposed handrail 18 is integrally joined to the front and rear legs 15 , 16 and provides a means by which a patient can securely grip and control the walker 10 when situated between the two side frames 12 , 13 . A lower rail 20 also extends between the front and rear legs 15 , 16 of each side frame 12 , 13 in order to provide additional strength to the walker 10 .
[0020] The two side frames 12 , 13 are supported in a spaced apart relationship by an upper cross member 22 and a lower cross member 23 that are secured between the two front legs 15 of the frame. The rear section of the walker 10 remains open so that a patient using the walker can pass in an unobstructed manner between the two side frames 12 , 13 . Each of the side frames 12 , 13 is equipped with a wheel 21 that is rotatably supported upon a shaft 24 that is mounted in the lower part of the front leg 15 . In assembly, the two shafts 24 and the two cross members 22 , 23 lie close to or actually within a common vertical plane. The above construction defines the majority of walkers in general, whose construction in and of itself is acknowledged as well known in the field and not forming an essential part of the present invention.
[0021] A container, preferably in the form of an flexible open top bag 29 , is suspended from the upper cross member 22 of the walker 10 , as best illustrated in FIGS. 1 and 4. The flexible bag 29 is preferably made from a flexible fabric, such as polyester or other lightweight material, and is of a size and shape such that the bag can hold a standard size oxygen bottle 25 that is slidably inserted into the bag through a top opening thereof. A close sliding fit is provided between the bottle 25 and the bag 29 so that the bottle is snugly supported within the bag. Preferably, the upper mouth portion of the bag 29 includes an imbedded plastic-reinforced periphery, see also FIG. 7, that maintains a predetermined shape and has adequate stiffness to easily permit a bottle 25 to be fitted directly into the bag 29 . The length of the bag 29 , according to this embodiment, is such that the upper part of the oxygen bottle 25 protrudes through the top opening whereby the regulator 26 and gauges 27 that are associated with the bottle are exposed and thus are easily accessible to one using the walker 10 .
[0022] The flexible bag 29 is suspended from the top cross member 22 of the walker 10 by two-piece hanger straps which include a center strap 30 , and two smaller side straps 32 and 33 that are spaced to either side of the center strap. The two extreme ends of each strap are sewn into the bag 29 and the free ends of the straps are joined by releasable fasteners. In assembly, the flexible bag 29 is centered upon the upper cross member 22 between the two side frames 12 , 13 and each of the side straps 32 , 33 are looped over the cross member 22 and their free ends are tightly fastened together using a hoop and loop (e.g., Velcro) type fastener 40 as illustrated in FIG. 3. To pull the bag 29 securely against the cross member 22 , the hook and loop fastener includes a hook pad that is sewn into one of the strap's free ends and an elongated loop pad that is sewn into the free end of the other strap.
[0023] The two side straps 32 , 33 are primarily used to hold the flexible bag 29 centered between the side frames 12 , 13 and to stabilize the top section of the bag. The center strap 30 , on the other hand, is designed to support the main weight of the bag 29 and a contained bottle 25 . The center strap 30 contains a first top piece 45 that has one end sewn into the bag 29 so that the top piece can loop over the upper cross member 22 , as illustrated in FIG. 2. The bottom piece of the center strap 30 has one end sewn into the bag 29 so that this end of the strap extends well below and behind the lower cross member 23 of the walker 10 when the top piece 45 is looped over the upper cross member 22 . As illustrated in FIG. 2, the two free ends of the center strap 30 are cojoined by a heavy duty buckle 47 . The strap parts 30 and the buckle 47 are fabricated of high strength materials, so that the strap is well able to support the container and the bottle 25 in an upright position upon the upper cross members 22 .
[0024] The bottom section of the bag 29 is further stabilized by a pair of lower stabilizing straps 50 and 51 . Each stabilizing strap 50 , 51 has one end sewn into the lower part of the bag 29 and is of sufficient length so that the opposite ends of the strap can be looped around the lower part of one of the front legs of the walker as illustrated in FIGS. 1 and 4. Here again, hook and loop type fasteners 53 are employed to fasten the free end of each strap upon itself. Each fastener 53 , for example, may have a hook pad sewn into the free end of the strap and an elongated loop pad sewn into a length of its body section so that the strap can be pulled taut and closed to hold the bag centered between the side frames.
[0025] As should now be evident, the bottle's center of gravity is located equidistance between the two side frames 12 , 13 of the walker 10 and lies about or within the vertical plane of the wheel shafts 24 . A patient (not shown) using the walker 10 needs simply to tip up the rear legs 16 of the walker about the axis of the wheels 21 and propel the walker in a forward direction. Because the center of gravity of the contained oxygen bottle 25 lies in a vertical plane that passes through or very close to the axis of the wheel 21 , the walker 10 can be easily tipped and propelled forwardly without much more exertion than that produced by a walker that is not equipped with an oxygen bottle. It should be further noted that because the bottle 25 is stabilized in this centered position, there is no tendency of the walker 10 to tip from side to side and it can be safely turned around corners without tipping over.
[0026] As illustrated in FIG. 4, an open top pouch 60 is also sewn into the bag 29 about opposite the location of the strap fastener 30 . One or more tools 61 associated with the oxygen bottle 25 can be conveniently stored in the pouch 60 so that they are readily available in the event some adjustment must be made to the regulator 26 and other parts of the oxygen system while the walker 10 is in use.
[0027] Referring now to FIGS. 5 - 7 , there is described an oxygen bottle carrier 70 made in accordance with a second embodiment of the present invention. The carrier in this instance is uses in conjunction with a wheelchair 74 shown most particularly in FIG. 5, the wheel chair including a frame 78 that is defined by a seat 82 and a backrest 86 . The frame 78 further includes a pair of spaced vertical handles 90 disposed on either side of the backrest 86 used for pushing the wheelchair 74 , whereas the seat 82 includes armrests 94 and respective vertically extending front and rear legs 98 , 102 . The wheelchair 74 further includes a pair of swivelable front wheels 106 connected to a lower portion of the front legs 98 of the frame 78 as well as a pair of rear wheels 110 attached to the lower portion of each of the rear legs 102 . The above construction defines the majority of wheelchairs in general, whose construction in and of itself is acknowledged as well known in the field and not forming an essential part of the present invention.
[0028] Referring to FIGS. 5 and 6, the carrier 70 is defined by a flexible bag 114 made preferably from a fabric such as polyester or other lightweight material and having a configuration that permits same to establish a close fitting relationship with a standard sized oxygen bottle, shown partially as 25 . The bag 114 includes an upper mouth section 118 that includes a peripheral plastic reinforcement section, as more particularly shown at least partially in FIG. 7. The purpose of this section 118 is to provide certain stiffness and rigidity in initially accommodating an oxygen bottle 25 (not shown in FIG. 7), wherein the bottle can easily be loaded by one person while the carrier is attached to the appliance, whether a walker or wheelchair, for example.
[0029] Still referring to FIGS. 5 and 6, the flexible bag 114 defining the carrier 70 further includes a flexible bottle retaining section 122 directly above the upper mouth section 118 made from a fabric, such as nylon, polyester or other lightweight material and including a drawstring 126 in order to tighten the section once a bottle 25 has been successfully accommodated into the bag 114 . The above section 122 is sewn, according to this embodiment, to the upper periphery of the upper mouth section 118 of the bag 114 . It should be readily apparent, however, that other forms of flexible sections can be attached through various means such as zippers, clips, and the like. The flexible covering section can also be alternately made from a transparent material and can cover the regulator and gauges, but provide needed access to the oxygen line directly.
[0030] The carrier 70 further includes separate upper and lower retaining means for retaining the bag to each of the vertical handles 90 of the wheelchair behind the backrest 86 . The upper retaining means includes a strap 130 sewn or otherwise attached, either permanently or removably, to the bag 114 and including respective ends 134 and 138 . Each of the ends 134 , 138 of the strap 130 include a buckle 137 and a respective strap section 139 , wherein the entire length of the strap can be adjusted at either end, each of the strap sections being wrappable about a portion of the handle 90 .
[0031] The bottom section of the bag 114 is further stabilized by a pair of lower stabilizing straps 140 , 142 . Each stabilizing strap 140 , 142 has one end sewn into the lower part of the bag 114 and is of sufficient length so that the opposite ends of the strap can be looped around the lower part of one of the rear legs 102 of the wheelchair 74 . Preferably, hook and loop type fasteners 145 are employed to fasten the free end of each strap 140 , 142 upon itself. Each fastener 145 , for example, may have a hook pad sewn into the free end of the strap 140 , 142 and an elongated loop pad sewn into a length of its body section so that the strap can be pulled taut and closed to hold the bag 114 centered between the rear legs 102 of the wheelchair 74 .
[0032] Finally, the upper mouth section 118 of the bag 114 includes a pair of slots 149 , FIG. 7, used to accommodate a pair of straps that retain an outer basket 152 that can be used for storage of items. The basket 152 can further include at least one exterior pocket 156 .
[0033] Parts List For FIGS. 1 - 7
[0034] [0034] 10 walker
[0035] [0035] 12 side frame
[0036] [0036] 13 side frame
[0037] [0037] 15 front leg
[0038] [0038] 16 rear leg
[0039] [0039] 18 handrail
[0040] [0040] 20 lower rail
[0041] [0041] 21 wheels
[0042] [0042] 22 upper cross member
[0043] [0043] 23 lower cross member
[0044] [0044] 24 wheel shafts
[0045] [0045] 25 oxygen bottle
[0046] [0046] 26 regulator
[0047] [0047] 27 gauges
[0048] [0048] 29 flexible bag
[0049] [0049] 30 center strap
[0050] [0050] 32 side strap
[0051] [0051] 33 side strap
[0052] [0052] 45 top piece
[0053] [0053] 47 buckle
[0054] [0054] 50 stabilizing strap
[0055] [0055] 51 stabilizing strap
[0056] [0056] 53 fasteners, hoop and loop
[0057] [0057] 60 pouch
[0058] [0058] 61 tool
[0059] [0059] 70 carrier
[0060] [0060] 74 wheelchair
[0061] [0061] 78 wheelchair frame
[0062] [0062] 82 seat
[0063] [0063] 86 backrest
[0064] [0064] 90 handles
[0065] [0065] 94 armrests
[0066] [0066] 98 front legs
[0067] [0067] 102 rear leags
[0068] [0068] 106 front wheels
[0069] [0069] 110 rear wheels
[0070] [0070] 114 bag
[0071] [0071] 118 upper mouth section
[0072] [0072] 122 flexible retaining section
[0073] [0073] 126 drawstring
[0074] [0074] 130 strap
[0075] [0075] 134 strap end
[0076] [0076] 137 buckle
[0077] [0077] 138 strap end
[0078] [0078] 139 strap section
[0079] [0079] 140 stabilizing strap
[0080] [0080] 142 stabilizing strap
[0081] [0081] 145 hook and loop-type fasteners
[0082] [0082] 149 slots
[0083] [0083] 150 basket straps
[0084] [0084] 152 outer basket
[0085] [0085] 156 exterior pocket
[0086] While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by the claims. For example, the basket attachment described in the wheelchair embodiment can easily be utilized in a walker-type carrier as well. In addition, it should be apparent that the herein described carrier can be used with other appliances and that, for example, other pockets can be formed on the flexible bag other than a tool pouch.
[0087] In addition, the preceding embodiments each supported a specifically sized oxygen bottle though it should be apparent that type “D” and “E” bottles, among others, can be supported. Moreover, the present carrier can be configured to accommodate different or varying lengths of bottles using the identical supporting details to attach to the various orthopedic appliances but include means within the bottle to define various sized compartments or enclosures to properly accommodate a given bottle. Such means can include belts, strips, hook and loop fasteners, as well as flaps, among others.
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A carrier for retaining an oxygen bottle said carrier comprising a flexible open-top container adapted for maintaining a close fitting relationship with an oxygen bottle, said container including an upper mouth portion made at least partially from a stiff material to enable an oxygen bottle to be loaded therein vertically; and a flexible upper bottle retaining portion, for preventing said bottle from falling out of said carrier.
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[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional App. No. 61/214,759 filed Apr. 28, 2009 for, “Tuner With Capo”.
BACKGROUND
[0002] Guitarists use electronic tuners to adjust the instrument to a standard or selected reference pitch, and can place capos in various positions on the guitar neck to change the pitch of all the strings on the instrument. Capos allow the use of chords or different chord versions that would not be available to the musician if he tried to play them without the capo. The use of a capo enables the musician to use chords in positions that include more open string combinations. Open strings tend to have unique sound characteristics that are desirable in many musical situations.
[0003] For ideal performance, the musician should re-tune the instrument after repositioning the capo. Many performers will take the stage with both a capo and a tuner in hand. This can be cumbersome to the artist and distracting to the audience.
[0004] There are many types of tuners available on the market. Each one directly or indirectly senses the vibrating string, processes the sensed audio signal to determine the closest corresponding note, and then compares the actual pitch of the string to the target tuning pitch. A display interface shows the user if the note is flat or sharp and the user tunes the string until he gets and in-tune indication from the tuner display. Tuner displays are typically LED lights, an analog needle mete, or an LCD or other digital graphic display device.
[0005] The audio signal from the instrument can be input into the tuner three ways. Some tuners have an input jack to directly wire the instrument to the tuner. Electric guitars or acoustic guitars with pickups (built in magnetic, piezo or microphone sensors) can be wired directly into the tuner. Some tuners use a built in microphone to pick up the signal. This is effective in quiet room conditions and for acoustic instruments. Noisy settings such as concert halls, studios, classrooms, and the like make it difficult to use a tuner in microphone mode. Some tuners clamp onto the instrument and utilize a built in sensor (usually a piezo type pickup) to pick up the vibrations in the guitar neck.
[0006] A plugged in version is the most efficient as the input signal is directly coupled to the input circuit of the tuner and no ambient noise will affect the sensitivity or accuracy of the signal recognition. The disadvantages are that the tuner must be plugged in. This can be an inconvenience or simply not possible in certain stage, recording or practice conditions. Serious musicians are reluctant to run their signal through a tuner and then into their amplification devices because deterioration of the audio signal is always possible when additional devices are wired into the signal path.
[0007] Tuners with a microphone input can be very effective also, but ambient room noise can confuse the input circuitry of the tuner giving erroneous readings. Using a microphone input tuner in a stage or studio environment is not practical.
[0008] Clip-on type tuners that use a sensor and pick up the vibrations from the guitar body can be very effective. If designed properly they can be as sensitive as a direct wired version and can work well in noisy environments. They are also very convenient. They can be kept in a pocket or clipped on to the headstock of the guitar when not being used.
SUMMARY
[0009] The inventive concept is to provide the combination of a capo with attached tuner having a sensor that picks up vibrations through the capo. The capo and tuner are connected together as a unitary accessory that is attachable along the neck of the guitar, in the manner of a conventional capo, but with the significant advantage of automatic and continuous visibility of the tuner display while tuning at a particular capo position and while pausing between songs.
[0010] In one embodiment, the tuner can be purchased as a standalone item that is adapted to be retrofitted onto one or more standard capos.
[0011] There are at least three benefits that the performer will realize using this invention.
[0012] The performer will need only one tool on stage, in studio or while practicing.
[0013] The tuner functions efficiently and accurately when used in conjunction with the capo. The clamping force of the capo makes a strong connection with the guitar neck and efficiently transmits the string vibrations to the sensor in the tuner that is mounted on the capo. Ambient noise does not degrade the tuning. Tuning can be efficiently achieved upon placing the capo anywhere on the neck. The capo can also be stored on the headstock when not being used as a capo. The tuner will function perfectly as a stand alone, clip-on type tuner when stored on the headstock.
[0014] It is very common for an artist to make minor adjustments in tuning after installing or moving a capo to a different position on the guitar neck. Having the tuner right at the capo where his hand is during installation will make it very convenient and easy for him or her to re-tune quickly and perfectly after each move of the capo. It will not be necessary to clip on a tuner or reach up to the headstock if he is using a clip-on type tuner to turn the unit on. The artist can capo the strings and tune them very quickly without having to interrupt his performance.
DRAWING
[0015] FIG. 1 shows one type of known professional quality capo;
[0016] FIG. 2 shows an embodiment of the present invention as a combination of a tuner integrated with a capo of the type shown in FIG. 1 , with the open side of capo facing to the left and the tuner on the right;
[0017] FIG. 3 shows the combination of tuner and capo of FIG. 2 , but from a different view in which the open side of the capo faces to the right and the tuner is on the left;
[0018] FIG. 4 shows the combination capo and tuner of FIG. 4 , installed on the headstock of a guitar;
[0019] FIG. 5 shows the combination of capo and tuner of FIG. 3 installed on the neck of a guitar;
[0020] FIG. 6 is a view similar to FIG. 2 , partially cut away to show how the tuner is connected to the capo;
[0021] FIG. 7 is a view of the device of FIG. 6 , from right; and
[0022] FIG. 8 is a schematic of a tuning circuit suitable for implementing the present invention.
DESCRIPTION
[0023] FIG. 1 shows a capo as described in U.S. Pat. No. 6,008,441, the disclosure of which is hereby incorporated by reference. The neck 10 of a guitar (including strings 10 ′) is clamped between top jaw 11 and bottom jaw 12 . The jaws ( 11 and 12 ) are both preferably lined with elastomeric pads ( 13 and 14 ), pad 13 assuring that all of the strings are clamped to the neck, and both pads preventing the neck from being marred. The bottom jaw 12 wraps partially around, and is pivotally attached to the shank of top jaw at pin 15 . Torsion spring 16 bears against the foot 17 extending from the shank of top jaw 11 and the inside of bottom jaw 12 , tending to close the jaws, and thereby apply clamping pressure to the guitar neck.
[0024] The force to open the jaws is provided by a hand operated two bar toggle type linkage comprising link 18 and link 19 on graspable arm 22 . While link 18 and link 19 comprise a toggle type of linkage, the motion is such that the linkage does not actually toggle, since the jaws are fully open before the two elements which form the toggle are aligned. This type of linkage is used to provide a reducing force requirement as the jaws are opened, but the links do no cross over, i.e., the force does not go to zero and become negative, as in usual toggle applications.
[0025] To open the capo, finger pressure is applied to arm 22 (which projects from link 19 ) and arm 21 (which projects from jaw 11 ). As graspable arm 22 approaches arm 21 , link 18 rotates to become closer to aligning with graspable arm 22 , and the opening force required correspondingly decreases, even while the spring 16 exerts increasing force. Hence, relatively little actuating force is required maintain the capo open, and the musician can position it on the instrument without having to exert excessive force.
[0026] In the combination 20 of capo and tuner according to FIGS. 2-7 , the torsion spring has been replaced by a coil spring 21 that extends perpendicularly from the lower jaw 12 in parallel with an extension of the shank 11 ′ of the upper jaw 11 , and the upper end of link 18 is connected to a short stem 12 ′ extending from lower jaw 12 . The tuner 23 has a front end that firmly receives the shank 11 ′ such that vibrations in the shank can be transmitted to a sensor within the tuner body 25 . A tuner circuit is located within the body and a tuner display, such as a plurality of lights, is visible on the body. The tuner body preferably extends from the shank 11 ′ in parallel with the spring 21 .
[0027] FIGS. 2-3 show the inventive combination 20 in different views while off the instrument and FIGS. 4-5 show it while mounted in the alternative play/tuning positions on the headstock 39 and the neck 40 of the guitar, respectively.
[0028] As is well known, the headstock 39 has a top surface 41 on which the strings (not shown) engage heads or pegs 42 , which can be turned by respective tuning keys or winders 43 . The neck 40 has a fret board 44 on its upper surface, with spaced apart frets 45 .
[0029] FIGS. 6 and 7 show details of how the tuner 23 , spring 21 , and spring tension adjusting bolt 26 are preferably configured in a compact yet functional manner. The tuner body has an integral boss or the like 27 extending through the axis of the coil spring 21 . A bore 28 in the boss receives the shank 29 of bolt 26 , with the bolt head 30 accessible at one end of the boss and the threaded tip 31 of the bolt passing through a threaded insert 32 at the other end of boss. The tip of the bolt carries a disc 33 or the like that provides a seat for the coil spring. The other end of the spring bears on a seat 34 that is fixed with respect to the lower jaw 12 . The bolt 26 can thus adjust the neutral length of the spring and the leverage forces associate with the linkages that open and close the capo jaws. In this embodiment, there is no need for the upper jaw 11 to have a foot (see item 17 of FIG. 1 ) to rigidly support one end of the spring, because the equivalent function is provided by the seat 33 which is supported by the shank 11 ′ of upper jaw 11 through the intermediary structure of the tuner 23 and bolt 26 . The tuner 23 is held in place by the close fit of the extension into the body 25 of the upper jaw shank 11 ′ and the connection of the threads of the bolt 26 to the threaded insert 32 which is rigidly connected to the boss 27 .
[0030] The tuner 23 has a sensor or transducer such a piezo device 35 to detect mechanical vibration that originates with a plucked string and is transmitted through the capo, especially the upper jaw 11 via the shank 11 ′, to the tuner 23 . The detected waveform is analyzed by a printed circuit board or the like 37 powered by battery 36 , and the resulting tuning figure of merit is displayed as by a light pattern at 38 . As can be appreciated from FIGS. 4 , 5 and 6 , the light pattern is readily visible to the artist when the capo is mounted to the neck or headstock of the guitar. The figure of merit typically indicates whether the string is too sharp or too flat, and may also indicate the degree of deviation from the target pitch.
[0031] FIG. 8 shows a representative tuning circuit for analyzing mechanical vibration of a stringed instrument. One of ordinary skill in the relevant field can readily incorporate this or other known tuner circuits into the tuner described above.
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A combination of a capo with attached tuner having a sensor that picks up vibrations through the capo. The capo and tuner are connected together as a unitary accessory that is attachable along the neck of the guitar, in the manner of a conventional capo, but with the significant advantage of automatic and continuous visibility of the tuner display while tuning at a particular capo position and while pausing between songs.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a textile to which water repellency, oil repellency and soil release property are concurrently imparted, and a treatment method for obtaining such a textile.
[0003] 2. Related Arts
[0004] Treatments for imparting water repellency and oil repellency to textiles have been conventionally well known. For example, a fluorine-containing water- and oil-repellent agent or a silicone-based water repellent agent is adhered to fibers, using a padding machine, and the fibers are then heated for their treatment. The resultant treated textile exhibits an effect to be hardly stained by aqueous soil and oily soil because of the imparted water- and oil-repellency. However, aqueous soil and oily soil, once adhered to the textile, tend to be hard to release by washing. In addition, the feeling of the treated textile tends to degrade, as compared with a non-treated textile.
[0005] On the other hand, soil release agents for imparting soil release properties to textiles [agents for removing soils adhered to treated textiles, called soil release or SR agents] are also well known. For example, a fluorine-containing or hydrophilic polymer type soil release agent is adhered to fibers, using a padding machine, and the fibers are then heated for their treatment. The resultant treated textile exhibits an effect to easily remove adhered aqueous soil and oily soil by washing. However, needless to say, aqueous soil and oily soil easily adhere to such a textile as compared with a water repellency- and oil repellency-imparted textile.
[0006] There are disclosed a method of compatibly blending a fluorine-containing soil release agent and a fluorine-containing unsaturated ester for use in a fluorine-containing water- and oil-repellent agent in a padding bath, in order to concurrently impart a water and oil repellency and a soil release property to a textile to thereby obtain a treated textile which is hardly stained and easily cleaned (cf. Japanese Laid-Open Patent Publication No. 60-104576); and a method of compatibly blending a fluorine-containing soil release agent and other various agents (cf. Japanese Laid-Open Patent Publication No. 11-21765). However, these blending methods suffer from the following disadvantages because their effects are produced basically by controlling relative balances between hydrophobicity and hydrophilicity: that is, to obtain a high water and oil repellency is to lower a soil release property; or to obtain a high soil release property is to lower a water and oil repellency, so that a maximum effect can not be induced, or so that the effect is insufficient to other fiber materials except for a specific fiber material.
[0007] In the meantime, the treatment methods for imparting water repellency, oil repellency and soil release properties to textiles are discussed below. Employed as such methods are usually, for example, a spraying method and a foam-contacting method in addition to the above-mentioned padding method. There are disclosed several specific treatment methods which employ printing techniques: a technique for stripe-pattern forming water repellent portions and water non-repellent portions on a textile to obtain swimming race wears having lower surface frictional resistance therefrom (cf. Japanese Laid-Open Patent Publication No. 09-49107); a technique for locating a water repellent agent a dot pattern, a linear pattern or a lattice pattern on a surface of a textile on the skin contacting side, and locating a water-absorbing agent on remainder portion of the surface of the textile to thereby improve the water-absorbing efficiency of the textile, in order to eliminate the sweaty and sticking feeling of the textile (cf. Japanese Laid-Open Utility Model Publication No. 61-111995), etc.
[0008] However, there has not yet been reported any effective treatment method for concurrently imparting a water and oil repellency and a soil release property to a textile, in order to obtain a treated textile which can compatibly exhibit the incompatible effects, that is, the effect to be hardly stained and the effect to be easily cleaned.
[0009] Lately, it has been announced regarding a C 8 Rf group-containing compound obtained by telomerization that there is possibility to produce perfluorooctanoic acid (abbreviated to “PFOA”) when a telomer is decomposed or metabolized (cf. Federal Register (FR Vol. 68, No. 73, Apr. 16, 2003 [FRL-2303-3] (http://www.epa.gov/opptintr/pfoa/pfoafr.pdf), EPA Environmental News FOR RELEASE: MONDAY Apr. 14, 2003, EPA INTENSIFIES SCIENTIFIC INVESTIGATION OF A CHEMICAL PROCESSING AID (http://www.epa.gov/opptintr/pfoa/pfoaprs.pdf) and EPA OPPT FACT SHEET, Apr. 14, 2003 (http://www.epa.gov/opptintr/pfoa/pfoafacts.pdf). The Environmental Protection Agency (or EPA) has announced that the scientific investigation of PFOA should be more intensively promoted (cf. Report by EPA, “PRELIMINARY RISK ASSESSMENT OF THE DEVELOPMENTAL TOXICITY ASSOCIATED WITH EXPOSURE TO PERFLUOROOCTANOIC ACID AND ITS SALTS” (http://www.epa.gov/opptintr/pfoa/pfoara.pdf)).
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a treatment method for compatibly imparting “a water and oil repellency” and “a soil release property” to a textile without degrading the feeling of the textile, in order that the textile can exhibit the effect that a soil is hardly stained and easily released. Another object thereof is to provide such a treated textile.
[0011] The object of the present invention is achieved by a textile which has a main surface consisting of a surface having an exposed water- and oil-repellent agent and a surface having an exposed soil release agent, by applying both the water- and oil-repellent agent and the soil release agent to the main surface, characterized in that, in any of square surface regions, of the main surface of the textile, having a side length of 3,000 μm, a ratio A of the area of the surface having the exposed water- and oil-repellent agent is from 10 to 90%, and a ratio B of the area of the surface having the exposed soil release agent is from 90 to 10%, provided that the total of the ratios A and B is 100%.
[0012] The present invention provides a kit comprising a water- and oil-repellent agent and a soil release agent, for use in treating a textile.
[0013] The present invention further provides a process for manufacturing a textile, which comprises a step of padding or printing a soil release agent on the textile before or after printing a water- and oil-repellent agent on the textile, to give the textile.
[0014] The length of one side of said square region may be 1,000 μm, for example, 500 μm, particularly 100 μm, especially 50 μm. Preferably, the ratio A is from 18 to 82%, for example, from 30 to 70%, and preferably, the ratio B is from 82 to 18%, for example, from 70 to 30%.
[0015] Preferably, the water- and oil-repellent agent and the soil release agent are located with a predetermined pattern on the textile. For example, the water- and oil-repellent agent is located in a dot pattern or a lattice pattern on the textile, and the soil release agent is located on the remaining portions of the textile to thereby form the predetermine pattern on the textile. Preferably, the water- and oil-repellent agent exposed on the surface of the textile is in the shape of a dot (particularly a circular dot) or in the shape of a lattice, and the soil release agent is exposed on the remainder of the surface of the textile. The diameters of the dots or the widths of the stripes of the lattice comprising the water- and oil-repellent agent may be controlled to from 10 to 1,500 μm, for example, from 20 to 1,200 μm, particularly from 40 to 600 μm; and the distances between each of the dots or between each of the stripes of the lattice may be controlled to from 10 to 1,500 μm, for example, from 20 to 1,200 μm, particularly from 40 to 800 μm.
[0016] As the case may be, the soil release agent may be located in a dot pattern or a lattice pattern on the textile, and the water- and oil-repellent agent may be located on the remainder portions of the textile.
[0017] The predetermined pattern on the textile is obtained by two steps of treatments, that is, a treatment step using the water- and oil-repellent agent and a treatment step using the soil release agent.
[0018] To locate the water- and oil-repellent agent in the dot pattern or lattice pattern on the textile, a generally industrialized printing machine can be used to print the water- and oil-repellent agent on the textile.
[0019] To locate the soil release agent on the remainder portion of the textile, a generally industrialized printing machine can be used to print the soil release agent on the remainder portion of the textile; or a padding machine can be used to pad the soil release agent thereon.
[0020] As the order of the treatments, there may be optionally employed either the treatment with the water- and oil-repellent agent followed by the treatment with the soil release agent, or the treatment with the soil release agent followed by the treatment with the water- and oil-repellent agent.
[0021] In case of the treatment with the water- and oil-repellent agent followed by the treatment with the soil release agent, the soil release agent which is printed or padded on the textile later is repelled at the portion of the textile previously treated with the water- and oil-repellent agent, so that the water- and oil-repellent agent can be located at the uppermost surface of the textile. In case of the treatment with the soil release agent followed by the treatment with the water- and oil-repellent agent, the water- and oil-repellent agent is inevitably located at the uppermost surface of the textile. As a result, the same surface states can be obtained in both the cases.
[0022] Water droplets and oil droplets, when contacting the textile of the present invention, are repelled by the water- and oil-repellent agent located in the predetermined pattern (for example, a dot pattern or lattice pattern) on the textile, to exhibit the water- and oil-repellency. The mechanism of this phenomenon is analogous to the water droplet-repelling effect of lotus leaves. Accordingly, the water droplets and the oil droplets hardly contact the hydrophilic soil release agent, so that the textile can maintain high water- and oil-repellency. As a result, soil hardly adheres to the textile.
[0023] Aqueous soil and oily soil adsorbed onto the textile attributed to a load such as continuous use of the textile are retained in the portion of the textile on which the soil release agent is located. Since the portion on which the soil release agent is located does not have the water- and oil-repellent agent, the inherent soil release effect of the soil release agent can be exhibited, without lowering the washing efficiency during washing.
[0024] In other words, the inherent effects of the water- and oil-repellent agent and the soil release agent are compatibly exhibited, respectively, without impairing each other. Therefore, the textile can compatibly have the effect that the soil is hardly stained and easily removed.
[0025] Furthermore, the dot-pattern or lattice-pattern location of the water- and oil-repellent agent on the textile prevent the deterioration of the textile feeling, as compared with the method of adhering the water- and oil-repellent agent to fibers, followed by the heating of the fibers for treatment.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 shows cloth on which a water- and oil-repellent agent is dot-pattern (particularly circular dot-pattern) located, and a soil release agent is located on remainder portion of the cloth.
[0027] FIG. 2 shows cloth on which a water- and oil-repellent agent is lattice-pattern located, and a soil release agent is located on remainder portions of the cloth.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The “water- and oil-repellent agent” referred to in the present invention comprises a silicone-based or fluorine-containing water- and oil-repellent polymer as an active component. This polymer is a copolymer comprising a silicone-based monomer or a fluorine-containing monomer and a non-hydrophilic monomer copolymerizable with these monomers. On the other hand, the “soil release agent” herein referred to comprises a hydrophilic and water-soluble fluorine-containing or fluorine-free polymer as an active component. This polymer is a copolymer comprising a polymerizable hydrophilic monomer as an essential component. The “non-hydrophilic monomer” herein used is a monomer which is solely water-insoluble, while the hydrophilic monomer is a monomer which is solely water-soluble. The wording “water-insoluble” means that the solubility of the monomer in 100 g of water at 25° C. is 1 g or less, for example, 0.5 g or less. The wording “water-soluble” means that the solubility of the monomer in 100 g of water at 25° C. is 10 g or more, for example, 30 g or more.
[0029] Preferably, the water- and oil-repellent agent is a fluorine-containing water- and oil-repellent agent or a silicon-containing water- and oil-repellent agent, and preferably, the soil release agent is a fluorine-containing soil release agent or a phospholipid-containing soil release agent. The polymer constituting the water- and oil-repellent agent is preferably a copolymer which comprises a silicone-based monomer or a fluorine-containing monomer and a silicon-free and fluorine-free non-hydrophilic monomer polymerizable with the former monomer as essential components. On the other hand, the polymer constituting the soil release agent is preferably a polymer which comprises a phosphorus-free and fluorine-free containing hydrophilic monomer as an essential component. Preferably, the polymer constituting the soil release agent contains a fluorine atom (i.e., a fluorine-containing monomer).
[0030] As the water- and oil-repellent agent, the conventionally known agents for use in treatments for imparting water repellency and oil repellency to textiles can be used. These agents are commercially available in the forms of dispersions of water repellent and oil-repellent polymers such as silicone-based polymers and fluoropolymers in water or in the forms of solutions of the polymers in organic solvents. Among those, the fluorine-containing water- and oil-repellent agent is particularly preferred, since this agent can impart also oil repellency.
[0031] The silicone-based polymer to be used in the water- and oil-repellent agent (e.g., the silicone-based water- and oil-repellent agent) is a polymer having at least two siloxane groups. The molecular weight of the silicone-based polymer is generally from 1,000 to 1,000,000, particularly from 10,000 to 200,000. As the silicone-based polymer, the conventional silicone-based water- and oil-repellent agents can be used. A specific example of the commercially available silicone-based water- and oil-repellent agent is, but not limitative to, POLONCOAT N01 (silicone-based, manufactured by Shin-Etsu Chemical Co., Ltd.).
[0032] The fluoropolymer, in the water- and oil-repellent agent (i.e., the fluorine-containing water- and oil-repellent agent), is a copolymer which comprises a fluorine-containing monomer (particularly a monomer containing a fluoroalkyl group (hereinafter referred to as a Rf group)) and another monomer (particularly a fluorine-free monomer) as essential components.
[0033] Specific examples of the Rf group-containing monomer includes, but not limitative to, compounds or fluorine-containing monomers represented by the formula (1):
CH 2 ═C(—X)—C(═O)-A-Rf (1)
wherein X represents a hydrogen atom, a C 1 -C 21 linear or branched alkyl group, a fluorine atom, a chlorine atom, bromine atom, an iodine atom, a group of CFX 1 X 2 (in which each of X 1 and X 2 is a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom or an iodine atom), a cyano group, a C 1 -C 21 linear or branched fluoroalkyl group, an optionally substituted or non-substituted benzyl group, or an optionally substituted or non-substituted phenyl group; A represents a group of —O—Y 1 — (in which Y 1 is a C 1 -C 10 aliphatic group, a C 6 -C 10 aromatic group or a cycloaliphatic group, a group of —CH 2 CH 2 N(R 1 )SO 2 —(CH 2 CH 2 ) a (in which R 1 is a C 1 -C 4 alkyl group, and a is 0 or 1), a group of —CH 2 CH(OR 11 )CH 2 — (in which R 11 is a hydrogen atom or an acetyl group), or group of —(CH 2 ) n SO 2 — (in which n is a number of from 1 to 10)),
or a group of —Y 2 —[—(CH 2 ) m -Z-] p —(CH 2 ) n (in which Y 2 is —O— or —NH—; Z is —S— or —SO 2 —; m is a number of 0 to 10; n is a number of 0 to 10; and p is 0 or 1); and
Rf represents a C 1 -C 21 fluoroalkyl group.
[0034] The fluorine-containing monomer of the formula (1) constitutes a fluorine-containing repeating unit.
[0035] In the fluorine-containing monomer, the α-position (of acrylate or methacrylate) may be optionally substituted by, for example, a halogen atom. Accordingly, in the formula (1), X may be a C 2 -C 21 linear or branched alkyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a group of CFX 1 X 2 (in which each of X 1 and X 2 is a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom or iodine atom), a cyano group, a C 1 -C 21 linear or branched fluoroalkyl group, an optionally substituted or non-substituted benzyl group, or an optionally substituted or non-substituted phenyl group.
[0036] In the formula (1), the Rf group is preferably a perfluoroalkyl group. The number of carbon atoms of the Rf group may be 1 to 6, for example, 1 to 5, particularly 1 to 4. Examples of the Rf group include —CF 3 , —CF 2 CF 3 , —CF 2 CF 2 CF 3 , —CF(CF 3 ) 2 , —CF 2 CF 2 CF 2 CF 3 , —CF 2 CF(CF 3 ) 2 , —C(CF 3 ) 3 , —(CF 2 ) 4 CF 3 , —(CF 2 ) 2 CF (CF 3 ) 2 , —CF 2 C(CF 3 ) 3 , —CF(CF 3 )CF 2 CF 2 CF 3 , —(CF 2 ) 5 CF 3 , —(CF 2 ) 3 CF(CF 3 ) 2 , —(CF 2 ) 4 CF(CF 3 ) 2 , —(CF 2 ) 7 CF 3 , —(CF 2 ) 5 CF(CF 3 ) 2 , —(CF 2 ) 6 CF(CF 3 ) 2 , and —(CF 2 ) 9 CF 3 .
[0037] In the formula (1), m may be, for example, a number of 2 to 10; n may be, for example, a number of 1 to 10 (particularly 2 to 5); and p is preferably 1 when Y 2 is —O—, or is preferably 0 when Y 2 is —NH—.
[0038] The following are exemplified as the fluorine-containing monomer.
CH 2 ═C(—X)—C(=0)-0-(CH 2 ) n —Rf,
CH 2 ═C(—X)—C(=0)-0-C 6 H 10 —Rf
[0039] (in which —C 6 H 10 — is a bivalent cyclohexane group),
CH 2 ═C(—X)—C(=0)-0-C 6 H 4 —Rf
[0040] (in which —C 6 H 4 — is a bivalent benzene group),
CH 2 ═C(—X)—C(=0)-0-C 12 H 8 —Rf
[0041] (in which —C 12 H 8 — is a bivalent biphenyl group),
CH 2 ═C(—X)—C(=0)-0-(CH 2 ) m —S—(CH 2 ) n —Rf,
CH 2 ═C(—X)—C(=0)-0-(CH 2 ) m —SO 2 —(CH 2 ) n —Rf, and
CH 2 ═C(—X)—C(=0)—NH—(CH 2 ) n —Rf,
wherein X represents a hydrogen atom, a C 1 -C 21 linear or branched alkyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a CFX 1 X 2 group (in which each of X 1 and X 2 is a hydrogen atom, a fluorine atom or a chlorine atom), a cyano group, a C 1 -C 21 linear or branched fluoroalkyl group, an optionally substituted or non-substituted benzyl group, or an optionally substituted or non-substituted phenyl group;
Rf represents a C 1 -C 21 , particularly C 1 -C 6 fluoroalkyl group;
m is a number of 1 to 10; and
n is a number of 0 to 10.
[0042] The fluoropolymer also comprises a non-hydrophilic monomer which is generally free from a fluorine atom.
[0043] The non-hydrophilic monomer may be a non-crosslinkable monomer. The fluoropolymer may further contain a non-hydrophilic or hydrophilic, preferably non-hydrophilic crosslinkable monomer.
[0044] Preferably, the non-crosslinkable monomer is free from a fluorine atom, and has a carbon-carbon double bond. The non-crosslinkable monomer is preferably a vinyl monomer free from a fluorine atom. The non-crosslinkable monomer is generally a compound having one carbon-carbon double bond. Examples of the non-crosslinkable monomer include, but not limited to, halogenated vinyl compounds such as 3-chloro-2-hydroxypropyl(meth)acrylate, N,N-dimethylamino-ethyl (meth)acrylate, N,N-diethylaminoethyl(meth)acrylate, butadiene, chloroprene, glycidyl(meth)acrylate, derivatives of maleic acid, and vinyl chloride; ethylene; halogenated vinylidene compounds such as vinylidene chloride; vinyl alkyl ether; glycerol (meth)acrylate; styrene; acetoacetoxyethyl(meth)acrylate; alkyl (meth)acrylate; vinyl pyrrolidone; and isocyanate group-containing (meth)acrylates such as 2-isocyanate ethyl methacrylate, or (meth)acrylate thereof in which the isocyanate group is blocked with a blocking agent such as methyl ethyl ketoxime.
[0045] The non-crosslinkable monomer may be an alkyl group-containing (meth)acrylate. The number of carbon atoms in the alkyl group is 1 to 30, for example, 6 to 30, or 10 to 30. For example, the non-crosslinkable monomer may be an acrylate of the formula:
CH 2 ═CA 1 COOA 2
wherein A 1 represents a hydrogen atom or a methyl group; and A 2 represents an alkyl group of the formula: C n H 2n+1 (n=1 to 30).
[0046] The fluoropolymer may contain a crosslinkable monomer. The crosslinkable monomer may be a fluorine-free compound having at least two reactive groups and/or carbon-carbon double bonds. The crosslinkable monomer may be a compound having at least two carbon-carbon double bonds, or a compound having at least one carbon-carbon double bond and at least one reactive group. Examples of the reactive group include a hydroxyl group, an epoxy group, a chloromethyl group, a blocked isocyanate, an amino group, and a carboxyl group.
[0047] Examples of the crosslinkable monomer include, but not limited to, diacetone acrylamide, (meth)acrylamide, N-methylolacrylamide, hydroxymethyl(meth)acrylate, hydroxyethyl(meth)acrylate, 3-chloro-2-hydroxypropyl (meth)acrylate, N,N-dimethylaminoethyl(meth)acrylate, N,N-diethylaminoethyl (meth)acrylate, butadiene, chloroprene, and glycidyl(meth)acrylate.
[0048] By copolymerizing with the non-crosslinkable monomer and/or the crosslinkable monomer, the resultant fluoropolymer can be improved in various properties such as water- and oil-repellency and soil resistance, cleaning resistance and washing resistance of these properties, solubility in a solvent, hardness, and feeling.
[0049] In the fluoropolymer, the amount of the non-hydrophilic monomer may be 0.1 to 250 parts by weight, for example, 1 to 150 parts by weight, particularly 3 to 100 parts by weight, per 100 parts by weight of the fluorine-containing monomer. In the fluoropolymer, the amount of the non-crosslinkable monomer may be 200 parts by weight or less, 0.1 to 100 parts by weight, for example, 0.1 to 50 parts by weight per 100 parts by weight of the fluorine-containing monomer; and the amount of the crosslinkable monomer may be 50 parts by weight or less, for example, 20 parts by weight or less, particularly 0.1 to 15 parts by weight.
[0050] The weight-average molecular weight of the fluoropolymer of the present invention may be 1,000 to 1,000,000, preferably 5,000 to 500,000, determined by gel permeation chromatography, in terms of polystyrene.
[0051] The soil release agent [i.e., an agent to be used to make it easy to remove soil adhered to a substrate, which is also called a SR (Soil release) agent] is commercially available as a dispersion of a fluorine-containing or phospholipid type hydrophilic and water-soluble polymer as a main component in water or as a solution of the polymer in an organic solvent. A fluorine-containing SR agent is particularly preferred because of its high soil release property. As the soil release agent, the conventionally known agents for use in SR treatment of textiles can be used.
[0052] The fluoropolymer to be used in the fluorine-containing soil release agent is a copolymer comprising a fluorine-containing monomer (particularly a monomer containing a fluoroalkyl group (hereinafter referred to as a Rf group)) and another monomer (particularly a fluorine-free monomer) as essential components.
[0053] Examples of the Rf group-containing monomer are not particularly limited, in so far as they are polymerizable. Examples of such a monomer are, for example, the compounds of the above-mentioned formula (1).
[0054] Preferably, the other monomer contains a hydrophilic group-containing monomer. Preferably, the hydrophilic group-containing monomer is free from a fluorine atom.
[0055] The hydrophilic group-containing monomer may be polyalkyleneglycol mono(meth)acrylate and/or polyalkyleneglycol di(meth)acrylate. The molecular weight of the hydrophilic group-containing monomer may be 100 or more, for example, 150 or more, particularly 200 or more, especially 250 to 3,000.
[0056] Preferably, the polyalkyleneglycol mono(meth)acrylate is a monomer represented the formula (2)
CH 2 ═CX 1 C(═O)—O—(RO) n —X 2 (2)
wherein X 1 is a hydrogen atom or a methyl group;
X 2 is a hydrogen atom or a C 1 -C 22 optionally non-saturated or saturated hydrocarbon group; R is a C 2 -C 6 alkylene group; and n is an integer of 2 to 90. Particularly, n may be an integer of 2 to 30, for example, 2 to 20.
[0057] The group R in the formula (2) is preferably an ethylene group.
[0058] The group R in the formula (2) may be 2 or more different alkylene groups combined. In this case, preferably, at least one of the groups R is an ethylene group. As the combination of the groups R, there can be exemplified a combination of an ethylene group and a propylene group, and a combination of an ethylene group and a butylene group. The hydrophilic group-containing monomer may a mixture of two or more hydrophilic group-containing monomers. In this case, preferably, at least one of the hydrophilic group-containing monomers is a monomer of the formula (2) in which R is an ethylene group.
[0059] Specific Examples of the hydrophilic group-containing monomer include, but not limited to, the following:
CH 2 ═CX 1 COO—(CH 2 CH 2 O) n —H,
CH 2 ═CX 1 —(CH 2 CH 2 O) n —CH 3 ,
CH 2 ═CX 1 COO—(CH 2 CH(CH 3 )O) n —H,
CH 2 ═CX 1 COO—(CH 2 CH(CH 3 )O) n —CH 3 ,
CH 2 ═CX 1 COO—(CH 2 CH 2 O) 5 —(CH 2 CH(CH 3 )O) 2 —H,
CH 2 ═CX 1 COO—(CH 2 CH 2 O) 5 —(CH 2 CH(CH 3 )O) 3 —CH 3 ,
CH 2 ═CX 1 COO—(CH 2 CH 2 O) 8 —(CH 2 CH(CH 3 )O) 6 —CH 2 CH(C 2 H 5 )C 4 H 9 ,
CH 2 ═CX 1 COO—(CH 2 CH 2 O) 23 —OOC(CH 3 )C═CH 2 , and
CH 2 ═CX 1 COO—(CH 2 CH 2 O) 20- −(CH 2 CH(CH 3 )O) 5 —CH 2 —CH═CH 2 .
[0060] The hydrophilic group-containing monomer may be a monomer having an ionic group (i.e., a cationic group or an anionic group) and a carbon-carbon double bond. Specific examples of such a monomer include 2-methacryloyloxyethyl-trimethylammonium chloride and N,N,N-trimethyl-N-(2-hydroxy-3-methacyloyloxypropyl)ammonium chloride.
[0061] In the copolymer of the soil release agent, the amount of the fluorine-containing monomer is 20 to 90% by weight, preferably 30 to 85% by weight, for example 35 to 75% by weight, based on the total weight of the fluorine-containing monomer and the hydrophilic group-containing monomer. When it is 20 to 90% by weight, the resultant soil release agent can have a high soil release property and prevent the infiltration of an oily soil.
[0062] The amount of the hydrophilic group-containing monomer is 10 to 80% by weight, preferably 15 to 60% by weight, for example 20 to 50% by weight, based on the total weight of the fluorine-containing monomer and the hydrophilic group-containing monomer. When it is 10 to 80% by weight, the resultant soil release agent can have a high soil release property and prevent the infiltration of an oily soil.
[0063] Another monomer, particularly a fluorine-free monomer, may be introduced into the copolymer of the soil release agent in order to improve the durability of the soil release property, and in order to impart, to the copolymer, solubility in an organic solvent and adhesion to a softness-imparted textile.
[0064] Specific examples of such another monomer include, but not limited to, diacetone acrylamide, (meth)acrylamide, N-methylolacrylamide, hydroxyethyl(meth)acrylate, 3-chloro-2-hydroxypropyl(meth)acrylate, N,N-dimethylaminoethyl (meth)acrylate, N,N-diethylaminoethyl(meth)acrylate, butadiene, chloroprene, glycidyl(meth)acrylate, derivatives of maleic acid, halogenated vinyls such as vinyl chloride, ethylene, halogenated vinylidenes such as vinylidene chloride, vinyl alkyl ether, glycerol (meth)acrylate, styrene, acetoacetoxyethyl(meth)acrylate, alkyl(meth)acrylate, vinyl pyrrolidone, isocyanate group-containing (meth)acrylate such as 2-isocyanatoethyl methacrylate or (meth)acrylate thereof in which the isocyanate group is blocked with a blocking agent such as methyl ethyl ketoxime.
[0065] The copolymerization ratio of such another monomer is 0 to 40% by weight, preferably 0 to 30% by weight, for example, 0.1 to 20% by weight, based on the weight of the copolymer. Such another monomer may be a mixture of 2 or more different monomers.
[0066] The weight-average molecular weight of the copolymer of the soil release agent may be 1,000 to 1,000,000, preferably 5,000 to 500,000, determined by gel permeation chromatography, in terms of polystyrene.
[0067] The copolymer of the soil release agent may be a random copolymer or a block copolymer.
[0068] The polymerization methods for obtaining the copolymer of the water- and oil-repellent agent and the copolymer of the soil release agent are not limited, and may be selected from various polymerization methods such as bulk polymerization, solution polymerization, emulsion polymerization and radiation polymerization. In general, for example, solution polymerization using an organic solvent or emulsion polymerization using water, or an organic solvent and water in combination is employed. The resultant copolymer is diluted with water or is emulsified in water in the presence of an emulsifier to thereby prepare a treatment agent.
[0069] Examples of the organic solvent include ketones such as acetone and methyl ethyl ketone; esters such as ethyl acetate and methyl acetate; glycols such as propylene glycol, dipropylene glycol monomethyl ether, dipropylene glycol, tripropylene glycol and low molecular weight polyethylene glycol; and alcohols such as ethyl alcohol and isopropanol.
[0070] As the emulsifier for use in emulsifying the copolymer in water in the emulsion polymerization or after the polymerization, ordinary anionic, cationic or nonionic emulsifiers can be used.
[0071] As a polymerization initiator, there can be used, for example, peroxides, azo compounds or persulfuric acid compounds. The polymerization initiator is generally water-soluble and/or oil soluble.
[0072] Specific examples of the oil soluble polymerization initiator include, preferably, 2,2′-azobis(2-methylpropionitrile), 2,2′-azobis(2-methylbutylonitrile), 2,2′-azobis(2,4-dimethylvaleronitrile), 2,2′-azobis(2,4-dimethyl-4-methoxyvaleronitrile), 1,1′-azobis(cyclohexane-1-carbonitrile), dimethyl-2,2′-azobis(2-methylpropionate), 2,2′-azobis(2-isobutylonitrile), benzoyl peroxide, di-tertiary-butyl peroxide, lauryl peroxide, cumene hydroperoxide, t-butylperoxy pivalate, diisopropylperoxy dicarbonate and t-butyl perpivalate.
[0073] Specific examples of the water-soluble polymerization initiator include, preferably, 2,2′-azobisisobutylamidine dihydrochloride, 2,2′-azobis(2-methylpropionamidine) hydrochloride, 2,2′-azobis[2-(2-imidazoline-2-yl)propane]hydrochloride, 2,2′-azobis[2-(2-imidazoline-2-yl)propane]sulfate hydrate, 2,2′-azibis[2-(5-methyl-2-imidazoline-2-yl)propane]hydrochloride, potassium persulfate, barium persulfate, ammonium persulfate and hydrogen peroxide.
[0074] The polymerization initiator is used in an amount of 0.01 to 5 parts by weight per 100 parts by weight of the monomers. A known mercapto group-containing compound further may be used in order to adjust the molecular weight of the copolymer. Examples of such a compound include 2-mercaptoethanol, thiopropionic acid, and alkyl mercaptan. The mercapto group-containing compound is used in an amount of 5 parts by weight or less, for example, 0.01 to 3 parts by weight per 100 parts by weight of the monomers.
[0075] Specifically, the copolymer is produced as follows.
[0076] In the solution polymerization, the monomers are dissolved in an organic solvent in the presence of a polymerization initiator. After the displacement of an inner atmosphere with a nitrogen gas, the resulting solution is stirred under heating at a temperature of, for example, 50 to 120° C. for 1 to 10 hours. In general, the polymerization initiator may be an oil soluble polymerization initiator. The organic solvent to be used is inactive with the monomers and dissolves them. Examples of such an organic solvent include pentane, hexane, heptane, octane, cyclohexane, benzene, toluene, xylene, petroleum ether, tetrahydrofuran, 1,4-dioxane, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, butyl acetate, 1,1,2,2-tetrachloroethane, 1,1,1-trichloroethane, trichloroethylene, perchloroethylene, tetrachlorodifluoroethane and trichlorotrifluoroethane. The organic solvent is used in an amount of 50 to 1,000 parts by weight per total 100 parts by weight of the monomers.
[0077] In the emulsion polymerization, the monomers are emulsified in water in the presence of a polymerization initiator and an emulsifier. After the displacement of an inner atmosphere with a nitrogen gas, the resulting emulsion is stirred at a temperature of, for example, 50 to 80° C. for 1 to 10 hours for the copolymerization thereof. The polymerization initiator may be a water-soluble polymerization initiator and/or an oil soluble polymerization initiator. To obtain an aqueous dispersion of the copolymer excellent in standing stability, it is desirable to use an emulsifying apparatus capable of exhibiting a powerful grinding energy, such as a high pressure homogenizer and ultrasonic homogenizer to grind the monomers into very fine particles, which are then polymerized in the presence of a water-soluble polymerization initiator. The emulsifier may be selected from various emulsifiers such as cationic, anionic and nonionic emulsifiers for use. The emulsifier is used in an amount of 0.5 to 10 parts by weight per 100 parts by weight of the monomers. When the monomers are not completely dissolved into each other, preferably, an agent for imparting sufficient compatibility to the monomers, for example, a water-soluble organic solvent or a low molecular weight monomer, is added to the monomers. The addition of such an agent makes it possible to facilitate the emulsion and copolymerization of the monomers.
[0078] Examples of the water-soluble organic solvent include acetone, methyl ethyl ketone, propylene glycol, dipropylene glycol monomethyl ether, dipropylene glycol, tripropylene glycol, and ethanol. This solvent may be used in an amount of 1 to 80 parts by weight, for example, 5 to 50 parts by weight, per 100 parts by weight of water.
[0079] Each of the copolymers for both agents, thus obtained, is optionally diluted with or dispersed in, for example, water, an organic solvent, and the resulting solution or dispersion is prepared into a desired form such as an emulsion thereof, a solution thereof in an organic solvent and an aerosol thereof, which can be used as a water- and oil-repellent agent or a soil release agent. The respective copolymers act as active components of the water- and oil-repellent agent and the soil release agent. The water- and oil-repellent agent and the soil release agent comprise the fluoro-copolymers and media (particularly liquid media) (e.g., organic solvents and/or water), respectively. The concentrations of the fluoro-copolymers in the water- and oil-repellent agent and the soil release agent may be 0.01 to 50% by weight, for example, 0.05 to 10% by weight, respectively.
[0080] In the present invention, the water- and oil-repellent agent and the soil release agent preferably contain the fluoro-copolymers and aqueous media, respectively. The term, “aqueous medium” herein referred to means a medium consisting of water, and it also means a medium containing an organic solvent in addition to water (the amount of the organic solvent being 80 parts by weight or less, for example, 5 to 50 parts by weight, per 100 parts by weight of water).
[0081] A method for printing the water- and oil-repellent agent on a textile, using a generally industrialized printing machine, can be employed in order to locate the water- and oil-repellent agent in the dot pattern or the lattice pattern on the textile while the diameters of the located dots or the stripe width of the located lattice being controlled to 10 to 1,500 μm with the intervals between the dots or between the stripes of the lattice controlled to 10 to 1,500 μm, so that the soil release agent is located on remainder portions of the textile. In this method, as the case may be, it is needed to prepare a treatment liquid of which the viscosity is appropriately adjusted, in order to prevent the bleeding of the agent from the printed pattern. Thus, a treatment liquid viscosity-adjusting agent can be added to the treatment liquid. As such a viscosity-adjusting agent, for example, acrylic polymer salts which are commercially available as sizing agents, can be used. As the commercially available sizing agent, for example, CARBOPOL 846 (manufactured by Goodrich Corporation) can be used. The viscosity-adjusting agent for the treatment liquid is not necessarily removed by washing after the treatment of the textile. If needed, the treatment liquid may optionally contain other agents such as a crease-proofing agent, a shrink-proofing agent, a flame retardant, a crosslinking agent, an antistatic agent, a softening agent and an antibacterial agent.
[0082] The method for printing the water- and oil-repellent agent on a textile, using a generally industrialized printing machine, can be employed in order to locate the water- and oil-repellent agent dot-pattern or lattice-pattern on the textile. As the printing method, for example, a roller printing, a screen printing and an ink-jet printing can be exemplified.
[0083] Preferably, the diameters of the dots or the widths of the stripes of the lattice formed from the water- and oil-repellent agent on the textile are controlled to 10 to 1,500 μm, and the intervals between each of the dots or between each of the stripes of the lattice are controlled to 10 to 1,500 μm. More preferably, the diameters of the dots or the widths of the stripes of the lattice and the intervals between each of the dots or between each of the stripes of the lattice are both 20 to 1,200 μm. When the pattern of the dots or the lattice is too dense, the advanced technique and skill are needed for the treatment of the textile, which is likely to make it impossible to treat the textile, and which is also unlikely to make significant difference from a flat treatment and makes it impossible to achieve the object of the present invention. When the pattern of the dots or the stripes of the lattice is too sparse, water droplets and oil droplets easily infiltrate the intervals between each of the dots or between each of the stripes of the lattice, with the result that the water- and oil-repellency of the textile tends to lower.
[0084] To locate the soil release agent on remainder portions of the textile, there can be employed the above-mentioned printing method using the printing machine or a method of padding the textile by a generally industrialized padding machine. In case of the printing with the printing machine, a viscosity-adjusting agent may be added to a treatment liquid. The viscosity-adjusting agent may not necessarily be removed by washing after the treatment. If needed, other agents may be further added to the treatment liquid. Examples of the other agents include a crease-proofing agent, a shrink-proofing agent, a flame retardant, a crosslinking agent, a antistatic agent, a softening agent and antibacterial agent.
[0085] The predetermined pattern located on the textile is obtained by two treatment steps, that is, the treatment with the water- and oil-repellent agent followed by the treatment with the soil release agent, or the treatment with the soil release agent followed by the treatment with the water- and oil-repellent agent. The treatment order is not particularly limited. If needed, a heat treatment may be carried out after each of the treatment steps. The heat treatment may be carried out at a temperature of 80 to 200° C. for 10 to 300 seconds.
[0086] The textile is preferably in the form of a cloth such as a woven cloth, a knitted cloth and a non-woven cloth. The cloth may, for example, be a carpet. Fibers for the textile are, for example, natural animal and vegetable fibers such as cotton, hemp, wool and silk; synthetic fibers such as polyamide, polyester, polyvinyl alcohol, polyacrylonitrile, polyvinyl chloride and polypropylene; semisynthetic fibers such as rayon and acetate; inorganic fibers such glass fibers, carbon fibers and asbestos fibers; and a blend of said fibers.
[0087] The present invention is described with reference to the accompanying drawings.
[0088] FIG. 1 shows a cloth on which the water- and oil-repellent agent is located in a dot pattern (a circular dot pattern) so that the soil release agent is located on remainder portion of the cloth. The cloth 10 (cloth as a whole) has a region 12 coated with the water- and oil-repellent agent and a remainder region 14 coated with the soil release agent. In the water- and oil-repellent agent-located region 12 , the active component of the water- and oil-repellent agent is exposed on the surface of the cloth. In the soil release agent-located region 14 , the active component of the soil release agent is exposed on the surface of the cloth. In the water- and oil-repellent agent-located region 12 , the dots of the agent are positioned at the interval a.
[0089] FIG. 2 shows cloth on which the water- and oil-repellent agent is located in a lattice-pattern so that the soil release agent is located on remainder portions of the cloth. The cloth 20 (cloth as a whole) has a region 22 coated with the water- and oil-repellent agent and the remainder regions 24 coated with the soil release agent. The water- and oil-repellent agent-located region 22 is in the shape of lattice. In this lattice, the widths of the vertical lines are preferably equal to the widths of the horizontal lines, although the widths of both the lines may differ from each other. Both the lines of the lattice are spaced at intervals b1 and b2, respectively. The length of the interval b1 is preferably equal to the length of the interval b2, although the lengths of both the intervals may differ from each other.
EXAMPLES
[0090] Next, the present invention will be described in more detail by way of Synthesis Examples, Examples and Comparative Examples, which should not be construed as limiting the scope of the present invention in any way. In Synthesis Examples, Examples and Comparative Examples, “%” represents “% by weight”, unless otherwise specified.
[0091] The tests were conducted as follows.
[0000] Water-Repellency Test
[0092] A water-repellency test was conducted on a textile according to the spraying method regulated in JIS-L-1092. Water repellency was represented by the repellency No. in accordance with the spraying method of JIS-L-1092 (shown in Table 1).
TABLE 1 Criteria for Repellency Repellency No. Condition 5 No wetting on surface 4 Slight wetting on surface 3 Partial wetting on surface 2 Wetting on surface 1 Wetting on surface as whole 0 Wetting on front and back surfaces as whole
Oil-Repellency Test
[0093] An oil-repellency test was conducted on a textile according to AATCC-TM118-2000 (American Association of Textile Chemists and Colorists-Test Method 118-2000).
[0000] Summary of Oil-Repellency Test Procedure
[0094] A treated cloth test was stored in a thermo-hygrostat at a temperature of 21° C. and a humidity of 65% for 4 hours or longer. A test liquid (shown in Table 2) also maintained at a temperature of 21° C. was used. The test was conducted in an air-conditioned room at a temperature of 21° C. and a humidity of 65%. The test liquid (0.05 ml) was gently dropped on the cloth and was left to stand for 30 seconds. The test liquid was regarded as passing the test, when the droplets of the test liquid are left to remain on the cloth. The oil repellency was evaluated in nine levels of 0, 1, 2, 3, 4, 5, 6, 7 and 8, in the order of from the lowest level to the highest level, based on the highest mark of a test liquid which has passed the test.
TABLE 2 Oil Repellency Criteria Surface Tension Marks Test liquid (dyne/cm at 25° C.) 8 n-Heptane 20 7 n-Octane 21.8 6 n-Decane 23.5 5 n-Dodecane 25 4 n-Tetradecane 26.7 3 n-Hexadecane 27.3 2 Mixed liquid of n-hexadecane 29.6 35/Nujol 65 1 n-Nujol 31.2 0 inferior to 1 —
Soil Release (SR) Test
[0095] A test for evaluating a soil releasability (SR) was conducted on a similar textile to that used for the oil repellency test, in an air conditioned room according to AATCC Stain Release Management Performance test Method. As soils for test, used were an oily soil prepared by adding DAPHNE Mechanic Oil (manufactured by IDEMITSU KOSAN CO., LTD.) (100 ml) to a paste (1 g) consisting of carbon black (16.7%), a beef tallow extremely hardened oil (20.8%) and liquid paraffin (62.5%), and an aqueous soil consisting of UNI-STAMP INK (manufactured by MITSUBISHI PENCIL CO., LTD.).
[0000] Summary of Soil Release Test Procedure
[0096] A square test cloth (20 cm×20 cm) was spread over a blotting paper laid horizontally, and 5 drops of the soil (about 0.2 cc) was allowed to blot the test cloth. A glassine paper was laid over the test cloth, and a weight (2,268 g) was further laid on the glassine paper. This state was maintained for 60 seconds. Thereafter, the weight and the glassine paper were removed, and then, the test cloth was left to stand at a room temperature for 15 minutes. Thereafter, ballast cloths were added to the test cloth so that the total weight could be 1.8 kg. The test cloth and the ballast cloth were washed at a bath temperature of 38° C. for 12 minutes in an AATCC standard washing machine with a capacity of 64 L (manufactured by Kenmore, U.S.A.), using a detergent (a WOB detergent of AATCC standard). Thereafter, the test cloth was dried in a tumbler drier of AATCC standard (manufactured by Kenmore, U.S.A.). The conditions of the remaining soils on the dried test cloth were compared with standard photographic plates so as to determine a corresponding criterion which indicates the soil release performance (shown in Table 3). The standard photographic plates used for evaluation were in accordance with AATCC-TM 130-2000 (American Association of Textile Chemists and Colorists—Test Method 130-2000).
TABLE 3 Criteria for Soil releasability Level Criteria 1 Soils remarkably remain 2 Soils considerably remain 3 Soils slightly remain 4 Little soils remain 5 No soil remains
Test for Evaluating Feeling
[0097] A test for evaluating the feeling of a textile was conducted on a test cloth by hand feeling, and the feeling of the test cloth was evaluated based on the following criteria.
[0098] Feeling comparable to non-treated cloth: Good
[0099] Feeling slightly harder than non-treated cloth: Fair
[0100] Feeling apparently harder than non-treated cloth: Bad
Synthesis Example 1
[0101] A water- and oil-repellent agent was prepared as follows.
[0102] A 1 L beaker was charged with a fluorine-containing monomer (90 g) of the formula:
H 2 C═CHCOO—CH 2 CH 2 —(CF 2 CF 2 ) 3 CF 2 CF 3 ,
n-stearyl acrylate (10 g), N-methylolacrylamide (3 g), n-lauryl mercaptan (1 g), tripropylene glycol (40 g), polyoxyethylene (3 mol)dodecyl ether (4 g), polyoxyethylene (20 mol)lauryl ether (9 g) and pure water (250 g). The mixture in the beaker was emulsified and dispersed at 50° C. in a high pressure homogenizer until the average particle sizes of the emulsion reached 150 nm or less. Next, a whole volume of the emulsion was transferred to a 1 L autoclave equipped with a stirrer. After the inner atmosphere of the autoclave was replaced with a nitrogen gas, vinyl chloride (24 g) and azobisamidinopropane dihydrochloride (1 g) were added into the autoclave, so as to react them at 60° C. for 8 hours under seal. The resultant polymerization liquid was directly subjected to gel permeation chromatography to measure the molecular weight. As a result, it was confirmed that the peaks derived from the monomers substantially disappeared, and that peaks derived from a copolymer appeared. The weight-average molecular weight of the copolymer was 50,000 (in terms of polystyrene). The constituents of the copolymer were substantially equal to the composition of the charged monomers. The resultant polymerization liquid was diluted with pure water to obtain a water- and oil-repellent liquid having a copolymer concentration of 30%.
Synthesis Example 2
[0103] A soil release agent was prepared as follows.
[0104] A 1 L four-necked flask equipped with a stirrer was charged with a fluorine-containing monomer (60 g) of the formula:
H 2 C═CHCOO—CH 2 CH 2 —(CF 2 CF 2 ) 3 CF 2 CF 3 ,
methoxypolyethyleneglycol methacrylate (EO 9 mol) (30 g), 2-hydroxyethyl methacrylate (8 g), 2-methacryloyloxyethyl-trimethylammonium chloride (2 g), 2-mercaptoethanol (0.2 g) and isopropyl alcohol (250 g), and a nitrogen gas was allowed to flow into the flask for 60 minutes. The internal temperature of the flask was raised to 75 to 80° C., and azobisisobutyronitrile (1 g) was added. The mixture was reacted for 8 hours, and the resultant polymerization liquid was directly subjected to gel permeation chromatography so as to measure the molecular weight thereof. As a result, it was confirmed that the peaks derived from the monomers substantially disappeared, and that peaks derived from a copolymer appeared. The weight-average molecular weight of the copolymer was 11,000 (in terms of polystyrene). The constituents of the copolymer were substantially equal to the composition of the charged monomers. The resultant polymerization liquid was diluted with pure water to obtain a soil release liquid having a copolymer concentration of 20%.
Synthesis Example 3
[0105] The same operation as in Synthesis Example 2 was repeated to obtain a polymerization liquid, except that a fluorine-containing monomer of the formula:
H 2 C═CHCOO—CH 2 CH 2 CH 2 —SO 2 —C 4 F 9 ,
was used instead of the fluorine-containing monomer of the formula used in Synthesis Example 2:
H 2 C═CHCOO—CH 2 CH 2 —(CF 2 CF 2 ) 3 CF 2 CF 3 .
The resultant polymerization liquid was directly subjected to gel permeation chromatography so as to measure the molecular weight thereof. As a result, it was confirmed that the peaks derived from the monomers substantially disappeared, and that peaks derived from a copolymer appeared. The weight-average molecular weight of the copolymer was 11,000 (in terms of polystyrene). The constituents of the copolymer were substantially equal to the composition of the charged monomers. The resultant polymerization liquid was diluted with pure water to obtain a soil release liquid having a copolymer concentration of 20%.
Example 1
[0106] The soil release agent (18 g) of Synthesis Example 2 was diluted with tap water to prepare a diluted liquid (300 g). A white blended yarn cloth of polyester and cotton (hereinafter referred to as “PET/cotton blended white cloth”) was dipped in the diluted liquid and was then squeezed with a mangle to thereby pad the cloth with the diluted liquid. In this step, the mangle squeezing rate was controlled to adjust the adhering ratio of active component in the soil release agent, to 1.0 mass % relative to the cloth. Next, the water- and oil-repellent agent (15 g) of Synthesis Example 1 and a sizing agent (45 g) (CARBOPOL 846 manufactured by Goodrich Corporation) were diluted with tap water to give a liquid (100 g). This water- and oil-repellent formulation liquid was printed in a dot pattern on the cloth under a wet state by a screen printing machine, so that dots having the diameter of 500 μm were located at intervals of 700 μm among each of the dots, and so that the adhering ratio of active component in the water- and oil-repellent agent was 1.0 mass % relative to the cloth. The printed cloth was further subjected to heat treatment at 170° C. for 60 seconds to thereby prepare a cloth for use in evaluation. The water repellency, oil repellency, soil releasability and feeling of the cloth were evaluated. The results are shown in Table 4 below.
Example 2
[0107] The same operation as in Example 1 was repeated, except that, instead of the padding treatment using the soil release agent in Example 1, a liquid (100 g) prepared by diluting the soil release agent (20 g) of Synthesis Example 2 and the sizing agent (CARBOPOL 846 manufactured by Goodrich Corporation) (45 g) with tap water was printed on the whole surface of the cloth by a screen printing machine in the first treatment step, so that the adhering ratio of active component in the soil release agent could be 1.0 mass % relative to the cloth. The results are shown in Table 4.
Example 3
[0108] The same operation as in Example 1 was repeated, except that the order of the padding treatment using the soil release agent and the printing treatment using the water- and oil-repellent agent in Example 1 was reversed, and that the cloth treated by the printing of the water- and oil-repellent agent was additionally subjected to heat treatment at 170° C. for 60 seconds in order to prevent the removal of the water- and oil-repellent agent in a padding bath of the soil release agent. The results are shown in Table 4.
Example 4
[0109] The same operation as in Example 2 was repeated, except that the order of the printing treatment using the soil release agent and the printing treatment using the water- and oil-repellent agent in Example 2 was reversed. The results are shown in Table 4.
Example 5
[0110] The same operation as in Example 1 was repeated, except that, instead of the dot printing treatment using the water- and oil-repellent agent in Example 1, the water- and oil-repellent agent was printed in a lattice pattern on the cloth with the widths of the stripes of the lattice adjusted to 500 μm and the interval between each of the stripes, to 700 μm. The results are shown in Table 4.
Example 6
[0111] The same operation as in Example 1 was repeated, except that the soil release agent of Synthesis Example 3 was used instead of the soil release agent of Synthesis Example 2 used in Example 1. The results are shown in Table 4.
Comparative Example 1
[0112] The water- and oil-repellent agent (12 g) of Synthesis Example 1 was diluted with tap water to obtain a diluted liquid (300 g). A white PET/cotton blended yarn cloth was dipped in this liquid and was then squeezed with a mangle, so that the cloth was padded. The mangle squeezing rate was controlled to adjust the adhering ratio of active component in the water- and oil-repellent agent, to 1.0 mass % relative to the cloth. The cloth was further subjected to heat treatment at 170° C. for 60 seconds to obtain a cloth for evaluation. The water repellency, oil repellency, soil releasability and feeling of the cloth were evaluated. The results are shown in Table 4.
Comparative Example 2
[0113] The same operation as in Comparative Example 1 was repeated, except that the soil release agent (18 g) of Synthesis Example 2 was used instead of the water- and oil-repellent agent (12 g) of Synthesis Example 1. The results are shown in Table 4.
Comparative Example 3
[0114] The same operation as in Example 1 was repeated, except that the padding treatment using the soil release agent was not done. The results are shown in Table 4.
Comparative Example 4
[0115] A mixture of the water- and oil-repellent agent (12 g) of Synthesis Example 1 and the soil release agent (18 g) of Synthesis Example 2 was diluted with tap water to obtain a liquid (300 g). A white PET/cotton blended yarn cloth was dipped in the liquid of the agents and was then squeezed with a mangle, so that the cloth was padded with the agents. The mangle squeezing rate was controlled to adjust the adhering ratios of the active components of the water- and oil-repellent agent and the soil release agent to 1.0 mass %, respectively, relative to the cloth. The cloth was further subjected to heat treatment at 170° C. for 60 seconds to obtain a cloth for evaluation. The water repellency, oil repellency, soil releasability and feeling of the cloth were evaluated. The results are shown in Table 4.
Comparative Example 5
[0116] A mixture of the water- and oil-repellent agent (15 g) of Synthesis Example 1, the soil release agent (20 g) of Synthesis Example 2 and a sizing agent (CARBOPOL 846) (45 g) was diluted with tap water to obtain a liquid (100 g), which was then printed on the whole surface of a cloth, using a screen printing machine, so that the adhering ratio of each active components, i.e., each of the water- and oil-repellent agent and the soil release agent relative to the cloth could be 1.0 mass %, respectively. The cloth was further subjected to heat treatment at 170° C. for 60 seconds to obtain a cloth for evaluation. The water repellency, oil repellency, soil releasability and feeling of the cloth were evaluated. The results are shown in Table 4.
Comparative Example 6
[0117] The same operation as in Comparative Example 1 was repeated, except that the soil release agent (18 g) of Synthesis Example 3 was used instead of the water- and oil-repellent agent (12 g) of Synthesis Example 1. The results are shown in Table 4.
TABLE 4 Test Results Soil releasability Type and method of treatment Water Oil Oily Aqueous First step Second step repellency repellency soil soil Type Method Type Method (mark) (mark) (mark) (mark) Feeling Ex. 1 Soil Padding Water- Dot 5 6 4 3 Good releasing & oil- printing repelling Ex. 2 Soil Printing Water- Dot 5 6 4 3 Good releasing on whole & oil- printing surface repelling Ex. 3 Water- & Dot Soil Padding 5 6 4 3 Good oil- printing releasing repelling Ex. 4 Water- & Dot Soil Printing 5 6 4 3 Good oil- printing releasing on repelling whole surface Ex. 5 Soil Padding Water- Lattice 5 6 4 3 Good releasing & oil- printing repelling Ex. 6 Soil Padding Water- Dot 5 6 4 3 Good releasing & oil- printing repelling Blank* — — — — 0 0 2 2 Good C. Ex. 1 Water- & Padding — — 5 6 1 1 Bad oil- repelling C. Ex. 2 Soil Padding — — 2 5 4 3 Good releasing C. Ex. 3 Water- & Dot — — 1 1 1 1 Good oil- printing repelling C. Ex. 4 Water- & Padding — — 3 6 2 1 Fair oil- repelling and Soil releasing C. Ex. 5 Water- & Printing — — 3 6 2 1 Fair oil- on whole repelling surface and Soil releasing C. Ex. 6 Soil Padding — — 1 5 4 3 Good releasing *Blank indicates a non-treated cloth
[0118] It is known from the results shown in Table 4 that the inherent effects of the water- and oil-repellent agents and the soil release agents can be retained and compatibly exhibited, and also can impart to the textiles such properties that soils are hardly adhered and easily removed, and additionally the feeling of the textiles can be prevented from degrading.
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There is disclosed a textile which has a main surface consisting of a surface having an exposed water- and oil-repellent agent and a surface having an exposed soil release agent, by applying both the water- and oil-repellent agent and the soil release agent to the main surface, and which is characterized in that, in any of the square surface regions having a side length of 3,000 μm, of the main surface of the textile, the ratio A of the area of the surface having the exposed water- and oil-repellent agent is from 10 to 90%, and the ratio B of the area of the surface having the exposed soil release agent is from 90 to 10%, provided that the total of the ratios A and B is 100%. According to the present invention, there is provided a method for treating a textile to compatibly impart water- and oil-repellency and a soil release property to the textile so that the treated textile can exhibit such actions that make it hard for soil to adhere thereto and make it easy to remove the soil therefrom, without degrading the feeling of the textile, and there is also provided such a treated textile.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 USC § 119 to Korean Patent Application No. 2005-0002661, filed on Jan. 11, 2005, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method of manufacturing Fe-based soft magnetic powder and a soft magnetic core using the soft magnetic powder. More specifically, the invention relates to a method of manufacturing Fe-based soft magnetic power and a soft magnetic core using the powder, in which Fe-9Al-6Si powder is deformed into a flake-like form to have a superfine microstructure and then fabricated into a soft magnetic core having less expensive and good high-frequency characteristics as compared with a Ni-based powder core, thereby being applied to a high-performance micro soft magnetic component, such as a high-frequency power supply, a pulse transformer, a removal of electromagnetic noise, an electromagnetic shield, a supersaturated core, and a magnetic switching core.
[0004] 2. Background of the Related Art
[0005] In general, a high-frequency soft magnetic component has been made mainly of Ni—Fe permalloy, soft ferrite and amorphous alloys having a high magnetic permeability at high frequencies and a low permeability loss, and is categorized into a wound core of thin metallic strip and a press-formed powder core.
[0006] The materials for this powder core is classified into metals and oxides. The metals such as 80Ni-20Fe (permalloy), Fe-9Al-6Si (sendust), and 50Fe-50Ni (high flux) have a high saturation magnetization and do not cause a significant reduction in the initial permeability under DC-bias, thereby exhibiting a stable property of permeability and enabling a miniaturized core. In case of a powder core, in order to reduce core loss at high frequencies and maintain a stable permeability, the core may contain air gap of about 10˜20% inside thereof. The metallic core can be easily fabricated through press-forming, but the oxide core has relatively poor formability, which results in difficulties of fabrication. Thus, the metallic powder core is preferred as magnetic core components.
[0007] The metallic powder core is formed typically of 80Ni-20Fe (permalloy), Fe-9Al-6Si (sendust), and 50Fe-50Ni (high flux), and manufactured through the following process.
[0008] First, a spherical powder is manufactured through a gas atomizing method, and the particle size of the power is in a range of several tens to several hundreds microns. In addition, the grain size of the powder is in a range of a few to few tens microns. The manufactured powder is partially coated with an insulation film through an oxide coating process. In many cases, the powder is mixed with water glass in an appropriate ratio, and dried and heat-treated to thereby coat silica on the surface of the powder particle. These are press-formed to make a magnetic core, the magnetic property of which is shown in FIG. 1 .
[0009] The powder core made of permalloy has a saturation magnetization of about 0.7 T, a high permeability at a high frequency range as compared with other competitive materials, and exhibits a good stability of permeability with frequency change. This core has a good mechanical ductility to thereby provide an advantage of easy press-forming. However, the constituent metallic element, nickel, is expensive, which results in high price of the core products.
[0010] The Sendust core has a saturation magnetization of about 1.2 T and a relatively low permeability at a high frequency range as compared with other competitive materials, but has a similar stability of permeability with frequency change to the permealloy. This core is mechanically brittle and thus difficult in press-forming disadvantageously. However, the constituent elements are less expensive and thus the core products are also less expensive.
[0011] The high flux core has a high saturation magnetization of about 1.2˜1.4 T and a low permeability at high frequencies as compared to other competitive materials. Comparing with other materials (Permalloy and Sendust), it has the lowest stability of permeability with frequency change. This core has a mechanical ductility and thus its press-forming is relatively easy. The constituent metallic element, Ni, is expensive and thus the core products are expensive.
[0012] Typically, the above existing powder cores have a large particle size and a large grain size and the powder particles have a spherical shape. The core is provided with air gap inside thereof to thereby provide a low permeability loss at high frequencies and secure initial permeability in a stable manner advantageously. However, at a high frequency of above 10 MHz, its permeability remains at a lower value of less than about 30 so that the core size cannot be reduced. This problem has become a limiting factor to miniaturize the cores for high-frequency implementation.
SUMMARY OF THE INVENTION
[0013] Therefore, the present invention has been made in view of the above problems in the art, and it is an object of the present invention to provide a method of manufacturing a Fe-based soft magnetic powder for high-frequency implementations and a soft magnetic core using the powder, in which a less expensive Fe-based alloy powder is deformed into a flake form to minimize the demagnetizing factor and have a superfine microstructure, thereby improving production efficiency and high-frequency characteristics, as compared with a Ni-based power core.
[0014] To accomplish the above object, according to one aspect of the present invention, there is provided a method of Fe-based soft magnetic powder for a high-frequency application, the method comprises the steps of: (a) manufacturing Fe-9Al-6Si alloy powder; (b) deforming the Fe-9Al-6Si alloy powder into a flake-like form; and (c) heat-treating the flake-like Fe-9Al-6Si alloy powder to relieve stress and be re-crystallized to have a super fine grain size.
[0015] In the step (a), the Fe-9Al-6Si alloy powder is manufactured, preferably, through a gas atomizing or water atomizing process, but not limited thereto. In the step (b), the formation of the Fe-9Al-6Si alloy powder into a flake-like form is carried out, preferably, using a high-energy ball mill.
[0016] The flake-like Fe-9Al-6Si alloy powder deformed in the step (b) has a high density of dislocations since the lattice of the alloy powder is severely distorted. In the step (c), the heat-treatment is performed to re-crystallize the deformed powder to have a nano-scale grain size.
[0017] According to another aspect of the invention, there is provided a soft magnetic core using a Fe-based soft magnetic powder for high frequency applications manufactured according to the above method, wherein the Fe-based soft magnetic powder is mixed with a binder, the mixture is press-formed and heat-treated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is graphs plotting frequency versus permeability for various commercialized soft magnetic powder cores;
[0020] FIG. 2 is a SEM photo of Fe-9Al-6Si powder manufactured through a gas atomizing process;
[0021] FIG. 3 is a SEM photo of Fe-9Al-6Si powder manufactured according to a first embodiment of the invention;
[0022] FIG. 4 shows XRD spectrum for Fe-9Al-6Si powder manufactured according to the first embodiment of the invention;
[0023] FIG. 5 are graphs explaining a change in the grain size of Fe-9Al-6Si powder manufactured according to the first embodiment of the invention;
[0024] FIG. 6 shows a soft magnetic core press-formed according to the present invention; and
[0025] FIG. 7 is a graph showing variation of permeability with frequency for a Fe-9Al-6Si soft magnetic powder core of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The preferred embodiments of the invention will be hereafter described in detail, with reference to the accompanying drawings.
[0027] The embodiments of the invention will be explained, illustrating Fe-9Al-6si alloys.
1. First Embodiment (Manufacturing of Flake-Like Fe-9Al-6Si Alloy Powder)
[0028] (1) Preparation of Fe-9Al-6Si Alloy Powder
[0029] Fe-9Al-6Si alloy powder was manufactured using a gas atomizing process. The manufactured Fe-9Al-6Si alloy powder exhibited a spherical shape as shown in FIG. 2 .
[0030] (2) Manufacturing of Flake-Like Fe-9Al-6Si Alloy Powder
[0031] (a) 50 g of the spherical Fe-9Al-6Si alloy powder was charged into a stainless steel container of a high energy ball mill with 1 kg of stainless steel balls.
[0032] The weight ratio of the Fe-9Al-6Si alloy powder to the stainless steel ball is preferably 1:20. The lower weight ratio leads to an extended period of time, and the higher weight ratio can shorten the time.
[0033] In this embodiment, 1 weight % of stearic acid was added as a lubricant. In the case where the stearic acid was added less than 0.1%, the Fe-9Al-6Si power could not be deformed in a flake-shape, due to severe pressure-bonding among the power particles. Above 5% of stearic acid is excessive for preventing the pressure-bonding. Thus, 0.1˜5 weight % with respect to the charged powder and the balls is preferred. In addition, this embodiment employed a solid lubricant, but not limited thereto, for example, a liquid lubricant such as ethyl alcohol and trichloroethyl alcohol may be used.
[0034] Dissimilar to a conventional method where the lubricant is used in a limited way to maximize the pressure-bonding effect among the powder particles, in the present invention, the amount of the lubricant was controlled to minimize the pressure-bonding among the Fe-9Al-6Si powder particles and maximize pressurizing effect between the separate powder particles and the steel ball, thus obtaining a flake-like powder.
[0035] (b) The high energy ball mill was operated for one hour to deform the spherical Fe-9Al-6Si alloy powder into flake-shaped Fe-9Al-6Si alloy powder, which is shown in FIG. 3 .
[0036] FIG. 4 is a graph showing XRD (X-ray diffraction) peak of Fe-9Al-6Si alloy powder with variations of milling time, after heat-treating as in the embodiment 2. As shown in FIG. 4 , it has been found out that the width of X-ray diffraction peak is widened and the intensity thereof is decreased as the milling time increases.
[0037] On the other hand, the reasons why the spherical Fe-9Al-6Si alloy powder is converted into flake-form and simultaneously into superfine microstructure through the high-energy ball mill process are as follows.
[0038] When gas-atomized spherical Fe-9Al-6Si alloy powder is processed using a ball mill without meeting the above conditions, pressure-bonding severely occurs and the pressure-bonded powder is again crushed into spherical powder particles. Thus, the ball-mill process is to be carried out under the above conditions, i.e., an appropriate time of mechanical crushing and addition of lubricant can provide a flake-form powder.
[0039] During this course of processes, the flake-like Fe-9Al-6Si alloy powder comes to have a fine structure while causing partial cracking, and experiences severe plastic deformation to increase the density of dislocations by means of the ball-mill process to thereby store elastic deformation. In addition, the powder is transformed into nano-size grains through the heat-treatment as in the following third embodiment.
2. Second Embodiment (Heat-Treatment of Flake-Form Fe-9Al-6Si Alloy Powder)
[0040] In order for the flake-form Fe-9Al-6Si alloy powder prepared in the first embodiment to have a nano-structure, a heat-treatment is required. The alloy powder is not crystallized at a temperature less than 300° C. and causes a grain growth at a temperature of above 800° C. Thus, it is preferable that the heat-treatment is performed in a range of 300˜800° C. Although it varies with the grain size of the Fe-9Al-6Si alloy powder, the minimum time for crystallization is at least 10 minutes and the grain growth occurs more than 5 hours. In this embodiment, the heat-treatment was performed for 1˜3 hours at 600° C.
[0041] The Fe-9Al-6Si alloy powder mill-processed for 36 hours was heat-treated under the above conditions. As the result, as shown in FIG. 5 (A), the peak intensity representing crystallization was found to be increased as the heat-treating time increases. As a result of calculating the grain size and the lattice strain energy using the Williamson-Hall method, the gain size was controlled to about 60 nm at 3 hours of heat-treatment, as shown in FIG. 5 (B). As shown in FIG. 5 ( c ), the lattice strain was reduced to 0.09% from 0.16% when the heat-treating time (annealing time) was increased to 2, 3 hours from 1 hour.
3. Third Embodiment (Fabrication of Soft Magnetic Core Using Flake-Form Fe-9Al-6Si Alloy Powder)
[0042] (1) A binder such as 0.1˜3% water glass or polyimide was added into the flake-form Fe-9Al-6Si alloy powder prepared in the second embodiment and mixed together using a ball mill.
[0043] (2) The mixture of the Fe-9Al-6Si alloy powder and the binder was press-formed under a pressure of 10 Ton/cm 2 to fabricate an annular core as shown in FIG. 6 .
[0044] At this time, depending upon the forming pressure, various annular cores having the apparent density of 50˜90% can be fabricated. The density of the fabricated core was measured using the Archimedes principle.
[0045] (3) The press-formed core was heat-treated at a range of 300˜800° C. to release stress.
[0046] At this time, below 300° C., the stress release is not adequate and, above 800° C., grain growth occurs due to contact among powder particles.
[0047] FIG. 7 shows magnetic property of the core of the invention. As shown in FIG. 7 , the permeability is above about 50, and remains constant until 50 MHz. At 100 MHz, it exhibited permeability of above 40. These results are very excellent, exceeding the magnetic property of the conventional Permally core containing high-cost nickel.
[0048] As described above, according to the present invention, spherical Fe-9Al-6Si alloy powder is transformed into flake-form Fe-9Al-6Si alloy powder to minimize demagnetizing factor being caused by the spherical powder. Superfine microstructure can be achieved through a heat-treatment of the flake-form alloy powder to improve permeability, which is maintained at a high-frequency range, as compared with conventional powders.
[0049] The heat-treated flake-form Fe-9Al-6Si can be press-formed into a powder core. In addition, the present invention can be applied to a soft magnetic material for ultrahigh frequency application, such as a chip inductor capable of low-temperature plasticity using a tape casting.
[0050] While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the 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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Disclosed is a method of manufacturing Fe-based soft magnetic powder for a high-frequency application. The method includes the steps of manufacturing Fe-9Al-6Si alloy powder; deforming the Fe-9Al-6Si alloy powder into a flake-like form using a high energy ball mill, and heat-treating the flake-like Fe-9Al-6Si alloy powder to relieve stress and be re-crystallized to have a super fine grain size. 0.1˜5 weight percent of lubricant with respect to the alloy powder and balls of the high energy ball mill is added during the ball mill processing. A soft magnetic core made of the Fe-based powder is also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in the manufacture of threaded fasteners that use thermoplastic patches to produce a self-locking effect. More particularly, the invention relates to the application, preferably by spraying, of high-temperature-resistant resin powders (specifically poly (C 6 -C 8 alkyl isophthalamides)) to the threads of heated fasteners, resulting in fusion of the powders to form a locking patch. Such patches retain their self-locking ability at much higher temperatures than was previously possible. Optionally, an adhesive may be pre-applied to the fastener, or mixed with the high-temperature-resistant resin, to facilitate adherence of the resin to the fastener.
2. Description of the Prior Art
The manufacture of self-locking threaded fasteners that use a patch of thermoplastic resin on one side of the threaded fastener, applied by heating the threaded fastener and then spraying powdered resin onto the threads of the fastener, is known in the art and has enjoyed commercial success. U.S. Pat. No. Re. 28,812 (formerly U.S. Pat. No. 3,579,684), for example, describes a method of manufacturing self-locking threaded fasteners comprising the following steps:
1. Application by spraying of a thin, heat-softenable, substantially continuous film of liquid primer or tying material to a selected area of the exterior threads of a fastener such as a bolt.
2. Drying of the primer film.
3. Heating of the primed bolt by high frequency induction, to a temperature at which the bolt will retain sufficient sensible heat to soften and fuse powdered thermoplastic resin.
4. Entraining fine powdered thermoplastic resin, such as nylon 11, in a stream of air and spraying it directly onto one face of the threads of the heated bolt, forming an eccentric locking patch of resin covering part of the threads.
When a bolt prepared in this manner is threadably engaged with a nut, the thermoplastic material adhering to the sides of the thread flanks (the bearing surfaces) provides locking pressure which dramatically increases the torque required for disassembly, thus rendering the bolt self-locking. Patches of this sort can be formed on the internal threads of female fasteners, as taught in U.S. Pat. No. 3,894,509 (Duffy), as well as on the exterior threads of male fasteners.
The prior art describes various methods for enhancing the ease of assembly of such fasteners, such as by applying the resin so as to provide a thicker layer of thermoplastic on the flanks of the threads than on their crests, as in U.S. Pat. No. Re. 28,812. The prior art also discloses methods for increasing the retaining power of such fasteners when the male and female members are at the outside limits of dimensional tolerances by applying the resin so as to form a continuous ridge or bar of plastic above the thread crests, a result accomplished by reducing the application temperature slightly below that required to form a smooth, continuous coating of plastic, as in U.S. Pat. No. 3,787,222. And several different types of heating and spraying machines for applying the thermoplastic resin coatings to the exterior threads of male threaded fasteners have been patented, as in U.S. Pat. Nos. 3,452,714 and 3,530,827. Methods of applying such patches to the internal threads of female threaded fasteners also are known, as illustrated by U.S. Pat. No. 3,894,509.
The use of adhesives as one constituent of coatings for self-locking threaded fasteners also has been suggested. See, for example, U.S. Pat. Nos. 4,282,913 (Trimmer); 3,179,143 (Schultz); 4,632,944 (Thompson); and 4,927,307 (Fitzgerald). None of these references teaches or even suggests use of any adhesive to facilitate adherence of a high-temperature-resistant patch.
Finally, it has been suggested that light weight threaded fasteners can be fabricated entirely of certain thermoplastic resins containing high-modulus fibers for purposes of reinforcement. (See U.S. Pat. No. 4,863,330 to Olez). Among the resins suggested are TORLON® and XYDAR®. (Olez at Col. 5, lines 62-68). (TORLON® is a polyamide/polyimide polymer mixture and XYDAR® is an aromatic polyester polymer.) But Olez teaches that the bodies of the threaded fasteners themselves, and the threads, may be made from these thermoplastic resins reinforced with high-modulus fibers such as graphite. Olez teaches complex wrapped structures to enhance the strength of such fasteners. There is no suggestion that patches of these resins can be applied to threaded fasteners made of metal, or that once applied as patches to metal fasteners they will exhibit enhanced locking behavior at elevated temperatures. Indeed, Olez does not even suggest that the claimed fasteners fabricated of TORLON® or XYDAR® would be self-locking.
None of the prior art products and methods of manufacture for patch-type threaded fasteners solves the problem of retaining self-locking properties at elevated temperatures. Previous powdered patch material has included nylon 11 and similar thermoplastics which are applied to the threads of a fastener to obtain the desired self-locking capabilities. Such thermoplastics retain their self-locking properties only up to temperatures of 275° F. to 400° F. Above those temperatures, self-locking fasteners using conventional powdered thermoplastic resins lose their ability to lock and can no longer pass the test procedures required under qualifying specifications, such as Military Specification Mil-F-18240E, after exposure to elevated temperatures. (This Military Specification specifies a temperature requirement of 250° F., but its test procedures also are commonly used as a benchmark in evaluating the performance of locking fasteners that have been exposed to higher temperatures as well). Prior art users of thermoplastic patches have not been able to produce a patch that combines satisfactory adhesion to metal surfaces, particularly plated surfaces, with acceptable performance after exposure to elevated temperatures--that is, temperatures in excess of 400° F. For example, polyester patches made by the Long-Lok Fasteners Corporation of Cincinnati, Ohio and sold under the trade name "Poly-Lok" are advertised as maintaining effectiveness only up to 400° F. Other conventional plastic patches lose their self-locking ability when exposed to temperatures above about 275° F. to 300° F.
Prior art efforts to solve the problem of retention of self-locking properties at elevated temperatures have focused principally on mechanical approaches. U.S. Pat. No. 3,227,199, for example, discloses threaded fasteners in which a portion of the thread on a male threaded fastener differs in pitch from the remainder of the thread. Assembly of such a male threaded fastener with a female threaded fastener such as a nut creates a jamming action--that is, it retards disengagement of the female threaded fastener from the male threaded fastener by increasing the friction between the engagement surfaces of the two fasteners. As explained in that patent, other solutions to the problem have involved providing two sets of threads of the same pitch inside a single female threaded fastener, with the two sets of threads displaced axially from each other by a small distance in order to create a jamming action; or radially expanding a portion of the threads of a male fastener in order to engage the female fastener more tightly. But all of these solutions depend upon the manufacture of fasteners of non-standard dimensions, which are considerably more expensive and difficult to make than standard fasteners of uniform dimensions.
Accordingly, the object of this invention is to provide self-locking threaded fasteners of standard dimensions that rely on a thermoplastic patch to provide self-locking capability, and that can withstand appreciably higher temperatures than prior art patch-type fasteners while still maintaining the fastener's self-locking capabilities and meeting certain specifications outlining parameters for acceptable self-locking performance.
SUMMARY OF THE INVENTION
To achieve these objectives, a locking patch composed of high temperature resin is applied to a threaded fastener by spraying a fine powder of high temperature resin particles onto one or both sides or the entire circumference of a preheated threaded fastener. Optionally, the high temperature resin particles may be admixed with an adhesive before application, or an adhesive primer can be pre-applied to the fastener. Application can be accomplished by any one of the several spray processes and apparatus known to those skilled in the art, such as the methods and apparatus disclosed in U.S. Pat. Nos. 3,787,222 and Re. 28,812. We found that the result is a threaded fastener with a plastic locking patch that can withstand exposure to temperature of 400° F. or more for times in excess of one hour, while retaining its self-locking capabilities, compared to the 275° F. to 400° F. limitations advertised for the best prior art materials.
A variety of high temperature resin materials can be used to obtain the desired results of the present invention. We found that such resin materials include, but are not limited to, semicrystalline polyphthalamides formed from monomers such as hexamethyl isophthalamide; heptamethyl isophthalamide and octamethyl isophthalamide, and mixtures thereof. The foregoing resin materials have been found to produce satisfactory high-temperature-resistant patches without use of an adhesive. Commercially available resins in the foregoing group include AMODEL®, which is available from Amoco Performance Products, Inc., Atlanta, Georgia.
The high temperature resin is applied as a fine powder, preferably having particles in which about 100% of the powder particles are in the size range of below 149 microns, and a majority by weight of particles are below 105 microns. Moreover, the powder particles are preferably sized so that no more than about 10% of the particles are below about 30 microns.
We have therefore developed specific improvements on prior art patch application methods suitable for use with high temperature resistant resin powders, which produce locking patches that adhere effectively to the fastener threads and exhibit satisfactory high temperature locking behavior. The improvements involve the use of a high-temperature-resistant resin with suitable adhesion properties. A suitable high-temperature-resistant adhesive also may be used. The adhesive may improve adhesion of the high temperature-resistant resin patch to the threads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a view of a male threaded fastener, to one side of which a single plastic locking patch made of high temperature resin has been applied according to the method of this invention.
FIG. 2 is a cross-sectional view of the fastener along the line 2--2 of FIG. 1, showing the locking patch adhering to the threads of the fastener on one side of its shank.
FIG. 3 shows another pattern of application of a high temperature resin, in which the locking patch completely surrounds the circumference of the threaded fastener.
FIG. 4 illustrates yet another pattern of applying the high temperature resin, to form two discrete, circumferentially-opposed locking patches on opposite sides of the threaded fastener.
FIG. 5 illustrates a detail of one of the nozzles used to apply the high temperature resin.
FIG. 6 illustrates one method of practicing the invention, in which only one group of nozzles is required to apply the high temperature resin powder.
FIG. 7 illustrates an alternate method of practicing the invention, utilizing two stages of high-temperature-resistant resin application followed by a reheat cycle.
FIG. 8 shows the chemical structure of a preferred high-temperature-resistant resin.
FIG. 9 shows the chemical structure of one powdered adhesive which may be used in one embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
1. General Description Of The Application Of Self-Locking Patches To Bolts According To This Invention
A locking-type threaded element 9 made according to our invention is shown in FIG. 1 in the form of a bolt, but it will be understood that our invention can be used with other types of threaded fasteners, such as nuts, as well.
FIGS. 1 and 2 show a bolt having a threaded shank 2 to which a patch 3 of high temperature resistant resin has been applied according to our invention. The thin coating of primer 4 is optional; in this preferred embodiment it is not necessary. In cross-section, FIG. 2, the patch 3 is generally thickest in its center 10 and thins progressively toward both edges 11, with the side of the bolt's shank 12 opposite the spray nozzle uncovered by the patch. It will be understood that methods known to those skilled in the art can be used to produce variations in the thickness of the patch 3 in the valleys, on the crests and on the helical bearing surfaces of the threads so as to improve locking power when the male and female threaded fasteners are near the outer limits of dimensional tolerances, as in U.S. Pat. Nos. 3,787,222 and 3,554,258, and that fasteners with high temperature resin patches of such varying conformations also are within the scope of this invention. (See FIGS. 3 and 4).
One method of making the self-locking fasteners of this invention is illustrated in FIGS. 5 and 6. Referring to FIG. 6, a series of bolts 1 is positioned between and conveyed by two spaced parallel endless belts 13, with the bolt heads 9 supported by the belts 13 and the bolt shanks 2 hanging below the belts 13. The belts 13 carry the bolts 11 through a high frequency induction heating field created by heating coils 15, which are elongated in the direction of bolt travel and which provide a controlled heating time in order to raise the bolt shanks to the desired temperature for application of the high temperature resin powder. The heated bolts move out of the heating coils 15 and past a plurality of nozzles 16 (preferably two to four nozzles), through which high temperature resin powder is sprayed onto the bolt shanks 2. The nozzle is shown in FIG. 5.
It has been found that additional spraying and heating stations can be placed in series after the second heating station and high-temperature-resistant resin spraying station, as illustrated in FIG. 7. Such additional heating stations may include multiple spaced heating coils 15 separated by additional spraying stations which may include one or more additional nozzles 16. In addition, a post heating station 19 may also be utilized for purposes of finally setting and curing the high temperature resin powder. Such a post heating station 19 may include a heater such as an extension of heating coil 15 or similar heat source.
Moving past the second group of nozzles 16 (and the second heating station, if one is utilized), the bolts cool and are ejected from the belts 13 as finished products. FIG. 5 shows a detail of one of the nozzles 16 used to apply the high temperature resin powder.
By adjusting the orientation of nozzles 16, other configurations of locking patches can be produced. FIG. 3 shows a cross-section of the shank 2 of a threaded fastener of the type shown in FIG. 1 to which a uniform high-temperature locking patch 19 has been applied around the entire circumference of the shank.
FIG. 4 illustrates a cross-section of the shank 2 of a threaded fastener of the type shown in FIG. 1 to which two locking patches 20 and 21 have been applied.
Suitable spraying arrangement for applying patches to the internal threads of female threaded fasteners also may be used.
Practice of our invention involves application of high temperature resistant patches in such a way as to conform to MIL Spec MIL-F-18240E, modified to provide the following test protocol:
(1) Assemble fastener
(2) Expose fastener to 450° F. temperature for three hours
(3) Cool fastener to room temperature
(4) Disengage and reassemble fastener fifteen times, recording torque required
(5) Heat reassembled fastener to 450° F. and hold at that temperature for one hour
(6) Disassemble fastener at 450° F.; measure torque required for that sixteenth disassembly.
Measured disassembly torques (also called "removal torque" values) should meet or exceed MIL-F-18240E standards for all removals, including the sixteenth at elevated temperature.
Alternatively, our invention may be practiced by applying high temperature resistant patches in such a way as to conform to the Industrial Fastener Institute's IFI-124 standards regarding test protocol, modified as follows:
(1) Seat fasteners to 160 inch-pounds in hardened (Rockwell 62) test blocks
(2) Expose to 450° F. temperature for one hour
(3) Disassemble fastener at 450° F.; measure torque required for disassembly. Measured disassembly torque values (also called "removal torque" values) should meet or exceed IFI-124 standards.
2. Specific Embodiments of This Invention
Two embodiments of the invention are described below. The first is the preferred embodiment in which no primer or separate adhesive is needed. In the second embodiment, phenyl-based polymer adhesive is mixed with the high temperature-resistant resin powder before application of the powder to the threaded fastener.
A. Preferred Embodiment Using Poly (C 6 -C 8 alkyl isophthalamides)
In the preferred embodiment of our invention, the high temperature resin is a poly (C 6 -C 8 alkyl isophthalamide) having a particle size distribution with 100% of the particles below 149 micrometers and, preferably, also with the majority (by weight) below 105 micrometers and with no more than 10% of the particles (by weight) below about 30 micrometers. The preferred structure of the high temperature-resistant resin is shown in FIG. 8.
In the compound shown in FIG. 8, n is between 6 and 8; the weight average molecular weight (M w ) is in the range of about 30,000 to 60,000 and the number average molecular weight (M n ) is about 8,000 to 12,000. Any combination or mixture of poly (C 6 , C 7 and C 8 alkyl isophthalamides) may be used; poly (C 6 , C 7 and C 8 alkyl isophthalamide) resins also can be used individually. High temperature-resistant resins suitable for practicing the embodiments described above include AMODEL®, which is available from Amoco Performance Products, Inc., Atlanta, Georgia. Maximum temperature limitations for patches made of the resins disclosed have been found to exceed 400° F. based on tests made at 450° F.
For best results, the fasteners should be cleaned and degreased before application of the self-locking patches of this invention. In particular, care should be taken to ensure freedom from oil, grease, wax and heat-treating scale. If Cadmium or Zinc plating is desired, it should be applied after the application and fusion of the self-locking patches.
B. Second Embodiment Using Premixed High Temperature-Resistant Resin Powder Mixed With Adhesive
In a second embodiment, an adhesive is first mixed with the high temperature-resistant resin particles.
A suitable, optional powdered adhesive is poly (oxyl-1, 4-phenyleneisopropylidene-1, 4-phenyleneoxy-2-hydroxytrimethylene), having a weight average molecular weight (M w ) of about 60,000 to 65,000; a number average molecular weight of 25,000 to 30,000 and the structure shown in FIG. 9.
In addition, depending on the type of high temperature resin material and/or adhesive used, it may be desirable to include multiple heating and spraying stations such that the fasteners are first heated, then sprayed with high-temperature-resistant resin powder mixed with adhesive, then reheated and again sprayed with either high-temperature-resistant resin alone or high-temperature-resistant resin powder mixed with adhesive. One or more additional heating coils 15 and spray nozzles 16 can be utilized to accomplish such multiple heating and spraying operations. As described above, a post-heating operation may also be desirable.
EXAMPLES
The following examples illustrate the practice of the invention, but it is to be understood that the invention is not limited to the specific conditions described therein.
Without limiting the scope and content of the present invention, semicrystalline polyphthalamide (specifically, poly (C 6 -C 8 alkyl isophthalamide)) will be used as an example of the high temperature-resistant resin to be applied to the threads of a threaded fastener.
Example 1--No Adhesive
Poly (C 6 -C 8 alkyl isophthalamide) patches were applied to 5/16-18UNC-2A×2 inch unplated hex head cap screws according to the method of this invention. A particle size range of 90% below 130 microns and 10% below 30 microns was used for the high-temperature-resistant resin powder. The screws were heated to approximately 800° F. to 850° F. before the high-temperature-resistant resin powder was applied.
For comparison purposes, patches of the same configuration but made of conventional nylon were applied to the same size screws. Both the conventional screws (with ordinary nylon patches) and those made according to our invention (with poly (C 6 -C 8 alkyl isophthalamide) patches) were seated at 160 inch-lbs in 5/16-18UNC-2B hardened steel (Rockwell 62) test blocks. The modified IFI-124 standards regarding test protocol described herein was then applied. The mean torques required to remove the screws at 450° F. after a one hour exposure to that temperature was then measured:
______________________________________Type of Patch Torque, Inch-Lbs______________________________________Conventional Patch 1.4Our Invention 21IFI-124 Specification 8______________________________________
The screws made with a conventional patch failed to meet the 8 inch-lb minimum required by the IFI-124 specification, retaining no effective self-locking capability at all. The screws made with the patch of our invention, in contrast, easily satisfied that specification.
Example 2--No Adhesive
Comparison tests were made with 5/16-18UNC-2A×2 inch unplated hex head cap screws equipped with nylon patches (conventional technology) and with patches made of the poly C 6 -C 8 alkyl isophthalamide) used in the preferred embodiment of this invention. The mating nuts were 5/16-18UNC-3B AQ steel test nuts. The procedures of MIL-F-18240E 4.5.2 through 4.5.4 were used, with the modifications detailed herein. The following results were obtained:
______________________________________ Removal Torque, In-lbs Conventional Our Invention______________________________________Torque at 15th Removal 10.3 17.4(Removal at room temperatureafter 3 hrs. at 450° F.)Torque at 16th Removal 0.15 16.0(Removal at 450° F. afterone additional hour at 450° F.)MIL-F-1840E Specification 6.5 6.5______________________________________
The patches made of poly (C 6 -C 8 alkyl isophthalamides) according to our invention satisfied the standards both after a three hour heat soak and cooling to room temperature, and after an additional hour of exposure with removal of the nuts at elevated temperature. The conventional patches failed to meet the minimum removal torque requirements after the additional exposure.
Moreover, the torque required for the first removal of the screws with conventional patches after three hours at 450° F. was 106.5 in-lbs. The first removal torque for the conventional screws exceeded the maximum set by MIL-F-18240E; the screws made according to our invention, in contrast, satisfied that portion of the standard with a first removal torque of 46 in-lbs.
It will be appreciated by those skilled in the art that there are other methods of practicing the invention. For example, conventional liquid primers can be pre-applied to the threaded fasteners before application of the self-locking patches. Among such conventional liquid primers are oligomers of polyglycidyl ethers of bis phenol A (having one to three monomeric groups); resorcinol diglycidyl ether (RDGE), and commercially-available products such as DURALON EFI® thermosetting adhesive available from the Thermoclad Company of Erie, Pa. The foregoing examples are illustrative only, and are not intended to limit the scope of the claims in any manner.
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This invention describes self-locking threaded fasteners having a patch or patches of fused high-temperature-resistant resin adhered to a portion of the threads, providing self-locking capabilities at temperatures above 400° F., well beyond the range of temperatures attainable using prior art patch materials such as nylon. A process for making such fasteners by spraying finely-divided high-temperature-resistant resin powder onto the threads of a fastener also is claimed.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2014-008744 filed on Jan. 21, 2014, the entire contents of which are incorporated herein by reference.
FIELD
The embodiments discussed here are related to a technology which supports a collating operation.
BACKGROUND
In the related art, there is a case in which identity verification by an operator (for example, security guard, or the like), not only authentication using identification information (ID) and a password of an access applicant is performed in an access management of a location or information. The identity verification operation by an operator is performed when the operator executes visual verification with respect to reference information such as a photograph (photograph of face or whole body) which is registered in advance, and a verification target. In addition, a related technology is disclosed in Japanese Laid-open Patent Publication No. 2005-092700, and Japanese Laid-open Patent Publication No. 2012-239004.
SUMMARY
According to an aspect of the invention, a display control device includes circuitry configured to detect a specific object that is supported by an authentication target in an image, obtain content data associated with the specific object, the content data including a registered image of a registered user and positional information between the specific object and the registered image, and control a display to superimpose the registered image on the image at a position based on the positional information in order to provide a comparison between the authentication target and the registered user.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram which illustrates an example of a system configuration of an authentication system according to a first embodiment.
FIG. 2 is a diagram which illustrates an example of a hardware configuration of a terminal device.
FIG. 3 is a diagram which describes a function of a device which includes the authentication system according to the first embodiment.
FIGS. 4A and 4B are diagrams which illustrate examples of reference destination tables.
FIG. 5 is a diagram which illustrates an example of a superposition definition table.
FIG. 6 is a diagram which illustrates an example of a reference information database.
FIGS. 7A and 7B are diagrams which describe images which are included in the reference information.
FIG. 8 is a flowchart which describes operations of an authentication system according to the first embodiment.
FIGS. 9A and 9B are first diagrams which illustrate an example of an authentication result in the first embodiment.
FIGS. 10A and 10B are second diagrams which illustrate an example of the authentication result in the first embodiment.
FIGS. 11A and 11B are third diagrams which illustrate an example of the authentication result in the first embodiment.
FIG. 12 is a diagram which describes a function of a device which is included in an authentication system according to a second embodiment.
FIG. 13 is a diagram which illustrates an example of an error determination table.
FIG. 14 is a flowchart which describes operations of the authentication system in the second embodiment.
FIG. 15 is a diagram which illustrates an example of an authentication result in the second embodiment.
DESCRIPTION OF EMBODIMENTS
In a visual identity verification operation, it is not easy to discern the whole face, a part of the face, height, or the like, with high accuracy using a comparison of characteristics or sizes.
When characteristics of parts of a face, or the like, are compared, for example, there is a possibility that a hair style, glasses, or the like, may exercise influences on determinations. In addition, in comparison in parts, or the like, there is a case in which it is not easy to make a comparison when a size of a face is different, or the like, even when eyes are similar, for example. In addition, in a comparison in the whole body, there is a possibility that a change in clothes, a body shape, or the like, may exercise an influence on the comparison.
An object of the disclosed technology is to provide a display control program, a display control device, and a display control system which can perform a visual collating operation with high accuracy.
First Embodiment
Hereinafter, a first embodiment will be described with reference to drawings. FIG. 1 is a diagram which illustrates an example of a system configuration of an authentication system according to the first embodiment.
An authentication system 100 according to the embodiment includes a terminal device 200 , and an authentication server 300 . The terminal device 200 and the authentication server 300 are connected to each other through a wireless communication network, or the like, for example.
The terminal device 200 according to the embodiment has an imaging function, and images an image of a verification target who is wearing a predetermined marker 400 . The authentication server 300 according to the embodiment receives a recognition of the marker 400 using the terminal device 200 , and transmits reference information related to the verification target who is correlated with the marker 400 to the terminal device 200 .
The terminal device 200 makes an identity verification operation easy using the terminal device 200 by displaying an imaged image which is imaged using the imaging function, and reference information which is related to a verification target which is received from the authentication server 300 in an overlapping manner. Accordingly, the authentication system 100 according to the embodiment also has a function of a display control system which performs a display control of the reference information in the terminal device 200 . In addition, a detail of the reference information in the embodiment will be described later.
Hereinafter, the marker 400 according to the embodiment will be described.
According to the embodiment, a predetermined marker 400 which a verification target wears is set to an identification body which is referred to as an augmented reality (AR) marker.
The AR marker is a printed matter, or the like, on which a pattern which can measure a relative position or a relative angle with respect to an imaging apparatus is printed based on an imaged image in which the AR marker is photographed. That is, the AR marker is a pattern image which is a standard for specifying what a worker who possesses the terminal device 200 is viewing from where, when the AR marker is photographed using the imaging function of the terminal device 200 .
The terminal device 200 according to the embodiment adjusts a position, a size, an orientation, and the like, of the reference information when being displayed according to a position, a size, an orientation, and the like, of the marker 400 which is included in the imaged image, and displays the reference information by overlapping the information with the imaged image.
The terminal device 200 according to the embodiment measures a relative position and a relative orientation (relative angle) between the marker 400 and the imaging apparatus using the projected image of the marker 400 in the imaged image. In addition, the terminal device 200 obtains identification information of a verification target corresponding to the AR marker by analyzing a pattern which is printed on the AR marker, and obtains reference information corresponding to the identification information from the authentication server 300 . The terminal device 200 according to the embodiment may be a tablet terminal, a smartphone, or the like, for example.
The authentication system 100 according to the embodiment may be used in an identity verification operation, or the like, which is performed at an entrance when going into and out of a specific place, for example. The specific place may be a site of a company or a school, and may be an event site, or the like, for example.
In the following descriptions, a specific place is set to the inside of a site of a company, a verification target who is wearing a predetermined marker 400 being set to a person who is wearing an employee ID card, or the like, on which the AR marker is printed.
FIG. 2 is a diagram which illustrates an example of a hardware configuration of a terminal device.
The terminal device 200 according to the embodiment includes a display operation unit 21 which is mutually connected to each other using a bus B, a drive unit 22 , an auxiliary storage unit 23 , a memory unit 24 , an arithmetic processing unit 25 , an interface unit 26 , and an imaging unit 27 .
The display operation unit 21 is a touch panel, or the like, and is used for inputting of various signals and displaying of various information.
The interface unit 26 includes a modem, a LAN card, or the like, and is used so as to be connected to a network. The imaging unit 27 includes an imaging element, and images an image.
An authentication program is at least a part of various programs which control the terminal device 200 . The authentication program is provided using a distribution of a recording medium 28 , downloading from a network, or the like, for example. As the recording medium 28 in which the authentication program is recorded, it is possible to use a recording medium of various types in which information is optically, electrically, or magnetically recorded such as a CD-ROM, a flexible disk, and a magneto-optical disc, and a semiconductor memory, or the like, in which information is electrically recorded such as a ROM, and a flash memory.
In addition, when the recording medium 28 in which the authentication program is recorded is set to the drive unit 22 , the authentication program is installed in the auxiliary storage unit 23 from the recording medium 28 through the drive unit 22 . The authentication program which is downloaded from a network is installed in the auxiliary storage unit 23 through the interface unit 26 .
The auxiliary storage unit 23 stores the installed authentication program, and stores desired files, data, or the like. The memory unit 24 stores the authentication program by reading the program from the auxiliary storage unit 23 when a computer is started up. In addition, the arithmetic processing unit 25 executes various processes which will be described later, according to the authentication program which is stored in the memory unit 24 .
In addition, the authentication server 300 according to the embodiment may be a desktop computer, or a notebook computer, for example. In such a case, the authentication server 300 includes an input unit including a keyboard, a mouse, or the like, and an output unit including a display, or the like, instead of the display operation unit 21 . In addition, the authentication server 300 may be a tablet terminal. Since the authentication server 300 according to the embodiment is a general computer which includes the arithmetic processing unit and the memory unit, descriptions of a hardware configuration thereof will be omitted.
FIG. 3 is a diagram which describes a function of a device including the authentication system according to the first embodiment.
In the authentication system 100 according to the embodiment, the terminal device 200 includes a reference destination table 210 . The reference destination table 210 according to the embodiment may be stored in the auxiliary storage unit 23 or the memory unit 24 of the terminal device 200 .
The reference destination table 210 according to the embodiment is a table in which a marker ID for identifying a marker, and reference destination information corresponding to the marker ID are correlated with each other in advance. The reference destination information is information which is correlated with definition information which will be described later and the reference information, and specifies the definition information and the reference information corresponding to the marker ID. The reference destination table 210 is set to be registered in the terminal device 200 in advance by a manager, or the like, of the authentication system 100 . Details of the reference destination table 210 will be described later.
In addition, the terminal device 200 according to the embodiment includes an imaging control unit 220 , a marker recognition unit 230 , a reference destination information transmission unit 240 , a reference information obtaining unit 250 , a definition information obtaining unit 260 , a reference information correction unit 270 , and a display control unit 280 .
The imaging control unit 220 according to the embodiment controls operations of the imaging unit 27 when the imaging unit 27 is used by a user of the terminal device 200 (worker who performs identity verification operation). The imaging unit 27 according to the embodiment mainly images an image of a verification target who is wearing the marker 400 .
The marker recognition unit 230 according to the embodiment identifies (recognizes) an image of the marker 400 included in an imaged image which is imaged using the imaging unit 27 , and obtains identification information (hereinafter, referred to as marker ID) of the marker 400 corresponding to a marker by analyzing the marker image. In addition, the marker recognition unit 230 also obtains a size of the image of the marker 400 , a position of the marker 400 in the imaged image, an angle (distortion in appearance) of the marker 400 in the imaged image, and the like.
The reference destination information transmission unit 240 refers to the reference destination table 210 , obtains reference destination information which is correlated with the marker ID obtained by the marker recognition unit 230 , and transmits the information to the authentication server 300 .
The reference information obtaining unit 250 obtains reference information corresponding to the reference destination information from the authentication server 300 . The definition information obtaining unit 260 obtains definition information corresponding to the reference destination information from the authentication server 300 .
The reference information according to the embodiment is information (including image data and text data) which is displayed by being overlapped with the imaged image which is imaged using the imaging unit 27 . The definition information according to the embodiment is information which definite a size, an angle, a position, or the like, of a display when displaying the reference information.
That is, the reference information and the definition information corresponding to the marker 400 of the embodiment are AR content data items which are displayed by corresponding to the marker 400 . Details of the reference information and the definition information according to the embodiment will be described later.
The reference information correction unit 270 according to the embodiment corrects the reference information which is displayed by being overlapped with the imaged image based on a size, a position, an angle, or the like, of the image of the marker 400 in the imaged image which is obtained by the marker recognition unit 230 . Detailed processes of the reference information correction unit 270 will be described later.
The display control unit 280 according to the embodiment displays the reference information which is corrected by the reference information correction unit 270 by overlapping the information with a position which is denoted by the definition information in the imaged image.
The authentication server 300 according to the embodiment includes an overlapping definition table 310 , and a reference information database 320 . The overlapping definition table 310 and the reference information database 320 according to the embodiment may be stored in the auxiliary storage unit and the memory unit of the of the authentication server 300 in advance, for example.
In the overlapping definition table 310 according to the embodiment, the reference destination information, a display position, a rotation angle, and a display size of the reference information corresponding to the reference destination information, and a file name, or the like, of the reference information are stored. In the reference information database 320 according to the embodiment, a photograph, personnel information, and the like, which are correlated with the reference destination information are stored. The overlapping definition table 310 and the reference information database 320 according to the embodiment are stored in the authentication server 300 in advance.
In addition, the authentication server 300 according to the embodiment includes a reference destination information obtaining unit 330 , an information obtaining unit 340 , and an information transmission unit 350 .
The reference destination information obtaining unit 330 according to the embodiment obtains the reference destination information from the terminal device 200 . The information obtaining unit 340 refers to the respective overlapping definition table 310 and reference information database 320 , and obtains the definition information and the reference information which are correlated with the reference destination information. The information transmission unit 350 transmits the definition information and the reference information to the terminal device 200 .
Hereinafter, the reference destination table 210 will be described with reference to FIGS. 4A and 4B . FIGS. 4A and 4B are diagrams which illustrate examples of the reference destination table. FIG. 4A illustrates an example of a table in which a marker ID and an employee number of a verification target are correlated with each other, and FIG. 4B illustrates an example of a table in which the employee number and a reference ID which is correlated with the definition information and the reference information are correlated with each other.
A reference destination table 210 A illustrated in FIG. 4A has a marker ID and an employee number as items of information, and both are correlated with each other.
According to the reference destination table 210 A in the embodiment, it is understood that, in an employee ID card of a person with an employee number of 012345, for example, a marker (AR marker) 400 of which a marker ID is identified as 1 is printed. In addition, according to the reference destination table 210 A in the embodiment, it is understood that, in an employee ID card of a person with an employee number of 012346, for example, a marker (AR marker) 400 of which a marker ID is identified as 2 is printed.
In addition, in the reference destination table 210 A according to the embodiment, a plurality of marker IDs may be correlated with one employee number, for example. In the example in FIG. 4A , it is understood that a marker ID “1” and a marker ID “10” are correlated with the employee number of 012345.
When a plurality of marker IDs are correlated with one employee number in this manner, it is possible to substitute an employee ID card which is printed with the marker of the marker ID “10”, when an employee ID card which is printed with the marker of the marker ID “1” is lost, and to save time and effort of performing a registration of the reference information again, which will be described later.
A reference destination table 210 B illustrated in FIG. 4B has an employee number and a reference ID as items of information, and both are correlated with each other.
According to the reference destination table 210 B in the embodiment, it is understood that the employee number 012345 is correlated with a reference ID of “01”, for example.
According to the embodiment, the reference destination information corresponding to the marker ID may be set to an employee number which is applied to a verification target. In addition, according to the embodiment, the reference destination information corresponding to the marker ID may be set to a reference ID which is correlated with the marker ID through the employee number.
According to the embodiment, for example, it is possible to change the definition information and the reference information which are correlated with the marker ID, only by changing a reference ID which is correlated with the employee number in the reference destination table 210 B.
Specifically, for example, a case in which the reference information and the definition information corresponding to the employee number 012345 are updated is taken into consideration. In this case, the updated reference information and the definition information may be stored in the authentication server 300 by being correlated with a new reference ID, and the new reference ID may be correlated with the employee number 012345 in the terminal device 200 . In this manner, it is possible to cause the employee number 012345, the updated reference information, and the definition information to be correlated with each other. Accordingly, when the reference destination information is set to the reference ID, it is possible to easily change the reference information and the definition information which are correlated with the marker ID.
In the following descriptions of the embodiment, a case in which the reference destination information corresponding to the marker ID is set to the reference ID will be described.
Subsequently, the overlapping definition table 310 and the reference information database 320 according to the embodiment will be described. FIG. 5 is a diagram which illustrates an example of the overlapping definition table.
The overlapping definition table 310 according to the embodiment includes a reference ID, position information, a display size, a rotation angle, and a file name as items of information, and items other than those are correlated with an employee number. According to the embodiment, the position information, the display size, the rotation angle, and the file name which are correlated with the reference ID are set to definition information corresponding to the reference ID.
The position information according to the embodiment is information which denotes a relative positional relationship between reference information and an image of the marker 400 included in an imaged image, and denotes a display position of the reference information when displaying the reference information by overlapping the information with the imaged image. According to the embodiment, when an image of the marker 400 is recognized in the imaged image which is imaged using the imaging unit 27 , the reference information is displayed with respect to the marker 400 at a position which is defined by the position information. In addition, in the example in FIG. 5 , the position information is set to be denoted using three-dimensional coordinates, however, the position information maybe denoted using two-dimensional coordinates.
The display size according to the embodiment denotes a display size of the reference information when displaying the reference information. Details of the position information and display size according to the embodiment will be described later.
The rotation angle according to the embodiment denotes a rotation angle of the reference information when displaying the reference information by overlapping the information with the imaged image. The file name is a file name of an image which is displayed as reference information.
In addition, according to the embodiment, the overlapping definition table 310 is set to be stored in the authentication server 300 along with the reference information in advance, however, there is no limitation to this. For example, when the image of the marker 400 is included in the image which is registered as the reference information, for example, definition information may be generated from the image of the marker 400 included in the reference information after the terminal device 200 obtains the reference information from the authentication server 300 .
FIG. 6 is a diagram which illustrates an example of a reference information database. The reference information database 320 according to the embodiment includes a reference ID, a face picture, a photograph of the whole body, and personnel information as items of information, and the face picture, the photograph of the whole body, and the personnel information are correlated with the employee number.
In the example in FIG. 6 , a file name of an image file which is a face picture of an employee of the employee number which is correlated with the reference ID “01” is 1.jpg, a file name of an image file of the photograph of the whole body is 11.jpg, and a file name of a text file which is personnel information is text 1. That is, in the example in FIG. 6 , reference information corresponding to the reference ID “01” becomes a face photograph 1.jpg, the whole body photograph 11.jpg, and personnel information text 1. In addition, the personnel information according to the embodiment includes a name, an affiliated division, or the like, of a person corresponding to an employee number, and a photograph number, for example.
Subsequently, position information included in the definition information according to the embodiment will be described with reference to FIGS. 7A and 7B . FIGS. 7A and 7B are diagrams which describe images included in the reference information. FIG. 7A is a diagram which describes imaging of an image which is stored in the reference information database 320 , and FIG. 7B illustrates an example of an image which is obtained by the imaging.
When imaging an image, a person who is an imaging target is imaged by wearing the marker 400 . More specifically, for example, imaging is performed in a state in which the person (employee) as the imaging target is wearing an employee ID card on which the marker 400 is printed.
Hereinafter, a sequence of storing an image as the reference information in the reference information database 320 after obtaining an imaged image G 1 illustrated in FIG. 7B will be described. In addition, the following sequence is executed using a computer such as the authentication server 300 which obtains the imaged image G 1 , for example.
For example, when an image of a face picture is stored in the reference information database 320 , an image of a region G 2 of a face part which is selected in the imaged image G 1 is stored.
According to the embodiment, for example, each point (Ps 1 , Ps 2 , Ps 3 , and Ps 4 ) which defines the region G 2 is subjected to a perspective conversion, and is converted into coordinates (Pc 1 , Pct, Pc 3 , and Pc 4 ) on a real space. At this time, the depth from a camera 71 to an object is set to a value corresponding to a position of the marker 400 . For example, the depth from the camera 71 to the object may be set to a value which is the same as the depth of the marker 400 .
Subsequently, the (Pc 1 , Pct, Pc 3 , and Pc 4 ) are converted into coordinates (Pm 1 , Pmt, Pm 3 , and Pm 4 ) of a marker coordinate system (Xm, Ym, and Zm) using a model view conversion. The model view conversion is a conversion in which an object on local coordinates is moved to world coordinates, and is moved to a position which is viewed from a viewpoint.
Here, the authentication server 300 stores the converted coordinates in the overlapping definition table 310 by correlating the coordinates with a reference ID corresponding to the marker ID of the marker 400 as position information. In addition, the authentication server 300 sets an image in a region G 2 to be a face picture, and stores the image in the reference information database 320 by correlating the image with reference ID corresponding to the marker ID of the marker 400 .
According to the embodiment, in this manner, it is possible to display the image in the region G 2 (face picture) so that the image is present in a region surrounded by points Pm 1 , Pm 2 , Pm 3 , and Pm 4 with respect to the marker 400 when the marker 400 is recognized, by defining a positional relationship between the image included in the reference information and the image of the marker 400 . In addition, according to the embodiment, a predetermined value a (approximately 40 cm) is added to each of Xm coordinates of the points Pm 1 , Pm 2 , Pm 3 , and Pm 4 , and then the coordinates may be stored in the overlapping definition table 310 as position information. As a result, it becomes a display which is easy for a worker, who performs work for collating the imaged image with the reference information, to view, since the face picture is displayed next to a face of a person who wears the marker 400 , as the reference information.
In addition, position information which denotes a relative positional relationship between the image which is included in the reference information and the image of the marker 400 may not be the above described coordinates.
For example, when a shape of the marker 400 is set to a rectangle, the width of the image of the marker 400 is set to W, and the height is set to H, an X coordinate and a Y coordinate of the point Pm 1 of the region G 2 may be denoted as the width W and the height H of the image of the marker 400 . Specifically, there may be a calculation in which the X coordinate of the point Pm 1 is a position of the width W×2 of the image of the marker 400 from a center point of the image of the marker 400 , and the Y coordinate of the point Pm 1 is a position of the height H×5 of the image of the marker 400 from the center point of the image of the marker 400 , or the like.
In addition, in a display size of the reference information which is included in the definition information of the embodiment, for example, a size in the X axis direction may be set to the width W×5 of the image of the marker 400 , and a size in the Y axis direction may be set to the height H×3 of the image of the marker 400 , or the like.
Subsequently, operations of the authentication system 100 according to the embodiment will be described with reference to FIG. 8 . FIG. 8 is a flowchart which describes operations of the authentication system according to the first embodiment.
In the authentication system 100 according to the embodiment, the terminal device 200 recognizes an image of the marker 400 from an imaged image of a verification target which is imaged using the imaging unit 27 , using the marker recognition unit 230 (step S 801 ). Subsequently, the terminal device 200 according to the embodiment determines whether or not the image of the marker 400 is recognized in the imaged image (step S 802 ). When the image is not recognized in step S 802 , the terminal device 200 causes the display operation unit 21 to display that it is not possible to obtain the image of the marker 400 , for example, and causes a worker to adjust a position of the terminal device 200 (step S 803 ), and the process returns to step S 801 .
When the marker 400 is recognized in step S 802 , the marker recognition unit 230 analyzes the image of the marker 400 , and obtains a marker ID of the marker 400 , and state information of the marker which denotes a state of the marker 400 at a time of imaging (step S 804 ). In the marker state information according to the embodiment, for example, marker position information which denotes a position of the image of the marker 400 in the imaged image, information denoting a size of the image of the marker 400 in the imaged image, an angle of the marker 400 with respect to the imaging unit 27 at the time of imaging, and the like, are included.
Subsequently, the reference destination information transmission unit 240 refers to the reference destination tables 210 A and 210 B, and obtains a reference ID which is correlated with the marker ID (step S 805 ).
The terminal device 200 transmits the reference ID to the authentication server 300 using the reference destination information transmission unit 240 , and obtains reference information and definition information corresponding to the reference ID using the reference information obtaining unit 250 and the definition information obtaining unit 260 (step S 806 ).
Subsequently, the reference information correction unit 270 corrects the reference information based on the marker state information which is obtained in step S 804 (step S 807 ).
Hereinafter, the correction of the reference information using the reference information correction unit 270 according to the embodiment will be described. The reference information correction unit 270 according to the embodiment may calculate a distance between the terminal device 200 and a verification target from information denoting a size of the marker 400 which is denoted in the marker state information, and may perform a correction of changing a display size of an image of the reference information according to the distance.
In addition, the reference information correction unit 270 according to the embodiment may rotate the image of the reference information according to an angle of the marker 400 with respect to the imaging unit 27 at the time of imaging, which is included in the marker state information, for example.
According to the embodiment, as described above, the marker state information which denotes a positional relationship between the terminal device 200 and the marker 400 is obtained from the image of the marker 400 which is included in the imaged image, and the image included in the reference information is corrected based on the marker state information. Due to the correction, it is possible to set the image included in the reference information to an image which is photographed under the same conditions as that of the image of the verification target which is projected on the imaged image. Accordingly, according to the embodiment, it is possible to perform a visual collation of the image included in the reference information with the imaged image with high accuracy, and to make a visual identity verification operation easy.
Subsequently, the display control unit 280 displays the corrected reference information by overlapping the information with the imaged image (step S 808 ).
In addition, in FIG. 8 , it is set such that the reference information is corrected by obtaining the marker state information from the imaged image, however, there is no limitation to this. The corrected image may be the imaged image, not the image of the reference information.
Hereinafter, an authentication result using the authentication system 100 according to the embodiment will be described with reference to FIGS. 9A to 11B .
FIGS. 9A and 9B are first diagrams which illustrate an example of the authentication result in the first embodiment. FIG. 9A illustrates an example of an imaged image in which a verification target is imaged using the terminal device 200 by a worker who performs the identity verification operation using the authentication system 100 . FIG. 9B is a diagram which illustrates an example of an image which is formed by overlapping the reference information with the imaged image.
In the example in FIGS. 9A and 9B , an image 400 G of the marker 400 is included in an imaged image 91 . The marker recognition unit 230 according to the embodiment recognizes the image 400 G from the imaged image 91 , and analyzes the image, and obtains the marker ID of the marker 400 , and marker state information which denotes a state of the marker 400 at the time of imaging the imaged image 91 .
In addition, the terminal device 200 obtains definition information corresponding to the marker ID from the overlapping definition table 310 using the definition information obtaining unit 260 , and obtains pieces of reference information 93 and 94 corresponding to the marker ID from the reference information database 320 using the reference information obtaining unit 250 . The pieces of reference information 93 and 94 are displayed by being overlapped with the imaged image 91 based on the definition information and the marker state information. In the examples in FIGS. 9A and 9B , an image of a face picture is used as the reference information 93 .
In the example illustrated in FIG. 9B , in position information included in the definition information, a display position of the reference information 93 is defined to be present next to a face of the verification target, and it is possible to easily perform the identity verification operation. In the examples in FIGS. 9A and 9B , it is possible to confirm that a verification target who is included in the imaged image 91 is the same person as a person with an employee number of using the pieces of reference information 93 and 94 .
According to the embodiment, it is possible to cause a worker who performs a confirmation operation to perform a display including information on height, as well, by displaying a pointer 95 which becomes a standard for determining the height of the verification target, and to allow the visual identity verification operation to be performed easily.
FIGS. 10A and 10B are second diagrams which illustrate an example of an authentication result according to the first embodiment. FIG. 10A illustrates an example of an imaged image in which a worker who performs the identity verification operation using the authentication system 100 images a verification target using the terminal device 200 . FIG. 10B is a diagram which illustrates an example of an image in which reference information is overlapped with the imaged image.
In FIGS. 10A and 10B , an example in which the verification target who is included in an imaged image 101 is not the same person as a person with an employee number of is illustrated. The above described case is considered as a case in which, for example, a different person from the person with the employee number of is wearing an employee ID card of the person with the employee number of .
In FIG. 10B , the pieces of reference information 93 and 94 which are obtained from the image 400 G are displayed on the imaged image 101 . Position information of the reference information 93 is defined to be displayed next to a face of a person, when the person with the employee number of is the verification target, and is displayed on the imaged image 101 according to the position information.
For this reason, as illustrated in FIG. 10B , when a person with a different height from the person with the employee number of is photographed in the imaged image, for example, a deviation in height occurs between a display position of the reference information 93 and a position of a face of a person which is photographed in the imaged image 101 as a verification target. Therefore, according to the embodiment, it is possible to easily determine that the verification target who is photographed in the imaged image is not the person with the employee number of due to the condition of the height.
FIGS. 11A and 11B are third diagrams which illustrate an authentication result according to the first embodiment. FIG. 11A illustrates a case in which the verification target and the reference information match with each other. FIG. 11B illustrates a case in which the verification target and the reference information do not match with each other. FIGS. 11A and 11B illustrate an example of a case in which a whole body picture of the verification target is used as the reference information.
On a screen 111 A of the terminal device 200 illustrated in FIG. 11A , an imaged image 112 , and pieces of reference information 113 and 114 which are overlapped with the imaged image 112 are displayed.
In the example in FIG. 11A , an employee number corresponding to an image 400 G 1 of the marker 400 is xx, and the pieces of reference information 113 and 114 correspond to the employee number of xx. The reference information 113 is a whole body picture of a person with the employee number of xx.
On a screen 111 B of the terminal device 200 which is illustrated in FIG. 11B , an imaged image 115 , and pieces of reference information 113 and 114 which are overlapped with the imaged image 115 are displayed.
In FIGS. 11A and 11B , a whole body picture of the person with the employee number of xx is displayed next to images of verification targets who are included in both the imaged images 112 and 115 , as the reference information 113 .
In FIG. 11A , it is understood that then the image of the verification target in the imaged image 112 matches the reference information 113 . In addition, in FIG. 11B , the image of the verification target in the imaged image 115 does not match the reference information 113 .
As described above, according to the embodiment, when the image of the reference information is set to an image of a picture of the whole body, it is possible to easily perform a visual identity verification operation even when a distance from the verification target to the terminal device 200 is great, for example. In addition, according to the embodiment, when the image of the reference information is set to the image of the whole body picture, information on the height, a size of each part of the body, or the like, is included in the reference information, and it is possible to reduce an influence on a determination of the identity verification operation due to a change in body shape, clothes, or the like, for example.
In addition, in the above descriptions, an example in which reference destination information which is correlated with the marker ID is set to a reference ID has been described, however, there is no limitation to this. According to the embodiment, it is possible to perform the same processes even when the reference destination information is set to an employee number. When the reference destination information is set to the employee number, items of the reference IDs of the overlapping definition table 310 and the reference information database 320 are set to the employee number.
In addition, in the above descriptions, a form is described in which the embodiment is used in the identity verification operation, however, there is no limitation to this. The embodiment may be used in an operation, or the like, in which whether or not a height of a person who is a confirmation target satisfies a limit is determined, in an amusement park, or the like, for example.
Second Embodiment
A second embodiment will be described below with reference to drawings. In the second embodiment, a resolution of an imaged image is compared to a resolution of an image of reference information, differently from the first embodiment. Accordingly, in descriptions of the second embodiment, only differences from the first embodiment will be described, the same reference numerals as those used in the descriptions of the first embodiment are given to elements having the same functional configuration as those of the first embodiment, and descriptions thereof will be omitted.
FIG. 12 is a diagram which describes a function of a device included in an authentication system in the second embodiment. A terminal device 200 A according to the embodiment includes an error determination table 290 , and an error determination unit 295 , in addition to each unit included in the terminal device 200 according to the first embodiment. In addition, the terminal device 200 A according to the embodiment includes a display control unit 280 A.
The terminal device 200 A according to the embodiment compares a resolution of an imaged image to a resolution of an image of reference information, for example, and determines an error of a display size of the image of the reference information when overlapping the image of the reference information with the imaged image according to a difference in resolution.
The error determination unit 295 according to the embodiment determines whether or not a difference between the resolution of the imaged image and the resolution of the image included in the reference information is equal to or greater than a predetermined value. In addition, the error determination unit 295 refers to the error determination table 290 when the difference in resolution is equal to or greater than the predetermined value, and obtains an error value of a display size of the image of the reference information corresponding to the difference in resolution. In addition, the resolution included in the reference information may be registered in advance. In addition, the resolution of the imaged image may be obtained when an image of the marker 400 included in the imaged image is analyzed.
The display control unit 280 A according to the embodiment displays a pointer corresponding to the error value at a time of displaying the image of the reference information when the error determination unit 295 obtains the error value.
FIG. 13 is a diagram which illustrates an example of the error determination table.
The error determination table 290 according to the embodiment includes a difference in resolution and an error as information items, and the difference in resolution and the error are correlated with each other.
Hereinafter, an error of a display size of an image included in the reference information according to the embodiment will be described. Hereinafter, for example, a case in which a resolution of an image which is registered as reference information is lower than that of an imaged image will be described. In addition, the case in which the resolution of the image included in the reference information is low is a case in which an image which is a face portion cut out from a whole body picture, and is enlarged, or the like, is registered as a face picture of the reference information, or the like, for example.
When the resolution of the image of the reference information is lower than that of the imaged image, for example, an edge rises in an outer shape of an object in the image of the reference information, and as a result, a line in drawing becomes thick compared to an imaged image with high resolution. When the line in the drawing becomes thick, there is a case in which a display size become larger due to the thick line compared to an image with high resolution even in the same image.
In the error determination table 290 according to the embodiment, an error of a display size when a difference in resolution is 200 dpi is 50 mm. The error denotes a difference in thickness between thickness of a line in an image with high resolution and thickness of a line in an image of which a resolution is lower by 200 dpi compared to the image.
The error determination table 290 according to the embodiment is a table in which a relationship between a resolution and an error is correlated with each other using a measured value of thickness of a line corresponding to a difference in resolution, or the like, for example.
In the terminal device 200 A according to the embodiment, as described above, an error of a display size of an image which occurs from the thickness of a line due to a difference in resolution is taken into consideration, and a pointer which denotes the fact is displayed when the error occurs.
FIG. 14 is a flowchart which describes operations of an authentication system according to the second embodiment.
Since processes from steps S 1401 to S 1407 in FIG. 14 are the same as the processes from steps S 801 to S 07 in FIG. 8 , descriptions thereof will be omitted.
Subsequently to step S 1407 , the terminal device 200 A determines whether or not a difference between a resolution of the imaged image and a resolution of an image included in the reference information is equal to or greater than a predetermined value by the error determination unit 295 (step S 1408 ).
When the difference in resolution is less than the predetermined value in step S 1408 , the process of the terminal device 200 A proceeds to step S 1410 which will be described later. When the difference in resolution is equal to or greater than the predetermined value in step S 1408 , the error determination unit 295 refers to the error determination table 290 , draws a pointer based on the error value (step S 1409 ), and the process proceeds to step S 1410 .
Since the process in step S 1410 is the same as the process in step S 808 in FIG. 8 , descriptions thereof will be omitted.
FIG. 15 is a diagram which illustrates an example of an authentication result in the second embodiment.
Pieces of reference information 153 and 154 are overlapped with an imaged image 152 on a screen 151 which is illustrated in FIG. 15 . The reference information 153 displayed on the screen 151 is an image of which a resolution is lower than the imaged image 152 by a predetermined value or more, and it is understood that a line in drawing becomes thicker than a line in drawing of the imaged image 152 .
Therefore, according to the embodiment, for example, pointers 155 A and 155 B which denote an error of a display size which occurs due to the thickness of a line are displayed in the vicinity of a top of head of a face picture of the reference information 153 . The error of the display size is an error between a display size of an image of a verification target in the imaged image 152 and a display size of an image of the face picture in the reference information 153 .
When the top of head of the image of the verification target in the imaged image 152 comes between the pointers 155 A and 155 B on the screen 151 , it is possible to determine that height of the verification target in the imaged image 152 , and height of a person in the face picture in the reference information 153 are approximately the same.
As described above, according to the embodiment, it is possible to cause a worker who performs an identity verification operation to recognize an error which occurs due to a difference between a resolution of an image included in the reference information and a resolution of the imaged image, and to contribute to an increase in accuracy of the visual identity verification operation.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A display control device includes circuitry configured to detect a specific object that is supported by an authentication target in an image, obtain content data associated with the specific object, the content data including a registered image of a registered user and positional information between the specific object and the registered image, and control a display to superimpose the registered image on the image at a position based on the positional information in order to provide a comparison between the authentication target and the registered user.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority of U.S. Provisional Patent Application Ser. No. 61/833,834, filed 11 Jun. 2013, which is hereby incorporated herein by reference, is hereby claimed.
[0002] This application is related to U.S. patent application Ser. No. 13/364,114, filed 1 Feb. 2012, entitled “FLOOD WALL PROTECTION SYSTEM” (issued as U.S. Pat. No. 8,672,585 on Mar. 18, 2014); pending U.S. patent application Ser. No. 13/422,593, filed 16 Mar. 2012, entitled “FLOOD WALL PROTECTION SYSTEM” (published as No. US2012-0230766A1 on 13 Sep. 2012); and pending U.S. patent application Ser. No. 13/492,492, filed 8 Jun. 2012, entitled “FLOOD WALL PROTECTION SYSTEM” (published as No. US2013-0094905A1 on 18 Apr. 2013), each of which is hereby incorporated herein by reference thereto.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to flood barrier walls. The present invention relates to a barrier system constructed of interconnected fabric bags or cells or containers filled with material, such as sand, each bag having the capability to disengage the bottom of the bag, and allow the bag to be lifted from the material held therein, and the material to remain in place on the ground upon which it had been set to continue to function as a barrier wall.
[0007] 2. General Background of the Invention
[0008] The art of building temporary flood walls is well known. The most commonly known method is to fill small bags full of sand and to stack them up in a pyramid fashion to hold back flood waters. These small bags may weigh, for example, between 50 and 100 pounds. Building flood walls with this method involves a lot of labor and time.
[0009] It is also well known in the art that once flexible fabrics are formed into continuous cellular walls, and filled with sand and dirt, it forms a solid barrier against water. However, filling these flexible containers on banks along rivers and shore lines is not an easy task. The flexible walls must be properly supported until the containers are filled. One such method accomplishes this by using a large metal sled that supports each portion of the cellular wall as it is filled. The sled may then be pulled along a horizontal line until it clears the filled cell and new unfilled cells are opened and supported under the sled, waiting to be filled.
[0010] Existing methods support each cell's corner with a special plastic hangar that is not readily available and is therefore expensive. These plastic hangars can only be used a single time. As two hangars are used every two feet of the wall, the costs of these special parts add up over the course of each mile of wall that is placed. Further, with only the corners supported, there is noticeable sagging of the cellular walls as each cell is filled. This sagging creates uneven tensions on the four holders. The uneven tension can often overload individual hangars and cause them to fail during the movement of the sled.
[0011] The individual cells of the wall can be filled with up to 7,000 pounds of sand or dirt. After filling, the sled moves horizontally. The hangars must slide along metal rails until they clear the sled. Under this tremendous weight, these hangars can fail and cause the cells to drop from the sled prematurely.
[0012] Other methods involve simply piling truckloads of sand and dirt on top of levees. But while this method is fast, it is prone to washouts as the sand and dirt is uncontained against the flow of water.
[0013] Still another method uses open top bulk bags with wooden frames inside them which are bolted together in a cellular fashion to create vertical long walls that are then filled with sand and dirt. This method is a fairly fast method for constructing walls but has the expense of the wood and is limited to vertical walls that can be pushed over by fast moving flood waters, or collapsed from beneath as the flood waters hollow out the ground beneath them.
[0014] Still another method uses specially shaped bags that have triangular shaped sides. These bags are delivered using a large sled device that makes filling easier and faster than the methods listed above. However, this sled device relies on a bag support method that requires special parts to support each bag by its four corners that can be expensive and unreliable. Further the triangular shaped front of the containers are often unfilled due to the containers pointed toe. Due to the wave action of the flood waters, the sand and dirt can move after placement and cause some loss of control over its shape. And, just as the square bags can be hollowed out from below, so can this triangular faced design.
[0015] In short, the prior art methods of flood control that utilize flexible materials still have shortcomings that need to be addressed.
SUMMARY OF THE PRESENT INVENTION
[0016] The present invention solves the problems in the art in a simple and straightforward manner. What is provided is a method of constructing, and a system of utilizing, a removable flexible bag or container or cell by providing a flexible bag or container or cell of the type having sidewalls, a sloping front wall and a vertical rear wall to define a space for holding material, such as sand; forming a bottom, which comprises a pair of panels, each panel extending two feet under the bag when the bag is filled with material; folding each panel back onto itself to end at the nearest edge; securing loops onto the end of each panel, which extend from out of the front and rear of the bag; securing the ends of the bag beneath the bag while the bag is being filled with material; pulling the loops away from the bag to pull the panels from under the bag so that the contents of the bag are exposed to the ground beneath the bag; and lifting the bag upward and away from the material contents of the bag, the material contents to remain in place on the ground upon which it had been set to continue to function as a barrier wall.
[0017] In an embodiment of the method of the present invention, each of the bottom panels are four feet long, with two feet set under the bag, and two feet folded back onto itself, and wherein the lifting loops extend one foot out from under the bag; and wherein the ends of the panels are secured under the bag, with the use of a hog ring on each panel, for example; and wherein after the bag is lifted away, the bag is cleaned, the bottom panels are re-secured in place, and the bag is stored for further use; and wherein the bag may be a group of a plurality of bags interconnected with each bag having its own bottom panels to operate as disclosed.
[0018] An embodiment of the present invention comprises a method of constructing a removable flexible bag, comprising: a) providing a flexible bag of the type having sidewalls, a sloping front wall and a vertical rear wall to define a space for holding material, such as sand; b) forming a bottom, which comprises a pair of panels, each panel extending two feet under the bag when the bag is filled with material; c) folding each panel back onto itself to end at the nearest edge; d) securing loops onto the end of each panel, which extend from out of the front and rear of the bag; e) securing the ends of the bag beneath the bag while the bag is being filled with material; f) pulling the loops away from the bag to pull the panels from under the bag so that the contents of the bag are exposed to the ground beneath the bag; and g) lifting the bag upward and way from the material contents of the bag.
[0019] In another embodiment of the method of the present invention, each of the bottom panels are four feet long, with two feet set under the bag, and two feet folded back onto itself.
[0020] In another embodiment of the method of the present invention, the lifting loops extend one foot out from under the bag.
[0021] In another embodiment of the method of the present invention, the ends of the panels are secured under the bag with the use of a hog ring on each panel.
[0022] In another embodiment of the method of the present invention, after the bag is lifted away, the bag is cleaned, the bottom panels are re-secured in place, and the bag is stored for further use.
[0023] In another embodiment of the method of the present invention, the bag may be a group of a plurality of bags interconnected with each bag having its own bottom panels to operate as claimed herein.
[0024] Another embodiment of the present invention comprises a method of using a removable flexible bag or cell, comprising the steps of: a) providing a flexible bag of the type having sidewalls, a sloping front wall and a vertical rear wall to define a space for holding material, such as sand; b) forming a bottom, which comprises a pair of panels, each panel extending two feet under the bag when the bag is filled with material so that the four foot bottom of the bag is defined by the two panels; c) folding each panel back onto itself to end at the nearest edge; d) securing loops onto the end of each panel, which extend from out of the front and rear of the bag; e) securing the ends of the bag beneath the bag while the bag is being filled with material; f) filling the bag with material, such as sand; g) pulling the loops away from the bag to pull the panels from under the bag so that the contents of the bag are exposed to the ground beneath the bag; and h) lifting the bag upward and way from the material contents of the bag.
[0025] Another embodiment of the present invention comprises a removable flexible bag, comprising: a) a flexible bag of the type having sidewalls, a sloping front wall and a vertical rear wall to define a space for holding material, such as sand; b) a bottom portion, which comprises a pair of panels, each panel being four feet in length; c) each panel back folded onto itself so that each panel is two feet in length under the bag, and the end extends out to end at the nearest edge; d) a hog ring for securing each panel under the bag when material is poured into the bag; e) a loop secured to the end of each panel, which extend from out of the front and rear of the bag; and f) the loops pulled away from the bag to pull the panels from under the bag so that the contents of the bag are exposed to the ground beneath the bag, so the bag can be lifted upward and way from the material contents of the bag.
[0026] In another embodiment of the removable flexible bag of the present invention, each of the bottom panels are four feet long, with two feet set under the bag, and two feet folded back onto itself.
[0027] In another embodiment of the removable flexible bag of the present invention, the lifting loops extend one foot out from under the bag.
[0028] In another embodiment of the removable flexible bag of the present invention, the ends of the panels are secured under the bag with the use of a hog ring on each panel.
[0029] In another embodiment of the removable flexible bag of the present invention, the bag is lifted away, the bag is cleaned, the bottom panels are re-secured in place, and the bag is stored for further use.
[0030] In another embodiment of the removable flexible bag of the present invention, the bag may be a group of a plurality of bags interconnected with each bag having its own bottom panels to operate as claimed and disclosed herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0031] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0032] FIG. 1 illustrates a side view of an empty flexible cell or bag ready to be filled in an embodiment of the present invention;
[0033] FIG. 2 illustrates a flexible bag or cell filled with sand in an embodiment of the present invention;
[0034] FIG. 3 illustrates a bottom flap and pull straps in an embodiment of the flexible bag or cell of the present invention;
[0035] FIGS. 4A and 4B illustrate the first steps for removal of the flexible bag or cell in an embodiment of the method of the present invention;
[0036] FIG. 5 illustrates the step of lifting the flexible bag or cell straight up and off filler sand in an embodiment of the method of the present invention;
[0037] FIG. 6 illustrates reattaching the bottom panels to the flexible bag or cell in an embodiment of the method of the present invention;
[0038] FIG. 7 illustrates an overall view of a group of flexible bags or cells with the removal sleeves in place, in an embodiment of the present invention;
[0039] FIG. 8 illustrates constructing side panels of a flexible bag or cell in an embodiment of the present invention;
[0040] FIGS. 9A-9C illustrate constructing sleeves of a flexible bag or cell in an embodiment of the present invention;
[0041] FIG. 10 illustrates a side view of the sleeve attachment process in an embodiment of the present invention;
[0042] FIG. 11 illustrates adding the lifting structure to a flexible bag or cell in an embodiment of the present invention;
[0043] FIG. 12 illustrates the printing step on a flexible bag or cell in an embodiment of the present invention;
[0044] FIG. 13 illustrates the addition of a pull loop to a vertical panel in an embodiment of the present invention;
[0045] FIG. 14 illustrates the addition of pull loops to a sloped panel in an embodiment of the present invention;
[0046] FIG. 15 illustrates one main panel being sewn to two side panels in an embodiment of the present invention;
[0047] FIG. 16 illustrates the addition of a sloped panel in an embodiment of the present invention;
[0048] FIG. 17 illustrates the addition of the next center panel in an embodiment of the present invention;
[0049] FIG. 18 illustrates the addition of more vertical and sloped panels in an embodiment of the present invention;
[0050] FIG. 19 illustrates making a removal panel in an embodiment of the present invention;
[0051] FIG. 20 illustrates adding a removal panel to the side wall in an embodiment of the present invention;
[0052] FIG. 21 illustrates the attachment of loose ends to center panels in an embodiment of the present invention;
[0053] FIG. 22 illustrates the packing of the completed chains of a group of flexible bags or cells in an embodiment of the present invention;
[0054] FIG. 23 illustrates three photos of the process of filling the reusable flexible bags or cells in an embodiment of the present invention;
[0055] FIG. 24 illustrates three photos of the removal of the bottom flaps on the vertical side in an embodiment of the present invention;
[0056] FIG. 25 illustrates three photos of the removal of the flaps from the toe of a flexible bag or cell in an embodiment of the present invention;
[0057] FIG. 26 illustrates three photos of the partially lifted off cells in an embodiment of the present invention;
[0058] FIG. 27 illustrates two photos of completely lifted off cells in an embodiment of the present invention;
[0059] FIG. 28 illustrates the undamaged and ready for reuse group of flexible bags or cells in an embodiment of the present invention; and
[0060] FIG. 29 illustrates the liftoff and storage of the reusable flexible bags or cells in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0061] FIGS. 1 through 29 illustrate the preferred embodiment of the reusable and removable flexible bag or cell flood wall protection system and method of the present invention. As illustrated in FIG. 1 , there is a side view of an empty flexible bag or cel or container ready to be filled, illustrating a side or center panel 11 or 12 . A bottom portion 14 is shown, comprising two panel portions 14 a and 14 b as shown, each panel 14 a, 14 b extending 2 feet under the bag when it is in the filled position. A center opening 22 between the panel portions 14 a, 14 b is also shown. Each bottom panel portion 14 a, 14 b are folded back under the bag towards its nearest edge, and each bottom panel portion 14 a, 14 b ends with loops 16 designed to allow the bottom panel portion to be pulled out from under the bag. It should be noted that hog rings 17 hold unsewn panels 14 a and 14 b, in position while sand is poured into each cell or bag. Other suitable attachments may also be used to temporarily secure panels, which are not sewn, in position while sand is poured into each bag or cell.
[0062] Turning now to FIG. 2 , there is illustrated the flexible cell or bag 10 filled with sand 18 . In this illustration, sand 18 has been added to the cell 10 and lays on top of the removable bottom panels 14 a, 14 b. A reusable embodiment features an incomplete bottom. The center portion or opening 22 of the bottom is completely open.
[0063] In FIG. 3 , a pair of bottom flap pull straps or loops 16 are illustrated on a bottom panel 14 a, or 14 b. In a preferred embodiment, each bottom panel 14 a, 14 b, is four feet long and a pair of one foot long webbing loops 16 , for example, are attached as shown. Two feet of each panel 14 a, 14 b reaches into the cell 10 and two feet fold back under the cell 10 back to the edge of the flexible cell 10 . The webbing loops 16 may be one foot long and extend out from under the cell 10 for easy access, for removal and reuse.
[0064] FIGS. 4A and 4B show the first steps in a preferred embodiment of the method of the present invention for removal of the flexible bag or cell. Soft metal rings, for example a hog ring 17 , can be threaded through a side panel 11 , 12 and bottom panel 14 a, 14 b, to hold it in place during filling. In FIG. 4A , there is illustrated that when it is time to remove the flexible bags or cells, the method comprises pulling on the loops 16 to detach the hog rings 17 and allow the fabric to peel back under itself. In FIG. 4B it is illustrated that once the flaps are pulled out, there is nothing holding the flexible bag or cell 10 to the filler sand.
[0065] In FIG. 5 , a flexible cell 10 has been lifted straight up and off the filler sand 18 . The flexible cell 10 can then be cleaned with hoses, for example, to remove the remaining sand 18 .
[0066] In FIG. 6 , the reattachment of the bottom panels is illustrated. One would fold bottom flaps 14 a, 14 b back under the flexible bag or cell 10 as illustrated, and the hog ring 17 or other suitable temporary attachment means would be set into place. The bag may be folded and stored until needed.
[0067] An embodiment of the removable flexible cell or bag system of the present invention comprises a series of identical chambers that are sewn together to make a continuous cell wall 35 . In a preferred embodiment, the method of constructing a continuous cellular wall of the removable flexible cell or bag system, comprises building every other chamber completely, then connecting the completed chambers with a single main panel. A completed cell wall in a preferred embodiment would be comprised of 31 completed chambers and one connection chamber that is essentially an open chamber at the end of the string of chambers. An embodiment of the present invention would be made up of 17 complete chambers and 18 extra main panels. The system may be constructed in a series of steps, similar to those used in bulk bag production, except for the final stage of putting together the chain of bags.
[0068] In an embodiment of the present invention, each chamber will have two sleeves of fabric 19 near the top opening of each chamber or cell 10 . These sleeves will provide support for the chambers during the filling and emptying process. These sleeves 19 may be added to each side panel 11 , 12 prior to the production of the actual chamber.
[0069] Turning now to FIG. 7 , there is illustrated a group of flexible bags or chambers 10 sewn together with the bottom removal sleeves or loops 16 in place as illustrated.
[0070] FIG. 7 further illustrates dimensional details of a flexible bag or cell 10 and cellular wall 35 comprising a chain or bags or cells 10 , in a preferred embodiment of the present invention. As shown, “A” represents a vertical height, of a back or vertical panel portion 15 . “B” represents a base length of bottom portion 14 (which is equal to A+62 CM in a preferred embodiment). “C” represents a height of a front toe 20 . “D” represents length of a diagonal or sloping face portion 13 . “E” represents a length of fill mouth or opening 21 . “F” represents a finished width of a main panel and width of filling mouth or opening 21 . “G” represents a main or sloping panel 13 and may be equal to C+D+12 CM. “H” represents a toe anchor panel which may be 62 CM. “I” represents a vertical back panel 15 which is equal to A+31 CM in a preferred embodiment. “J” represents a removal loop or sleeve 16 which may be 35 CM.
[0071] Dimensions may further be as follows:
A=138 CM B=184 CM C=31 CM D=136 CM E=100 CM F=100 CM G=C+D+12 CM H=45 CM I=15 CM J=35 CM
[0082] In a preferred embodiment, dimensionally, a horizontal height “B” will be 46 centimeters longer than the vertical height “A”. The toe front 20 will be 31 centimeters tall. A reusable embodiment features an incomplete bottom 14 . The center portion 22 of the bottom 14 is completely open. The outer portions 14 a, 14 b are only slightly attached so that it can easily break free without damage during removal for reuse. A reusable embodiment also features pull straps 16 that will allow the bottom flaps to be pulled from beneath the load to free the filler sand 18 without damage. In a preferred embodiment, the lifting sleeves are strong enough to lift up to 6,000 pounds from the ground to allow easy removal of the flaps. However, the 5 to 1 safety ratio is not in play.
[0083] FIG. 8 illustrates constructing of the side panels, wherein one makes one cut to both sides of a flexible sheet 23 of fabric or material. One would cut the sheet 23 at 148 centimeters×333 centimeters, then cut this sheet in a diagonal manner as shown. Parts marked by “X” are either cut off or folded out of the way. Hem the entire panels with 5 centimeter fold to make completed side panels 11 , 12 .
[0084] In FIGS. 9A-9C there is illustrated the sleeve 19 construction of a bag or cell 10 . One would cut a 200 GSM sheet 24 of fabric or material, for example, to size 114 , 110 centimeters. One would sew the hem 25 on the two edges to create a sheet 114 by 100 centimeters. One would then fold panel at 26 to create one side 12 centimeters longer than the other side as illustrated.
[0085] In FIG. 10 , the process of sleeve 19 attachment is illustrated. In a preferred embodiment the fabric tunnel of the sleeve 19 at the top has a 25 centimeter lay flat. A sleeve 19 may be pre-attached to the panel with three sew lines 27 . In a preferred embodiment, one would position the sleeve 19 so that 25 centimeters of the sleeve extends above the side panel 11 , 12 , with one sew line that is 5 centimeters from the bottom, one would have a sew line 5 centimeters above the bottom of the short side and one sew line 3 centimeters from the top of the side panel. In a preferred embodiment the sleeve 19 is positioned even with vertical side edge.
[0086] In FIG. 11 there is illustrated adding the lifting structure where one attaches 138 centimeters by 5 centimeter webbing with 4,500 pounds tinsel strength to long vertical side and zigzag sewing 28 attached for 25 centimeters at top to attach sleeve 19 . An embodiment of the present invention further comprises 25 centimeter lift loops 30 at the toe. One folds a 100 centimeter by 5 centimeter piece of webbing loop in half and zigzags to the vertical portion of toe 20 panel as shown. This will form a 25 centimeter lift loop 30 at the toe.
[0087] When the units are complete, in a preferred embodiment fill openings 21 are 1 meter×1 meter. They are hemmed on all four sides with a 1 meter long sleeve 19 that has a 5 centimeter hem on each side that is even with the vertical edge of the center panel. For the connecting panels, the connecting panels will now be in two parts, each may be made of a 200 GSM sheet. There are two connecting panels for each cell. The panel for the vertical side 15 will be cut 184 centimeters×112 centimeters and hemmed 5 centimeters on all four sides. The panel for the slope side 13 will be cut 222 centimeters×112 centimeters and hemmed 5 centimeters on all four sides. Printing may be included on a cell and in a preferred embodiment will be oriented to start 40 centimeters from one edge, will then be placed near the fill opening when sewn into the cells. When attaching panels to center panels, a 1 centimeter same depth is preferred. Cells may also be in different colors, for example tan. If information, e.g. trademarks or contact information, is printed on the bag, such printing may be about 40 centimeters tall, with other printing being less tall, for example 10 centimeters. Printing may be, for example, on all panels near the top which is hemmed, or could be added to other locations as desired.
[0088] In FIG. 13 , there is shown adding the pull loops to the vertical side to the connection panels, while in FIG. 14 there is illustrated adding the pull loops to the sloped panels as illustrated in the Figure. A vertical panel 14 may be 174 CM after hemming For a vertical panel, 5 CM wide webbing may be used, cut at 132 CM. Form one 31 CM long loop on free end by zigzagging 12 CM as shown. In a preferred embodiment, it will be attached to an unprinted side by zigzagging 12 CM as shown. A sloped panel 13 may be 212 CM after hemming For a sloped panel one may use 5 CM wide webbing cut 144 CM. Form one 31 CM long loop on free end by zigzagging 12 CM as shown. In a preferred embodiment, it will be attached to an unprinted side by zigzagging 12 CM as shown.
[0089] In FIG. 15 , there is illustrated sewing one main panel or vertical panel 15 to a side panel 11 , 12 . The vertical panel may be sewn with a 5 centimeter fold to each center or side panel 11 , 12 on the vertical side. At the bottom, turn the corner and sew for 3 centimeters then run off This will leave 28 centimeters unsewn. The unsewn flap will be slightly anchored in place later.
[0090] In FIG. 16 , there is illustrated adding the sloped panel 13 . One may sew the sloped panel 13 in the same manner as discussed above. In a preferred embodiment, only 5 centimeters is sewn to the bottom of the center or side panel 11 or 12 then the seam should stop and leave 10 centimeters unattached.
[0091] In FIG. 17 , there is illustrated adding the next center or side panel 11 , 12 by sewing the next center panel to the vertical 15 and sloped 13 panels, wherein a 5 centimeter fold is made in a preferred embodiment.
[0092] In FIG. 18 one would add more vertical and sloped panels as illustrated in continuing the process of the present invention. One would continue this process until one would have 31 complete chambers and a 32 nd chamber that has sloped and vertical panels but no ending center or side panel, 11 , 12 . This last chamber is a connection chamber to the next flexible cell or bag string. The last or 32 nd chamber may look like the left hand chamber illustrated in FIG. 18 .
[0093] In FIG. 19 there is illustrated the process of making the removal panels from 200 GSM sheet as illustrated in the Figure. The sheet 31 may be 32.5 meters long by 147 centimeters wide. A 47 centimeter fold 32 may be made in the sheet 31 to make it a total of 1 meter wide. Sew flap down twice to make open sleeve with 31 cm lay flat. Sew lines 33 are shown in the figure.
[0094] In FIG. 20 there is illustrated adding a removal panel 14 b in an embodiment of the present invention. The removal panel 14 b is double sewn to a loose portion of sloped panel 13 with sleeve 34 laying beyond the toe 20 by 32 centimeters. Once sewn, total length from front of the toe 20 to end of removal panel 14 b is 67 centimeters, plus or minus 5 centimeters, in a preferred embodiment. Note that the removal panel 14 b may extend past a first chamber by 0.5 meters. This sleeve 34 will be capable of supporting a lot of weight as it lifts the toe for removal from the sand.
[0095] In FIG. 21 , there is illustrated the attachment of loose ends to the center panels. Loose ends of all panels 14 a, 14 b are attached to center or side panels 11 , 12 in a break away fashion in a preferred embodiment. Soft metal rings, for example a hog ring 17 , can be threaded through a side panel 11 , 12 and bottom panel 14 a, 14 b, to hold it in place during filling. During emptying, as the flexible bag 10 is lifted upwards, the rings 17 will easily bend and release. FIG. 21 illustrates completing the manufacturing of a chain of the flexible bags.
[0096] A completed chain or wall 35 may be folded accordion style by gusseting connection panels and lining center panels flat to each other in the manner to illustrate the packing of completed chains as set forth on a pallet 36 as seen in FIG. 22 . In a preferred embodiment, each chain is packed with an open final chamber down on the pallet first. In the final packing, one may add the cover bag and strap to the pallet. One may add identifying tags or trademarks, dimension information, company contact information and other information regarding where the product was made, for example, to the flexible bags or cells 10 . A tag may read for example “1.2 meter tall reusable flexible bag.”
[0097] In the procedures for use of the removable flexible bag or cell, there is illustrated in FIG. 23 three photographs, which depict procedures for single application design with one additional requirement. In the embodiment of the method as shown, all flap loops 16 are kept extended to the outside of the bag. Positioning flap loops 16 so they are extended to the outside of the bag allows them to be available to assist in pulling the bottom flaps from under the filler when it is time to remove the flexible bag or container.
[0098] In FIG. 24 there is illustrated three photos showing the removal of the bottom flaps on the vertical side. One would lift the vertical side of the flexible bag or container with a forklift, for example, or any appropriate powered lifting device, threaded through sleeves 19 . Lift far enough to remove pressure from the flaps. Each flap 14 a has two pull loops. Pull the loops 16 together to extract the flap 14 a from beneath the filler material or sand 18 . Repeat the process with neighboring cells until all the flaps 14 a are extracted from the vertical side.
[0099] In FIG. 25 , the three photos show the removal of flaps 14 b from the toe portion 20 of the flexible bag or container 10 . Using loops 30 on top of the toe 20 on the sloped side, raise the bag to take pressure off the bottom flaps. Using pull loops 16 , pull the bottom flaps 14 b from the filler materials, continue with adjacent cells until all bottom flaps 14 b are free.
[0100] In FIG. 26 there are the photos which show the process of partially lifting off cells or bags 10 . One would start on one side and lift 8 inches, for example, and then move two cells and repeat. Repeat this procedure until tie in for next line of flexible bag or cell is met. Cut connecting ties and continue 8 inch lifts. Proceed until the entire line has been partially lifted.
[0101] In FIG. 27 there are illustrated two photos showing the bag completely lifted off the cells. After lifting off entire cells one would clean each section, secure hog ring flaps 17 back into place, fold and pack for reuse.
[0102] In FIG. 28 , there is illustrated an undamaged group or chain of flexible bags or containers or cells, ready for reuse while in FIG. 29 there is illustrated the flexible bags or containers being lifted off and readied for storing. Now that the entire bottom has been easily removed, simply lift the flexible bag or container off the filler in sequential stages. The flexible bag or container will be durable and difficult to damage in a preferred embodiment. Wash the flexible bag or container to remove excess dirt, reapply hog rings to bottom and position during fill. Fold and store for next use.
[0103] The following is a list of parts and materials suitable for use in the present invention:
[0000]
PARTS LIST
Number
Description
10
removable and reusable
flexible bag or cell
11
side panel
12
side panel
13
sloping panel
14
bottom portion
14a
bottom panel portion
14b
bottom panel portion
15
back or vertical panel
16
bottom loop
17
ring
18
filler material/sand
19
fabric sleeve
20
toe portion
21
fill opening
22
bottom center opening
23
sidewall sheet
24
sleeve sheet
25
hem
26
fold
27
sew line
28
zigzag sewing
30
toe loop
31
sheet
32
fold
33
sew line
34
sleeve
35
cell wall
36
pallet
[0104] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0105] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method of constructing and a system of utilizing a removable flexible bag or cell by providing a flexible bag or container or cell of the type having sidewalls, a sloping front wall and a vertical rear wall to define a space for holding material, such as sand; forming a bottom, which comprises a pair of panels, each panel extending two feet under the bag when the bag is filled with material; folding each panel back onto itself to end at the nearest edge; securing loops onto the end of each panel, which extend from out of the front and rear of the bag; securing the ends of the bag beneath the bag while the bag is being filled with material; pulling the loops away from the bag to pull the panels from under the bag so that the contents of the bag are exposed to the ground beneath the bag; and lifting the bag upward and way from the material contents of the bag, the material contents to remain in place on the ground upon which it had been set to continue to function as a barrier wall.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 USC§119(e) of U.S. Provisional Patent Application bearing Ser. No. 61/093,924, filed on Sep. 3, 2008, the contents of which are hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates to the field of content access and protection.
BACKGROUND
Electronic piracy includes infringement, illegal copying, and distribution of electronic intellectual property. Music, videos, films, books, etc are vulnerable to electronic piracy. The Internet is one of the favorite tools for pirates. Because of its capacity to store and transfer large volumes of data, the Internet has allowed the illicit copying and dissemination of electronic multimedia content.
Therefore, there is a need for a method of protecting electronic multimedia data in order to reduce or eliminate piracy.
SUMMARY
In accordance with a first broad aspect, there is provided a method for providing an audio signal to a user-end, comprising: modifying an amplitude of at least some bits of the audio signal using at least one user-specific series of bits, thereby obtaining a non-identical copy of the audio signal; transmitting the non-identical copy to the user-end; at the user-end, identifying the at least some bits within the non-identical copy; and restoring the amplitude of the at least some bits using the at least one user-specific series of bits, thereby reconstructing the audio signal.
In accordance with a second broad aspect, there is provided a system for transferring a copy of an audio signal to a user, comprising: a first machine comprising a first memory, a first processor and first communication means, the first processor being adapted to modify an amplitude of at least some bits of the audio signal using at least one user-specific series of bits in order to obtain a non-identical copy of the audio signal; and a second machine comprising a second memory for storing the at least one user-specific series of bits, a second processor and second communication means and being in communication with the first machine, the second processor being adapted to identify the at least some bits within the non-identical copy and to restore the amplitude of the at least some bits using the at least one user-specific series of bits in order to reconstruct the audio signal.
In accordance with a third broad aspect, there is provided a method for downloading an audio signal, comprising: receiving a non-identical copy of the audio signal, the non-identical copy comprising a series of audio signal bits having an amplitude of at least some bits modified using at least one user-specific series of bits; identifying the at least some bits within the non-identical copy; and restoring the amplitude of the at least some bits using the at least one user-specific series of bits, thereby reconstructing the audio signal.
In accordance with a fourth broad aspect, there is provided a digital audio player comprising: communication means adapted to receive a non-identical copy of the audio signal, the non-identical copy comprising a series of audio signal bits having an amplitude of at least some bits modified using at least one user-specific series of bits; a memory for storing the at least one user-specific series of bits; a reconstruction module adapted to reconstruct the audio signal by identifying the at least some bits within the non-identical copy and restoring the amplitude of the at least some bits using the at least one user-specific series of bits; and a digital-to-analog converter adapted to convert the audio signal in an analog signal.
In accordance with a fifth broad aspect, there is provided a method for providing an audio signal to a user, comprising: sampling the audio signal at a user specific sampling rate, thereby obtaining temporally organized bits; removing a temporal organization between the temporally organized bits, thereby obtaining temporally unorganized bits; transmitting the temporally unorganized bits to the user; and reconstructing the audio signal by inserting a user-specific sampling interval between successive ones of the temporally unorganized bits, the user-specific sampling interval corresponding to the user-specific sampling rate.
In accordance with another broad aspect, there is provided a system for transferring an audio signal to a user, comprising: a first machine comprising a first memory, a first processor and first communication means, the first processor being adapted for sampling the audio signal at a user specific sampling rate in order to obtain temporally organized bits and to remove a temporal organization between the temporally organized bits in order to obtain temporally unorganized bits; and a second machine comprising a second memory for storing a user-specific sampling interval, a second processor and second communication means and being in communication with the first machine, the second processor being adapted for reconstructing the audio signal by inserting the user-specific sampling interval between successive ones of the temporally unorganized bits, the user-specific sampling interval corresponding to the user-specific sampling rate.
In accordance with another broad aspect, there is provided a method for downloading an audio signal, comprising: receiving a non-identical copy of the audio signal, the non-identical copy comprising temporally unorganized bits resulting from a sampling of the audio signal using a user specific sampling rate, thereby obtaining temporally organized bits, and from a removal of a temporal organization between the temporally organized bits; and reconstructing the audio signal by inserting a user-specific sampling interval between successive ones of the temporally unorganized bits, the user-specific sampling interval corresponding to the user-specific sampling rate.
In accordance with a further broad aspect, there is provided a digital audio player comprising: communication means adapted to receive a non-identical copy of an audio signal comprising temporally unorganized bits resulting from a sampling of the audio signal using a user specific sampling rate, thereby obtaining temporally organized bits, and from a removal of a temporal organization between the temporally organized bits; a memory for storing a user-specific sampling interval corresponding to the user-specific sampling rate; a reconstruction module adapted to reconstruct a digital reconstructed copy of the audio signal by inserting the user-specific sampling interval between successive ones of the temporally unorganized bits; and a digital-to-analog converter adapted to convert the digital reconstructed copy in an analog audio signal.
The term “master data” refers to data of which a copy is generated and sent to a user. Master data can be any type of data such as text, an audio signal, a video signal, and the like. For example, a master audio signal may be any type of audio signal such as a song, a movie soundtrack, and the like. The master audio signal can be an analog or digital audio signal. A master audio signal can comprise several audio channels. In the case of a song, the master audio file is called a master song.
The term “identical copy” refers to a substantially identical digital copy of the master data. In the case of a master text, the identical copy is an identical copy of the master text. In the case of a master audio or video signal, an identical copy of the master signal is a signal which reproduces the master audio or video signal after being converted into an analog signal. When an identical copy of an audio or video signal is played back, the rendered sound or video corresponds to the sound or video rendered when the master audio or video signal is played back.
In the case of a master audio or video signal, the term “non-identical copy” refers to a digital copy of a master audio or video signal that does not render the same sound or video as the master audio or video signal when it is played back. In the case of a master text, the non-identical copy of the master text is different from the master text.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
FIG. 1 is a flow chart of a method for transmitting a copy of an audio signal to a user, in accordance with an embodiment;
FIG. 2 a illustrates a master audio signal and the imaging process for a first user, in accordance with an embodiment;
FIG. 2 b illustrates the image signal resulting from the imaging process of FIG. 2 a , in accordance with an embodiment;
FIG. 2 c illustrates the reconstruction process of the image signal of FIG. 2 b , in accordance with an embodiment;
FIG. 2 d illustrates an analog signal generated from the reconstructed signal of FIG. 2 c , in accordance with an embodiment;
FIG. 3 a illustrates the master audio signal of FIG. 2 a and the imaging process for a second user, in accordance with an embodiment;
FIG. 3 b illustrates the image signal resulting from the imaging process of FIG. 3 a , in accordance with an embodiment;
FIG. 3 c illustrates the reconstruction process of the image signal of FIG. 3 b , in accordance with an embodiment;
FIG. 4 illustrates an analog signal generated when the reconstruction filter of FIG. 3 c is applied to the image signal 2 a , in accordance with an embodiment;
FIG. 5 illustrates a method for transmitting a copy of a master audio song comprising the modification of the amplitude of bits of the master audio signal for two users, in accordance with an embodiment;
FIG. 6 is a block diagram illustrating a system for transmitting a copy of a master audio signal to a user, in accordance with an embodiment;
FIG. 7 is a block diagram illustrating a digital audio player, in accordance with an embodiment; and
FIG. 8 is a block diagram illustrating a system for transmitting a copy of master data to be displayed, in accordance with an embodiment.
DETAILED DESCRIPTION
FIG. 1 illustrates one embodiment of a method 10 for transferring a copy of a master data. For example, the master data can be a master audio file such as a song. The user who wants to purchase a song, for example, connects to a server of a song retailer via a network such as the Internet, a local area network (LAN), a metropolitan area network (MAN), and the like. The first step of the method 10 is the creation of an image of the master song selected by the user 12 . The image of the master song is created by applying an imaging filter to the master song. The image is a digital non-identical copy of the master song. Information may be missing or altered in the image with respect to the master song. Alternatively, additional information may be added in the image with respect to the master song. As a result, if the image is executed on the user's side, the song is not properly rendered. The imaging filter is user-specific so that two different users have different imaging filters leading to different images of the same master song. As a result, the created image of the master song can only be properly read by the user for which it has been created.
The image of the master song is then sent to the user 14 . The last step of the method 10 is the creation of a reconstructed copy of the master song 16 . The reconstructed copy is obtained by applying a reconstruction filter to the image copy and is an identical digital copy of the master song. During the reconstruction step, the missing information is added to the image in order to obtain the reconstructed copy. Alternatively, the additional information that has been added during the imaging process is suppressed from the image to obtain an identical copy of the master song. The reconstructed copy of the song is finally converted into an analog signal to be listened to by the user.
In one embodiment, the method 10 is used in a pay-per-audition system and the received image of the master song is reconstructed without being stored.
In another embodiment, the method 10 is used in a pay-per-song system, the image copy of the master song is stored on the user's side. Each time the user wants to playback the song, the image copy is reconstructed before being converted into an analog signal.
The set of imaging and reconstruction filters is unique for each user. A particular imaging filter is used to create an image of a master song for a user A and only user A can playback the song since he is provided with a reconstruction filter corresponding to the particular imaging filter. If user B receives user A's image, its reconstruction filter is not adapted to properly reconstruct the master song. As a result, when player B plays back the reconstructed copy based on the image of user A, the resulting sound does not correspond to the initial master song.
While the description refers to the transfer of a copy of a master audio file to a user, it should be understood that the method 10 can be used for transferring any type of master data. For example, the master data can be a text or video signal. At step 12 , a user-specific imaging filter is applied to the master data in order to obtain a non-identical copy of the master data. The non-identical copy of the master data is sent to the user at step 14 and an identical copy of the master data is then reconstructed at the user-end by applying a reconstruction filter to the received non-identical copy of the master data, at step 16 .
In one embodiment where the master data comprises a master audio file, the step of applying an imaging filter comprises sampling the master song, and the imaging filter applies a sampling function to a copy of the master audio file. The imaging sampling function used for the sampling of the master song has a time-varying sampling rate (SR) or frequency. The sampling rate defines the number of samples or bits per second taken from the audio signal of the master song. FIG. 2 a illustrates an embodiment of the sampling process for a first user, namely user A. The audio signal 20 of the master song is represented as a function of time. The audio signal 20 is divided into several time intervals Δt 1 , Δt t , and Δt 3 . The sampling rate applied by the sampling function varies in time and is dependent on the time intervals. The sampling rates SR 1 , SR 2 , and SR 3 are applied within the time intervals Δt 1 , Δt 2 , and Δt 3 , respectively. As result, three series of bits are generated. Successive bits of the first, second, and third series are temporally spaced apart by a sampling interval T 1 , T 2 , and T 3 , respectively. The next step consists in removing the temporal relation between successive bits in each of the three series of bits in order to obtain a non-identical copy of the master song. FIG. 2 b illustrates the resulting image 22 of the master song signal for user A. The image is a series of bits of different amplitude and having no time interrelation or organization. The image is just a series of numbers corresponding to the amplitude of the sampling points or bits. It should be understood that the expression “no time interrelation” may also mean that the bits of the image 22 can be equally spaced in time.
While the audio signal 20 is split into three segments corresponding to the three time intervals Δt 1 , Δt 2 , and Δt 2 , it should be understood that the number of segments may be lower or greater as long as the audio signal 20 is divided into at least two segments corresponding to two time intervals. It should also be understood that the sampling function applies a different sampling rate to at least two segments of the audio signal 20 .
In one embodiment, the time intervals Δt 1 , Δt 2 , and Δt 3 have a constant duration. Alternatively, they can have varying durations. For example, Δt 1 and Δt 2 may have the same duration while Δt 3 may be longer than Δt 1 and Δt 2 . The combination of a particular sampling rate with a time interval duration defines a number of sampling points or bits n. For example, the association of the time interval Δt 1 with its corresponding sampling rate SR 1 defines five sampling points n, while the association of the time interval Δt 3 with its corresponding sampling rate SR 3 defines four sampling points n. The imaging filter can be represented as: {Δt 1 , SR 1 }, {Δt 2 , SR 2 }, {Δt 3 , SR 3 }. Alternatively, the imaging filter can be represented by pairs of sampling points and sampling rates {n 1 , SR 1 }, {n 2 , SR 2 }, {n 3 , SR 3 }, respectively. If the duration of the time intervals is constant, then the imaging filter can be represented as: SR 1 , SR 2 , SR 3 .
The image 22 is then sent to user A which is provided with an appropriate reconstruction filter. The reconstruction filter is represented by a series of sampling intervals T 1 , T 2 , and T 3 associated with a corresponding sampling point number n 1 , n 2 , and n 3 , or with a corresponding time interval Δt 1 , Δt 2 , and Δt a . Referring to the previous example, the reconstruction filter corresponding to the imaging filter used to create the image 22 can be represented by the following pairs of sampling rates and sampling point numbers: {T 1 , n 1 }, {T 2 , n 2 }, {T 3 , n 3 }. The sampling intervals T 1 , T 2 , and T 3 correspond to the sampling rates SR 1 , SR 2 , and SR 3 used in the imaging process. For example, T 1 =1/SR 1 . The sampling interval T 1 is applied to the first n 1 points or bits of the received image 22 , the sampling interval T 2 is applied to the points (n 1 +1) to (n 1 +n 2 ) of the image 22 , and the sampling interval T 3 is applied to the points (n 1 +n 2 +1) to (n 1 +n 2 +n 3 ). Alternatively, the reconstruction filter is represented by the following pairs of sampling intervals and time intervals: {T 1 , Δt 1 }, {T 2 , Δt 2 }, {T 3 , Δt 3 }. The bit numbers n 1 , n 2 , and n 3 are then determined using the sampling intervals T 1 , T 2 , and T 3 and their corresponding time intervals Δt 1 , Δt 2 , and Δt 3 . For example, n 1 =abs(Δt 1 /T 1 ). By inserting the appropriate sampling interval T 1 , T 2 , T 3 between successive bits of the received image, a reconstructed copy 24 of the master song signal is obtained as illustrated in FIG. 2 c . The reconstructed copy is a substantially identical copy of the master song. The reconstructed signal 24 is then converted into an analog signal 26 in order to play back the song. It should be understood that any method known to a person skilled in the art to convert a digital signal into an analog signal may be used.
In one embodiment, the bit numbers n 1 , n 2 , and n 3 and/or the time intervals Δt 1 , Δt 2 , and Δt 3 are predetermined. In this case, only the temporally unrelated or unorganized bits of the image 22 are sent to the user.
In another embodiment, the bit numbers n 1 , n 2 , and n 3 and/or the time intervals Δt 1 , Δt 2 , and Δt 3 are determined during the generation of the image 22 . In this case, the bit numbers n 1 , n 2 , and n 3 or the time intervals Δt 1 , Δt t , and Δt 3 are sent to the user in addition to the image 22 .
In one embodiment, the pairs {Δt 1 , SR 1 }, {Δt 2 , SR 2 }, and {Δt 3 , SR 3 } of the imaging filter are chosen so that the number of sampling points per time interval is constant: n 1 =n 2 =n 3 . In this case, the reconstruction filter can be represented by the constant number of sampling points and the series of sampling intervals: n 1 , T 1 , T 2 , T 3 .
In another embodiment, the pairs {n 1 , SR 1 }, {n 2 , SR 2 }, and {n 3 , SR 3 } are chosen so that the time intervals are constant: Δt 1 =Δt 2 =Δt 3 . In this case, the reconstruction filter can be represented by the constant time interval and the series of sampling rates: Δt 1 , SR 1 , SR 2 , SR 3 .
While the description refers to a sampling function which applies three user-specific sampling rates to different portions of the audio signal, it should be understood that the number of user-specific sampling rates contained in the sampling function may vary. For example, the sampling function may apply a single user-specific sampling rate to the whole audio signal. In this case, the reconstruction function inserts a single user-specific sampling interval between successive bits of the non-identical copy.
FIG. 3 a illustrates the sampling process of the master song for a second user, namely user B. User B is provided with an imaging filter and a reconstruction filter which are both different from those of user A. The imaging filter for user B can be represented as: {Δt 1 ′, SR 1 ′}, {Δt 2 ′, SR 2 ′}, {Δt 3 ′, SR 3 ′}. The series of bits 30 illustrated in FIG. 3 b is the image of the master song signal 20 for user B. The image 30 is then sent to user B. In order to play back the song, the image 30 is first reconstructed. This is done by applying the reconstruction filter to the received image 30 of the master song. User B reconstruction filter can be expressed as {T 1 ′, n 1 }, {T 2 ′, n 2 ′}, {T 3 ′, n 3 ′}, or {T 1 ′, Δt 1 ′}, {T 2 ′, Δt 2 ′}, {T 3 ′, Δt 3 ′}. The time intervals T 1 ′, T 2 ′, and T 3 ′ correspond to the sampling rates SR 1 ′, SR 2 ′, and SR 3 ′, respectively. T 1 ′ is the time interval to be applied between two following bits of the first n 1 ′ bits of the image 30 . T 2 ′ is the time interval to be applied between two following bits for the bits (n 1 ′+1) to (n 1 ′+n 2 ′) of the image 30 , etc. Spacing the bits of the image 30 with respect to the time intervals T 1 ′, T 2 ′, and T 3 ′ results in the reconstructed signal 32 illustrated in FIG. 3 c . The reconstructed signal 32 is a correct digital copy of the master song signal 20 . The analog signal 26 is then obtained by converting the reconstructed signal 32 into an analog signal.
While being images of the same master song signal, the received images 22 and 30 are different. If he receives the image 22 , user B will not be able to properly reconstruct the master song. FIG. 4 illustrates the analog signal 34 obtained when the reconstruction filter of user B is applied to the image 22 created for user A. The analog signal 34 is different from the target analog signal 26 and the sound rendered when the analog signal 34 is played back does not correspond to the master song.
While FIGS. 2 a - 4 illustrate a method for providing a user with a copy of a master song, it should be understood that the method can be used for transferring a copy of other type of master data. For example, the method can be used for transferring a copy of a master video to a user. In this case, the sampling rate defines the number of frames per second taken from the video signal. The image generated by applying the sampling function to the master video signal is a series of frames having no time interrelation or being equally spaced in time. The reconstruction filter temporally reorganizes the frames by applying an adequate time interval between two successive frames in order to obtain an identical copy of the master video. The identical copy is then rendered and the resulting video substantially appears the same as the master video to the user.
In one embodiment, the master signal is a video comprising an audio signal such as a movie soundtrack. In this case, a non-identical digital copy of the video signal and/or the audio signal of the video may be generated by applying a sampling function to the video signal and/or the audio signal. The sampling function applies different sampling rates to different segments of the video signal and/or audio signal. The video signal and/or the audio signal are then reconstructed on the user side by a applying a corresponding reconstruction sampling function to the video signal and/or the audio signal.
In one embodiment, the video signal comprises at least two video signal components. In this case, a sampling function is applied to at least one of the video signal components. For example, the master video signal may be an RGB (red-green-blue) signal which comprises three video components, i.e. a red video component, a green video component, and a blue video component. A sampling function is then applied to at least one of the three video components.
In one embodiment where the master data comprises a master song, the step of applying an imaging filter comprises creating a digital copy of the master song signal and changing the signal of the digital copy. FIG. 5 illustrates an embodiment of the method in which information is added to a copy of a master song before being sent to a user. Users A and B want to purchase an electronic copy of a same master song 100 . The first step consists in creating an identical copy 201 , 301 for users A and B, respectively, and then in applying an imaging filter 202 , 302 , to the copies 201 , 301 , respectively. The imaging filters 202 , 302 are user-specific so a particular imaging filter corresponds to a unique user. The imaging filters 202 , 302 add a digital signal to the copies 201 , 301 , respectively. Concerning user A, the imaging filter 202 adds a single segment of data 205 a to the digital copy 201 at a specific time location within the copy 201 . The imaging filter 302 of user B adds two segments of data 305 a and 305 b to the digital copy 301 at specific time locations within the copy 301 . The filtering process of the copies 201 , 301 results in signals 206 , 306 , respectively. The amplitude of the bits of the digital signals 206 , 306 corresponds to the sum of the amplitude of the bits of the copies 201 , 301 and the amplitude of bits of the segments 205 a , 305 a , 305 b , respectively. The digital signals 206 , 306 are then sent to users A and B, respectively.
User A is provided with a database 205 of digital signal segments 205 a to 205 f and user B is provided with a database 305 of digital signal segments 305 a to 305 d . After receiving the images 206 and 306 , users A and B filter these images to reconstruct the master song signal. This is done by applying a reconstruction filter to the images 206 and 306 . This filtering process consists in removing the digital segment of data 205 a from the image signal 206 and the digital segments of data 305 a , 305 b from the received image 306 . The digital segments of data 205 a , 305 a , 305 b are the segments that were previously added during the imaging process, and they are removed from the images 206 , 306 at the exact same time locations where they were previously added. The amplitude of the bits of the segments 205 a , and 305 a , 305 b is subtracted from the amplitude of the bits of images 206 , 306 , respectively. This results in signals 208 , 308 which are identical copies of the master song 201 , for both users A and B. The digital signals 208 , 308 are then converted into analog signals 209 , 309 , respectively, in order to play back the song.
It should be understood that the imaging filter adds at least one segment of data 205 a , 305 a , 305 b to the identical copy 201 , 301 of the master song 100 and that a segment of data 205 a , 305 a , 305 b is a signal comprising at least one bit. When a segment of data comprises more than one bit, the amplitude of the bits may be identical. Alternatively, the amplitude of the bits may vary from one bit to another in the segment of data.
In one embodiment, during the imaging process, user specific segments are added in a defined order and at defined locations within the copy of the master song. The defined order and location are information contained in the reconstruction filter so that the reconstruction filter removes the appropriate digital segments at the appropriate location within the received image signal. In this case, the imaging process always adds the same segments at the same location independently of the song master.
In another embodiment, the segments and/or the location where they are added may vary. For example, when user A purchases a first song, segment 205 a may be added at a first specific location. When user A purchases a second song, segments 205 c and e may be added to the copy of the master song at other different locations within the copy. In this case, an identification of the added segments and their respective time locations is sent to user A in addition to the image 206 of the master song. For example, user A may receive the following information in addition to signal 206 representing the image of the first song: segment 1 , time 1 . In the case of the second song, user A may receive the following information: segment 3 , time 2 , segment 5 , time 6 . As users are provided with different databases of digital segments, segment 1 corresponds to segment 205 a in the case of user A but corresponds to a different segment in the case of a different user. As a result, if he receives the image 206 and the respective identification information, user B would not be able to reproduce an identical copy of the master song as his segment 1 does not correspond to segment 205 a.
While the above description refers to the addition of digital segments of data to particular portions of the copy 201 , 301 of a master song 100 , it should be understood that some or all of the bits of the copy 201 , 301 may be altered in different ways during the imaging process. For example, segments of data may be subtracted during the imaging process and subsequently added during the reconstruction process. Alternatively, the amplitude of some bits may be increased while the amplitude of other bits may be reduced during the imaging process.
In one embodiment where segments of data are subtracted from the copy 201 , 301 of the master song 100 , the amplitude of bits in at least one segment of the copy 201 , 301 is reduced while ensuring that none of the altered bits has an amplitude equal to zero in the non-identical copy of the master song. This ensures that a particular user will not be capable to retrieve the correct amplitude of the zero amplitude bits in this non-identical copy from the non-identical copy of another user. This can be achieved by selecting the segments of data to be removed from the copy 201 , 301 in accordance with the copy 201 , 301 .
The alteration of the amplitude of bits may be continuous along the signal 201 , 301 or segments of the signal 201 , 301 . Alternatively, the amplitude alteration may be localized at specific time locations within the signal 201 , 301 .
While FIG. 5 illustrates a method for transferring an identical copy of an audio signal to a user, it should be understood that the method can be used for transferring a copy of any master data. In one embodiment, the master data is a text. In this case, the segments of data to be added or removed to an identical copy of the master text comprise words.
In one embodiment, words are added to the identical copy of the master text at user-specific locations within the text in accordance with a user-specific imaging filter in order to obtain a non-identical copy of the master text. The user-specific filter comprises specific locations at which words are to be added within the text. The non-identical copy is sent to the user. An identical copy of the master text is generated by removing words in accordance with a user-specific reconstruction filter to the received non-identical copy. The reconstruction filter contains the user-specific locations at which words are to be removed from the non-identical copy.
In another embodiment, words are removed from the identical copy of the master text at specific locations within the text in order to obtain a non-identical copy of the master text. The words to be removed are selected in accordance with the master text and a user-specific library of words. The non-identical copy of the master text is sent to the user in addition to an identification of the removed words and the specific locations from which words have been removed. It should be understood that the specific locations may also be the specific locations at which the words are to be inserted in the reconstruction process. Using the identification of the removed words, the words to be inserted are retrieved from the user-specific library and inserted into the non-identical copy at the received specific locations in order to obtain an identical copy of the master text.
In another embodiment, the master data is a master video. In this case, the segments of data comprises images which are added or removed from specific frames of a digital copy of the master video. The master video may be a movie, an animation, or the like. Each user is provided with a user-specific database of images. During the imaging step, user-specific images are added or removed from specific frames of an identical digital copy of the master video in order to obtain a non-identical digital copy of the master video. The non-identical copy is then sent to the user.
In one embodiment, the images to be added/removed and the locations at which they are added/removed are fixed and predetermined. In this case, only the non-identical copy of the master video is sent to the user.
In another embodiment, the images and/or the locations at which they are added/removed may vary. In this case, an identification of the added/removed images and/or the locations at which they have been added/removed is sent to the user in addition to the non-identical copy of the master video. The location may be a time reference or a frame number.
It should be understood that a non-identical copy of a master video can be a digital copy of the master video in which some images have been removed from some frames and other images have been added to other frames.
In one embodiment, the video signal comprises at least two video signal components. In this case, images are added and/or removed from at least one of the video signal components. For example, the master video signal may be an RGB (red-green-blue) signal which comprises three video components, i.e. a red video component, a green video component, and a blue video component. Images are then added or removed from the frames of at least one of the three video components.
It should be understood that the methods illustrated above may be executed by at least two machines, each being provided with a processor, a memory and communication means. The processor of a first machine is configured to create the non-identical copy of the master data by applying an imaging filter to the master data and the processor of the second machine is configured to reconstruct an identical copy of the master data by applying a reconstruction filter to the non-identical copy of the master data. The two machines are connected together so that the non-identical image can be sent from the first machine to the second machine. The two machines may be connected together via a network such as the Internet, a LAN, a MAN, or the like.
FIG. 6 illustrates one embodiment of a system 100 for transferring a copy of a master audio file to a user. The system 100 comprises a server 102 in communication with a digital audio player 104 . The server 102 is provided with a memory 106 and an imaging module 108 . The player 104 is provided with a memory 110 , a reconstruction module 112 and a digital-to-analog converter (DAC) 114 .
A user provided with the player 104 connects to the server 102 via a network such as the Internet in order to purchase an audio file such as a song, for example. The user selects a desired song amongst a selection of available master songs stored in the memory 106 of the server 102 . Once the user has chosen the master song of which he wants a copy, the imaging module 108 accesses the memory 106 in order to create an image of the master song.
In one embodiment, the user is provided with an identification (ID) which is used to connect to the server 102 . The information relative to the imaging filters for all users is stored in memory 106 . The user ID is used to determine which imaging filter corresponds to the user and should be applied during the creation of the image of the master song by the imaging module 108 .
In another embodiment, the user connects to the server and the server communicates with the user player 104 . The server 102 accesses the player memory 110 or the reconstruction module 112 , in which information relative to the reconstruction filter is stored. The server determines the imaging filter to be applied by the imaging module 108 according to the information relative to the reconstruction filter stored on the player 104 .
Once the server 102 has determined which imaging filter should be used for the particular user, the imaging module 108 generates an image of the selected master song. The image is a non-identical digital copy of the master song. In one embodiment, the imaging module samples the master song with a sampling function of which the sampling rate is time-varying, in accordance with the method described above. The image of the master song outputted by the imaging module 108 comprises a series of bits having a varying amplitude and having no temporal organization. In other words, the image is a series of amplitude numbers being independent of time. In another embodiment, the imaging module 108 generates a non-identical digital copy of the master song in which the amplitude of at least some bits is different from the amplitude of the bits of an identical copy of the master song, in accordance with the method described above.
The image of the master song generated by the imaging module 108 is then sent to the player 104 . In one embodiment, the received image is stored in the memory 110 . When the user wants to play back the song, the reconstruction module 112 accesses the memory 110 to retrieve the corresponding image of the master song. The reconstruction module 112 then applies a reconstruction filter to the image in order to generate an identical digital copy of the master song. This identical digital copy is then converted into an analog signal by the DAC 114 , which is sent to a speaker.
In an embodiment in which the imaging module 108 has sampled the master song with a time-varying sample rate, the reconstruction module 112 determines the time interval T to be inserted between two following bits of the received image according the method described above.
In one embodiment where it applies a time-varying sampling rate, the imaging module 108 is adapted to select the number and/or duration of the sampling intervals Δt corresponding to a particular sampling rate. In this case, the imaging module 108 is adapted to send the durations of the different time intervals or the number of bits contained in each time interval Δt, in addition to the non-identical copy. The reconstruction module 112 is adapted to generate a reconstructed copy of the master song using the non-identical copy and the duration of the time intervals or the number of bits for each time interval.
In one embodiment where the received image generated by the imaging module 108 is a copy of the master song in which the amplitude of some bits has been changed, the reconstruction module 112 identifies the bits of which the amplitude has been changed and adjusts the amplitude of these bits in order to generate a digital copy representative of the master song, according to the method described above. In this case, a library of digital audio segments used for the reconstruction may be stored in the memory 110 , and the imaging module 108 may access this library and generate the imaging filter according to the segments stored in the memory 110 . In one embodiment, the digital audio segments are parts of songs stored in the memory 110 .
In one embodiment where it is adapted to modify the amplitude of bits, the imaging module 108 is adapted to select particular segments of data to be used in the generation of the non-identical copy of the master song, and to send an identification of the selected segments of data. The reconstruction module 112 is adapted to retrieve the particular segments of data from the user-specific library or database of segments of data using the received identification.
In the same or an alternate embodiment, the imaging module 108 is adapted select the particular locations at which the segments of data are added/removed, and to send the particular locations to the reconstruction module 112 . The reconstruction module 112 is adapted to generate the reconstructed copy using the received locations in order to generate a substantially identical copy of the master song.
In one embodiment of the player 104 , the reconstruction module 112 is integrated into the DAC 114 and the server may identify a user using information relative to the DAC 114 .
FIG. 7 illustrates one embodiment of a digital audio player 150 in which a DAC 152 performs the reconstruction step in addition to the digital-to-analog conversion. The digital audio player 150 receives an image 154 of a master audio file which comprises an image 156 , 158 , 160 of three master audio tracks in addition to an event track 162 . Each image 156 , 158 , 160 is an image of a master audio track to which audio segments have been added. The event track 162 is a file which comprises the identification of the added audio segments and their temporal location, for each audio track 156 , 158 , 160 . The digital audio player 150 receives the image 154 and stores it into a memory 164 . When a user of the digital audio player 150 wants to listen to the song, the DAC 152 accesses the image 154 of the master audio file stored into the memory 164 . The DAC 152 comprises an internal memory in which audio segments are stored. The DAC 152 creates an identical copy of the master audio file by applying a reconstruction filter to the image 154 The reconstruction filter is generated using the event track 162 and the audio segments stored in the internal memory. Then the DAC 152 converts the identical copy into an analog signal which is sent to a speaker. The DAC 152 can be a sound card which receives the image of the master audio file and outputs the analog signal. The reconstruction step is the last step performed before the digital-to-analog conversion. Having the steps of reconstruction and digital-to-analog conversion performed by a same module, such as a DAC or a sound card, prevents a hacker from intercepting the reconstructed digital copy of the master audio file.
The master audio file may comprise several audio channels and a copy of each audio channels is sent to the user. Each audio channel may be associated with a different pair of imaging and reconstruction filters. Alternatively, the same imaging and reconstruction filters are applied to all of the channels.
It should be understood that the player 104 can be any digital audio player such as a home stereo, a car stereo, a personal computer, a portable digital audio player, and the like.
In one embodiment, a user owns several digital audio player 104 . In order to be able to play back a song on all of its players, these players are all provided with a reconstruction module which applies the same reconstruction filter. The reconstruction filter is user specific independently of the user's player on which the reconstruction filter is used.
While the description refers to a master song, it should be understood that the above illustrated methods and apparatus may be used to transfer an image of any master audio file. The image can be in any digital audio format.
FIG. 8 illustrates one embodiment of a system 200 for transferring a copy of master data to a user. The system 200 comprises a server 202 in communication with a digital decoder 204 connected to a display 214 . The server 202 is provided with a memory 206 and an imaging module 208 . The digital content access and protection (CAP) device 204 is provided with a memory 210 and a reconstruction module 212 .
A user provided with the CAP device 204 connects to the server 202 via a network such as the Internet in order to download a copy of master data. The user selects the desired data amongst a selection of available master data stored in the memory 206 of the server 202 . Once the user has selected the master data of his choice, the imaging module 208 accesses the memory 206 in order to create a non-identical digital image of the master data. The non-identical image of the master data are sent to the CAP device 204 and stored into memory 210 . The reconstruction module 212 accesses the non-identical copy from the memory 210 and generates an identical digital copy of the master data, which is sent to the display 214 .
While, in FIG. 8 , the display 214 is separate from the digital CAP device 204 , it should be understood that the display 214 may be integral with the digital CAP device 204 .
In one embodiment, the system 200 is adapted to transfer a copy of a master text from the server 202 to the CAP device 204 . Master texts are stored into the memory 206 of the server. Upon selection of a particular master text by the user of the CAP device 204 and identification of the user, the imaging module 208 generates a non-identical copy of the selected master text by adding and/or removing words at user-specific locations within an identical copy of the master text, in accordance with the method described above. The imaging module 208 is adapted to send the generated non-identical copy of the selected text in addition to an identification of the inserted words.
In one embodiment where words are removed from the identical copy of the master text, the user is provided with a user-specific library of words and the imaging module 208 is adapted to remove words from the identical copy in accordance with the user-specific library. A copy of the user-specific library may be stored in the memory 206 . Alternatively, the server 202 accesses the user-specific library stored in the memory 210 in order to select words to be removed from the identical copy of the master text. The imaging module is adapted to send, to the CAP device 204 , an identification of the removed words, such as word 23 , word 12 , word 78 , etc, and their corresponding location from which they have been removed. The reconstruction module 212 is adapted to retrieve the removed words from the library stored in the memory 210 using the received identification and to insert these words in the non-identical copy in order to obtain an identical copy of the master text. The identical copy is then displayed on the display 214 . It should be understood that only the non-identical copies of master texts are stored in the memory 210 of the CAP device 204 . Each time the user wants to read a text, the reconstruction module 212 generates an identical copy of the corresponding text and displays it on the display 214 .
In one embodiment, the system 200 is adapted to transfer a video from the server 202 to the digital CAP device 204 . Videos are stored into the memory 206 of the server. Upon selection of a particular master video by the user of the CAP device 204 and identification of the user, the imaging module 208 generates a digital non-identical copy of the selected video in accordance with the method described above.
In one embodiment, the imaging module 208 is adapted to apply a user-specific imaging sampling function to the master video in order to generate a non-identical copy of the master video in accordance with the method illustrated above. The non-identical copy comprises a series of frames having no time organization or being equally spaced in time. The non-identical copy is then sent to the digital CAP device 204 and stored into memory 210 . Each time the user wants to display the video, the reconstruction module 212 reorganizes the frames of the received non-identical copy by applying an adequate time interval between two successive frames in accordance with a user-specific reconstruction filter stored into the memory 210 . The reconstructed video is a substantially identical copy of the master video. The identical copy is then rendered and displayed to the user via the display 214 .
In one embodiment, the imaging module 208 is adapted to select the particular duration of the portions of video to which a particular sampling rate is to be applied. In this case, the imaging module 208 sends the durations of the portions of the video to the CAP device 204 . The duration of the different portions of the video may be represented by a time interval Δt or a number of frames.
In another embodiment, a user-specific library or database of images is stored in the memory 210 of the CAP device. The imaging module 208 is adapted to add/remove images to specific frames of an identical digital copy of the master video in accordance with the user-specific library of images in order to obtain a non-identical digital copy of the master video. A copy of the user-specific library may be stored in the memory 206 of the server 202 . Alternatively, the server is adapted to access the memory 210 of the CAP device 204 in order obtain the images to be added/removed for the specific user. The non-identical copy is sent to the digital CAP device 204 and stored in the memory 210 . The imaging module 208 can be adapted to add/remove images to the same frames. Alternatively, the imaging module 208 can be adapted to select particular frames to which images are to be added/removed. In this case, the imaging module 208 is adapted to send an identification of the frames of which the content has been changed in addition to the non-identical copy. The reconstruction module 212 is adapted to reconstruct a substantially identical image of the master video in accordance with the method illustrated above. Each time the user wants to display the video, the reconstruction module 212 identifies the frames of which content has been changed and retrieves the corresponding non-identical copy of the video and the corresponding images from the database of images stored in the memory 210 and generates a substantially identical copy of the master video. The identical copy is then rendered and displayed on the display 214 .
In one embodiment, the display 214 is a digital display connected to the digital CAP device 204 via any digital connection such as a Digital Visual Interface (DVI) connection, a High-Definition Multimedia Interface (HDMI) connection, or the like.
In another embodiment, the display 214 is a non-digital display and the reconstructed video converted into an analog signal before being sent to the display 214 . In this case, a digital-to-analog converter can be inserted between the digital CAP device 204 and the display 214 . Alternatively, the reconstruction module 212 can be adapted to convert the reconstructed video into an analog signal.
In one embodiment where segments of data are removed and/or added, because the data segments used to modify the master data are not sent to the user, the possibility of hacking is reduced. A hacker who would intercept the data sent to the user would only have the non-identical copy of the data and the identification of the data segments used to modify the data. Since the data segments used to modify the master data are specific to the library of data segments of the user for which the non-identical copy is intended, the hacker cannot retrieve the appropriate data segments from another library of data segments. Because the reconstructed copy of the master data is simply played back upon request of the user and not stored in memory, the identical copy of the master data cannot be distributed to other users.
In one embodiment, the division of a copy of master data to be sampled and/or the selection of segments of data to be added/removed to the copy of the master data is chosen in accordance with properties of the master data. Alternatively, the division of the copy of the master data to be sampled and/or the selection of the segments of data to be added/removed is predetermined or performed randomly.
In one embodiment, the non-identical copy of the master data is temporarily stored into memory so that the user may have access to a reconstructed and identical copy of the master data a predetermined number times. This allows for pay-per-audition and pay-per-view systems.
In one embodiment, no encryption and subsequent decryption of the data transferred from the server to the user device are required. The non-identical copy of the master data is simply reconstructed and played back at the user's end.
In one embodiment, the non-identical copy of the master data is compressed before being transmitted to the user-end, and subsequently decompressed at the user-end before reconstruction of a substantially identical copy of the master data. For example, the server can be adapted to compress a non-identical copy of an audio or video signal and to transmit the compressed non-identical copy to a user device. The user device is adapted to decompress the received non-identical copy of the audio or video signal. The user device subsequently reconstructs a substantially identical copy of the audio or video signal after decompression of the received non-identical copy. In another embodiment, the non-identical copy of the master data is sent without any compression step at the server-end.
It should be understood that the present methods, apparatuses and systems can be used in any content access and protection systems. It should be noted that the embodiments of the invention described above are intended to be exemplary only. The present invention can be carried out as a method, can be embodied in a system and/or an apparatus. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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There is described a method for providing an audio signal to a user-end, comprising: modifying an amplitude of at least some bits of the audio signal using at least one user-specific series of bits, thereby obtaining a non-identical copy of the audio signal; transmitting the non-identical copy to the user-end; at the user-end, identifying the at least some bits within the non-identical copy; and restoring the amplitude of the at least some bits using the at least one user-specific series of bits, thereby reconstructing the audio signal.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 USC 119 to German Patent Application No. 10 2010 007 642.2, filed on Feb. 5, 2010, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a drive arrangement for an electric vehicle.
2. Description of the Related Art
DE 296 11 867 U1 discloses a chassis for a utility vehicle with a portal axle and a wheel rotatably mounted at each of the two ends of the portal axle. Each wheel is driven by an electric traction motor installed in the portal axle. This portal axle is a rigid axle that is relatively heavy and provides only a low level of comfort.
The object of the invention is to improve the generic portal axle and to increase the level of comfort.
SUMMARY OF THE INVENTION
The invention relates to a drive arrangement for an electric vehicle. The drive arrangement is an axle drive device that has two electric machines combined with a respectively assigned transmission in an electric axle to drive individually suspended wheels of the axle by means of, in each case, one articulated shaft flange via a respective articulated shaft. Additionally, two frequency converters are assigned to the respective electric machines and are combined in a converter unit. Thus, a drive unit for an electric vehicle is formed in an easy way by integrating the two electric machines and the respectively assigned transmissions in a common unit that defines the electric axle. The guidance of the wheel is not influenced by the weight of the drive unit due to the separation of the drive unit from a wheel-guiding unit. The chassis, in particular the individual wheel suspension of the wheels therefore can be adopted from a conventional vehicle. Frequency converters are necessary for operating the respective electric machine. However, in accordance with the invention, the frequency converters are combined in a converter unit. This minimizes the number of necessary components and permits a reduction in the high voltage lines used.
The invention will now be presented in more detail on the basis of a drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top perspective view of a drive arrangement according to the invention.
FIG. 2 is a schematic plan view of the drive arrangement of FIG. 1 .
FIG. 3 is a schematic side view of the drive arrangement of FIGS. 1 and 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A vehicle 1 in accordance with the invention includes an electric axle 10 , a converter unit 20 and an electric energy store 30 , as illustrated in FIGS. 1 to 3 . The electric axle 10 illustrated in this embodiment is a rear axle of an electric vehicle. The electric axle 10 comprises two electric machines 11 that are arranged coaxially in a common housing. The electric machines 11 preferably are permanently excited synchronous machines to ensure that they can be actuated effectively. Each electric machine 11 drives a respective articulated shaft flange 13 via an associated transmission 12 , which comprises a spur gear stage. The articulated shaft flange 13 is provided for connection to an individually suspended wheel 2 via an articulated shaft 13 a . A wheel-guiding unit of the individually suspended wheel 2 comprises, for example, conventional front-axle crossmembers, front-axle crosslinks and vibration-damped McPherson strut axles. This produces an electric portal axle with a high level of comfort in an electric vehicle.
The electric axle 10 also comprises a cooling device so that a coolant, such as water, is fed in via a feed line 15 a , and the heated coolant is discharged again via a discharge line 15 b.
The electric axle 10 with the two coaxially arranged electric machines 11 is integrated directly into the rear axle of the electric vehicle in this embodiment. The housing of the electric axle 10 is screwed, for example, to longitudinal members or crossmembers of the electric vehicle. The low center of gravity as a result of the installation position, i.e. the portal arrangement owing to the spur gear stage around which the respective transmission 12 engages, is highly advantageous for the movement dynamics. Each electric machine 11 drives an associated wheel 2 . In this embodiment, the electric power of an electric machine 11 is 60 kilowatts and gives rise to a maximum drive torque of 80 Newton meters. Each electric machine 11 also has a position sensor that determines the precise position of the rotor for optimum operation. Each electric machine 11 is supplied with a suitable alternating current via terminals 14 on the electric axle 10 .
The forces are transmitted from each electric machine 11 to a respective wheel 2 via, in each case, a hydraulic multi-disk clutch (not illustrated) that permits precise transmission of force. The multi-disk clutches are closed permanently and are controlled automatically. For safety reasons a multi-disk clutch has to be opened by the driver by means of an operator control to decouple a respective electric machine 11 from a respective wheel 2 . A fixed transmission reduction of the respective transmission 12 reduces the high output rotational speed of the respective electric machine 11 and transmits the torques to a wheel 2 via the respective articulated shaft flanges 13 and the articulated shafts 13 a.
The converter unit 20 comprises an electronic power unit that comprises frequency converters (AC/DC transformers) for the two respective electric machines 11 of the portal axle 10 to regulate the currents for the respective electric machines 11 . The frequency converters convert the alternating current of the electric machine 11 into the direct current of the electric energy store 30 . The electric energy store 30 preferably is a high voltage battery, such as a lithium ion battery.
The portal axle 10 and the converter unit 20 have a low-temperature water cooling circuit. Cooling ducts for the cooling circuit are accommodated in the housing of the portal axle and have a feed line 15 a and a discharge line 15 b.
The electric currents are conducted via special high-voltage cables between the electric axle 10 , the converter unit 20 and the electric store 30 .
The essential components of the drive arrangement, specifically the electric axle 10 , the converter unit 20 and the electric energy store 30 , are arranged in an optimum way in the electric vehicle. In this context, to make available a necessary quantity of energy for the electric vehicle, a relatively large and relatively heavy electric energy store 30 is necessary, for example 350 kg. In view of this weight, the electric energy store 30 is arranged near the center of gravity of the electric vehicle. It is therefore located in the central region of the electric vehicle, between the two axles. In view of the large volume, the electric energy store 30 is arranged in the rear part of the central region of the electric vehicle and specifically behind the driver's space or the driver's cab. In particular in sports vehicles, corresponding installation space is available in this region in sports cars.
The electric energy store 30 is arranged in front of the rear axle when viewed in the direction of travel. Thus, good protection is provided in the case of a rear-end crash of the electric vehicle. The greater part of the crash energy is absorbed by the chassis or the crossmember of the rear axle and the electric energy store 30 therefore is protected effectively against damage. The electric energy store 30 is not wider than the distance between the longitudinal carriers of the electric vehicle. Hence, the electric energy store 30 also is protected well in the event of a side impact of the electric vehicle. In this case, the longitudinal carriers absorb the corresponding forces. The front part of the electric vehicle, with the crossmember of the front axle, forms a reliable protection of the electric energy store 30 against damage in the event of a head-on crash.
A high-performance electric vehicle is obtained due to the above-described optimization of the weight distribution. The electric energy store 30 is by far the heaviest component of the drive arrangement, and is arranged near the center of gravity of the electric vehicle. Thus, agile handling and good freedom of the electric vehicle from twisting are obtained. Furthermore, the arrangement permits the use of an individual compact electric energy store 30 . This provides advantages in terms of cooling and cabling.
The converter unit 20 also is arranged in the rear region of the electric vehicle. Thus, the necessary cabling between the converter unit 20 , the portal axle 10 and the electric energy store 30 is minimized. The converter unit 20 is arranged as low as possible for further optimizing weight distribution. Such a space preferably is behind the electric axle 10 when viewed in the direction of travel. The converter unit 20 comprises both frequency converters. Thus, just a single high-voltage cable is necessary between the electric energy store 30 , arranged in front of the electric axle 10 , and the converter unit 20 . This high-voltage cable permits direct current to flow between the converter unit 20 and the electric energy store 30 . The converter unit 20 then converts the direct current into two alternating currents that are suitable for the respective electric machines 11 . The converter unit 20 is positioned so that its electrical terminals for the alternating current which is made available by a respective frequency converter are positioned near to the terminals 14 of the electric axle to reduce the required cables even more.
The arrangement of the components therefore permits an ideal combination between crash safety and performance. All components are positioned precisely in a way so that the center of gravity is as low as possible and the required high-voltage cabling is as short as possible. Minimizing the high-voltage cabling results in a further reduction in weight and improved efficiency of the drive arrangement.
The electric energy store 30 is accessed in the region of the underfloor of the electric vehicle. This permits improved integration of the components of the drive arrangement into the electric vehicle, for example underneath the vehicle body components, as well as a more pleasing design.
A further improvement through increased use of identical components is obtained if the second axle of the electric vehicle also is provided as an electric axle 11 . In particular, two identical electric portal axles, each with an assigned identical converter unit 20 , can then be installed as identical components. This results in an electric vehicle whose four wheels can be driven separately by a respective electric machine. This electric vehicle also has a high level of comfort by virtue of the fact that the conventional chassis of a vehicle can be used for the individual suspension of the wheels.
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A drive arrangement for an electric vehicle has an axle drive device of a portal design with two electric machines for driving the wheels of an axle of the electric vehicle, and at least one electric energy store that can be discharged when an electric machine is operated as a motor and/or can be charged when an electric machine is operated as a generator. The drive arranged is characterized in that the two electric machines ( 11 ) of the axle drive device ( 10 ) are combined with a respectively assigned transmission ( 12 ) in an electric axle to drive the individually suspended wheels ( 2 ) of the axle by means of, in each case, one articulated shaft flange ( 13 ) via a respective articulated shaft. Frequency converters assigned respectively to the two electric machines are combined in a converter unit.
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RELATED APPLICATIONS
This application is a divisional application of U.S. Application Ser. No. 11/111,164, filed Apr. 21, 2005 now U.S. Pat. No. 7,125,463 entitled FLUID FILLED UNIT FORMATION MACHINE AND PROCESS, which is a divisional application of U.S. application Ser. No. 10/408,947, filed Apr. 8, 2003, entitled FLUID FILLED UNIT FORMATION MACHINE AND PROCESS, now issued as U.S. Pat. No. 6,889,739, the entire disclosures of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to fluid filled units.
BACKGROUND OF THE INVENTION
U.S. Pat. Nos. Re 36,501 reissued Jan. 18, 2000 and RE 36,759 reissued Jul. 4, 2000 respectively entitled “Method for Producing Inflated Dunnage” and “Inflated Dunnage and Method for its Production” and based on original patents respectively issued Sep. 3, 1996 and Dec. 2, 1997 to Gregory A. Hoover et al. (the Hoover Patents) disclose a method for producing dunnage utilizing preopened bags on a roll. The preopened bags utilized in the Hoover patents are of a type disclose in U.S. Pat. No. 3,254,828 issued Jun. 2, 1966 to Hershey Lerner and entitled “Flexible Container Strips” (the Autobag Patent). The preferred bags of the Hoover patents are unique in that the so called tack of outer bag surfaces is greater than the tack of the inner surfaces to facilitate bag opening while producing dunnage units which stick to one another when in use.
U.S. Pat. No. 6,199,349 issued Mar. 13, 2001 under the title Dunnage Material and Process (the Lerner Patent) discloses a chain of interconnected plastic pouches which are fed along a path of travel to a fill and seal station. As each pouch is positioned at the fill station the pouches are sequentially opened by directing a flow of air through a pouch fill opening to open and then fill the pouch. Each filled pouch is then sealed to create an hermetically closed, inflated dunnage unit. Improvements on the pouches of the Lerner Patent are disclose in copending applications Ser. No. 09/735,345 filed Dec. 12, 2000 and Ser. No. 09/979,256 filed Nov. 21, 2001 and respectively is entitled Dunnage Inflation (the Lerner Applications). The system of the Lerner Patent and Applications is not suitable for packaging liquids. Moreover, since the production of dunnage units by the process described is relatively slow, an accumulator is desirable. An improved accumulator and dispenser for receiving dunnage units manufactured by a dunnage unit formation machine is disclose in U.S. application Ser. No. 09/735,111 filed Dec. 12, 2000 by Rick S. Wehrmann under the title Apparatus and Process for Dispensing Dunnage.
Accordingly, it would be desirable to provide an improved system for filling pouches with fluid to produce dunnage or liquid filled units at high rates of speed.
SUMMARY
The present application relates to fluid filled pouches arranged in a row. The fluid filled units comprise elongate, heat sealable, face and back layers that are jointed together at a side edge, and by transverse seals to form pouches. The pouches are filled with fluid and are sealed at a split edge, defining fluid filled units. The fluid filled units can be separated along transverse lines of weakness. The transverse lines of weakness are defined by perforations, including perforations nearest the split edge that are shorter in length than perforations that are spaced further from the split edge and extend toward the side edge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the unit formation machine of the present invention;
FIG. 2 is a plan view of the machine of FIG. 1 as seen from the plane indicated by the line 2 - 2 of FIG. 1 showing a web being fed into the machine;
FIG. 3 is an enlarged sectional view of a heat shoe and a portion of the drum as seen from the plane indicated by the line 3 - 3 of FIG. 1 ;
FIG. 3 a is a further enlarged view of the shoe and the drum as seen from the same plane as FIG. 3 ;
FIG. 4 is a view showing a dunnage embodiment of the machine with components which delineate a air flow path from a supply to and through the cooling shoes and then the inflation nozzle;
FIG. 5 is a perspective view of a section of the novel and improved web;
FIG. 6 is a perspective view showing a section of a web as the web pouches are inflated and the web is separated into parallel rows of inflated pouches;
FIG. 7 is an enlarged plan view of a portion of the web including a transverse pair of heat seals;
FIG. 8 is a further enlarged fragmentary view of a central part of the web as located by the circle in FIG. 7 ;
FIG. 9 is a perspective view showing a pair of completed fluid filled units following separation and as they exit the machine; and,
FIG. 10 is an enlarged view of a preferred support embodiment and a shoe which arrangement is for supporting the shoes in their use positions and for moving them to out of the way positions for machine set up and service.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the following description describes a dunnage formation system, it should be recognized the preferred embodiment of the machine is sterilzable so that beverages such as water and fruit juice may be packaged using the novel web, machine and process.
Referring now to the drawings and FIGS. 1 and 2 in particular, a dunnage formation machine is shown generally at 10 . The machine includes a rotatable drum 12 which is driven by a motor 14 via a gear box 15 and a belt and pulley arrangement 16 , FIG. 2 . In the preferred and disclosed arrangement, the drum is comprised of spaced annular disks 18 .
When the machine is in use a web 20 is fed from a supply, not shown. As is best seen in FIG. 1 , the web 20 passes over a guide roll 22 and thence under a guide roll 24 to an inflation station 25 . The web 20 is fed around the disks 18 to pass under, in the disclosed embodiment, three heat shoes 26 which shoes heat metal transport belts 27 to seal layers of the web. The heat softened web portions and the transport belts then pass under cooling shoes 28 which freeze the seals being formed. As the now inflated and sealed web passes from the cooling shoes individual dunnage units 30 are dispensed.
In practice the machine 10 will be housed within a cabinet which is not shown for clarity of illustration. The cabinet includes access doors with an electrical interlock. When the doors are open the machine may be jogged for set up, but the machine will not operate to produce dunnage units unless the doors are closed and latched.
The Web
Referring now to FIGS. 5-9 , the novel and improved web for forming dunnage units is disclose. The web is formed of a heat sealable plastic such as polyethylene. The web includes superposed top and bottom layers connected together at spaced side edges 32 . Each of the side edges is a selected one of a fold or a seal such that the superposed layers are hermetically connected along the side edges 32 .
A plurality of transverse seal pairs 34 are provided. As best seen in FIGS. 5-7 , each transverse seal extends from an associated side edge 32 toward a longitudinally extending pair of lines of weakness 35 . The longitudinal lines of weakness 35 are superposed one over the other in the top and bottom layers of the web and are located midway between the side edges. Each transverse seal 34 terminates at a seal end 39 (see FIG. 8 ) that is in spaced relationship with the longitudinal lines of weakness which preferably are in the form of uniform, small perforations. The transverse seal pairs 34 together with the side edges 32 delineate two chains of centrally open side connected, inflatable pouches 37 .
As is best seen in FIGS. 7 and 8 , transverse lines of weakness 36 are provided. The pouches are separable along the transverse lines 36 . Like the longitudinal lines of weakness 35 the transverse lines are preferably perforations but in contrast to the to the longitudinal line perforations each has substantial length. The perforations of the transverse lines 36 , in a further contrast with the perforations of the longitudinal lines 35 , are not of uniform dimension longitudinally of the lines. Rather, as is best seen in FIG. 8 , a pair of small or short perforations 38 is provided in each line. The small perforations 38 of each pair are disposed on opposite sides of and closely spaced from the longitudinal lines 34 . Each transverse line of weakness also includes a pair of intermediate length perforations 40 which are spaced and positioned on opposite sides of the small perforations 38 . The intermediate perforations extend from unsealed portions of the superposed layers into the respective seals of the associated transverse seal pair. The remaining perforations of each line are elongated cuts 41 (see FIG. 7 ) that are longer than the intermediate perforations 40 .
The Machine
In the embodiment of FIG. 1 , the disks 18 are mounted on a tubular shaft 42 . The shaft 42 is journaled at 44 for rotation driven by the belt and pulley arrangement 16 . The shaft 42 carries a stationary, tubular, nozzle support 45 which extends from around the shaft 42 radially outwardly. A nozzle assembly 46 is carried by a support arm 45 A, FIG. 6 . The nozzle assembly 46 includes an inflation nozzle 48 . As is best seen in FIG. 6 , the nozzle 48 is an elongated tube with a closed, generally conical, lead end portion 49 . The nozzle 48 when in use extends into the web at a central location transversely speaking. The web transverse lines of weakness are spaced slightly more than a one half the circumference of the nozzle so that the web layers fit closely around the nozzle to minimize leakage of air exiting side passages 51 of the nozzle to inflate the pouches 37 .
The nozzle assembly 46 includes a web retainer 50 which guides the web against the nozzle 48 . The retainer also functions to cause the web to be longitudinally split along the longitudinal lines of weakness 35 into two strips of inflated pouches each having a split edge 149 (see FIG. 9 ).
As is best seen in FIGS. 3 and 3A , each of the heat shoes 26 has a mirror image pair of heat conductive bodies 52 . The bodies 52 together define a cylindrical aperture 54 , which houses a heating element, not shown. Each heat body 52 includes a seal leg 55 having an arcuate surface substantially complemental with a cylindrical surface of an associated one of the disks 18 . In the disclose embodiment the disk surfaces are defined by thermally conductive silicone rubber inserts 18 s , FIG. 3A . In the embodiment of FIGS. 3 and 3A , springs 56 bias the legs 55 against the transport belts 27 as the web passes under the heat shoes due to rotation of the drum 12 and its disks 18 . The cooling shoes 38 are mounted identically to the heat shoes.
Each cooling shoe 28 includes an expansion chamber 58 , FIG. 4 . An air supply, not shown, is connected to a chamber inlet 60 . Air under pressure is fed through the inlet 60 into the chamber 58 where the air expands absorbing heat and thus cooling the shoe. Exhaust air from the chamber passes through an exit 62 . Cooling shoe legs 63 are biased against the web to freeze the heat softened plastic and complete seals.
In the embodiment of FIGS. 1-4 cooling shoe exhaust air then passes through a conduit 64 to the tubular shaft 42 . Air from the cooling shoes is fed via the conduit 64 and the shaft 42 to a passage 65 in the nozzle support 45 . The passage 65 is connected to the nozzle 48 . Thus air from the cooling shoes is directed to and through the nozzle 48 and the exit passages 51 into the pouches.
With the now preferred and sterilizable embodiment, cooling shoes 28 ′ as shown in FIG. 10 are employed has a jacket 67 which surrounds a body having cooling fins shown in dotted lines in FIG. 10 . An inlet 60 ′ is provided at the top of the jacket. Air flowing from the inlet passes over the fins cooling them and the exits from the bottom of the jacket. Each of the shoes 28 ′ is vented to atmosphere through an outlet 67 . The nozzle 48 is directly connected to a supply of fluid under pressure and the shaft 42 may be made of solid material.
A pair of hold down belts 66 are mounted on a set of pulleys 68 . The belts 66 are reeved around a major portion of the disks 18 . As is best seen in FIGS. 3 and 3A , the belts 66 function to clamp portions of the web 20 against the disks on opposite sides of the shoe legs 55 . While test have shown that the machine is fully operable without the belts 66 , they are optionally provided to isolate pressurized air in the inflated pouches 37 from the heating and cooling shoes. A fixed separator 69 is provided. As the inflated pouches approach the exit from the downstream cooling shoe the fixed separator functions to cam them radially outwardly sequentially to separate each dunnage unit from the next trailing unit along the connecting transverse line of weakness except for a small portion under the transport belts 27 .
A separator wheel 74 is provided, FIG. 1 . The wheel 74 is rotated clockwise as seen in FIG. 1 such that arms 76 are effective to engage completed dunnage units 30 sequentially to complete the separation of each dunnage unit from the web along its trailing transverse line of weakness 36 . Thus, the separator wheel is effective to tear the last small connection of each pouch which was under an associated one of the transport belts as the pouch was substantially separated by the fixed separator 69 .
In the embodiment of FIG. 1 , each of the shoes 26 , 28 is mounted on an associated radially disposed shaft 71 . Clamping arrangements shown generally at 72 are provided to fix each of the shafts 71 in an adjusted position radially of and relative to the drum 12 . As is best seen in FIG. 3 , each shaft 71 carries a yoke 73 . The springs 56 span between yoke pins 75 and shoe pins 75 to bias the shoes against a web 20 . A cylinder 70 is provided for elevating a connected yoke and shoe for machine set up and service.
In the now preferred embodiment of FIG. 10 , each shoe is pivotally mounted on an arm 78 . The arm is also pivotally mounted at 80 on a frame 82 . A cylinder 70 ′ spans between the arm and the frame for elevating the connected shoe for set up and service and for urging the shoes 28 into their operating positions. The heat shoes 26 are, in the now preferred arrangement, identically mounted.
Operation
In operation, the shoes are elevated by energizing the cylinders 70 of FIGS. 1 and 4 or 70 ′ of FIG. 10 . A web 20 is fed along a path of travel over the guide roll 22 and under the guide roll 24 and thence threaded over the inflation nozzle 48 . The web is then fed under the transport belts and the retainer 50 . As the machine is jogged to feed the web around the discs 18 and the heating and cooling shoes 26 , 28 the web is split by the nozzle support 55 . The split of the web is along the longitudinal line of weakness but the transverse lines of weakness remain intact at this time. Thus, the web portions at opposite ends of the small perforations 38 are of sufficient size and strength to avoid a longitudinal split of the web as the web is fed over the nozzle. Since the transverse seals of each pair are spaced only very slightly more than one half the circumference of the nozzle the web closely surrounds the nozzle to minimize air leakage when the pouches are inflated.
Next the heating and cooling shoes are elevated by actuating either the cylinders 70 or 70 ′. The web is then fed sequentially, and one at a time, under the heating shoes 26 and the cooling shoes 28 . Since the web has been split by the nozzle support 55 , there are in fact two parallel paths of travel each with an associated transport belt 27 and chain of side connected and inflated pouches.
Once the web has been fed around the drum to an exit location near the separator wheel 74 and the machine has been jogged until the operator is satisfied the feed is complete and the machine is ready the heat shoe elements will be energized. Air will be supplied to the cooling shoes 28 and the nozzle 48 . Next the motor 14 will be energized to commence machine operation.
As we have suggested, one of the outstanding features of the invention is that the web closely surrounds and slides along the nozzle. The close surrounding is assured by the transverse seals being spaced a distance substantially equal to one half the circumference of the nozzle 48 . Thus, the two web layers together delineate a nozzle receiving space which will closely surround an inserted nozzle. As the web advances the pouches 37 on opposed sides of the nozzle will be filled efficiently by fluid under pressure exiting the nozzle passages 51 in opposed streams. Where dunnage units are being formed the fluid will be air. The web is then split by the nozzle support into two chains of side connected and fluid filled pouches respectively traveling along associated ones of the two paths of travel.
Each of the chains is fed under spaced legs 55 of the heating shoes 26 to effect heat seals or inflation seals 79 (see seals shown in FIG. 9 ). As the web passes under cooling shoe legs 63 the inflation seals 79 are frozen and the pouches are separated along most of the length of transverse lines of weakness by the separator. Facile separation is assured by the long perforations because the remaining connections of the web across the transverse seals are short in transverse dimension and few in number.
When the pouches exit the last of the cooling shoes, they have been formed into finished dunnage units 30 . The finished units 30 are sequentially completely separated from the web by the arms 76 of the separation wheel 74 .
While the system as disclosed and described in the detailed description is directed to dunnage, again, as previously indicated, units filled with fluids other than air such as water and fruit juices can be produced with the same machine, process and web.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, operation and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
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The present application relates to fluid filled pouches arranged in a row. The fluid filled units comprise elongate, heat sealable, face and back layers that are jointed together at a side edge, and by transverse seals to form pouches. The pouches are filled with fluid and are sealed at a split edge, defining fluid filled units. The fluid filled units can be separated along transverse lines of weakness. The transverse lines of weakness are defined by perforations, including perforations nearest the split edge that are shorter in length than perforations that are spaced further from the split edge and extend toward the side edge.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the manufacture and distribution of yogurt; and, more specifically, to a process and system for delivering freshly cultured yogurt or kefir containing a high concentration of active cultures at a retail location.
[0003] 2. Description of the Prior Art
[0004] Many patents address issues related to producing yogurt or kefir. These patents disclose processes that produce yogurt or kefir and seal the containers at the factory. Cold yogurt containers are then shipped to retail stores for sale to customers from a refrigerated display systems. The yogurt manufacturing facility uses a variety of yogurt or kefir forming cultures. Each culture requires a specific combination of incubation temperature and incubation time. The final yogurt product stored in a refrigerator is subject to degradation and generation of foul taste and stringy structure due to continued growth of cultures in the yogurt and other contaminant micro-organisms at the storage temperature. The concentration of health promoting active cultures in the yogurt or kefir decreases as a function of storage time and the customer does not receive the full benefit of these cultures. None of the prior art disclosures creates a yogurt or kefir product in a sealed container at the selling location to thereby provide a fresh yogurt or kefir product that has an undiminished concentration of active cultures.
[0005] U.S. Pat. No. 1,710,133 to Gustov Winkler discloses a process for preparation of mild aromatic yoghurt, curdled milk or a sweet yoghurt junket. The yoghurt produced has a lower degree of acidity than normal yoghurt. Milk is boiled and sterilized, cooled to 28° C. to 32° C. and is inoculated with mixed culture of cocci bacteria, rennet bacteria micrococcus lactis acidi lohnis and yeast of the torula and myciderma group that neither produces alcohol or carbonic acid. The yogurt is curdled in a period of 4 to 6 hours. This yogurt or kefir is produced at the factory not at the retail sale location.
[0006] U.S. Pat. No. 2,119,599 to Nordsiek discloses a milk product and process of manufacturing the same. Milk is heated to sterilize at 99° C., cooled to 40° C. and is immediately inoculated with Streptococcus thermophiius 4915 and Lactobacillus acidophilus , and fermented for 5 to 7 hours. This yogurt culture is immediately added to the 40° C. sterilized milk at the milk product producing factory.
[0007] U.S. Pat. No. 3,128,190 to Donay et al. discloses a method of making combined fruit yogurt. The milk, with sweeteners is heated to at least 96° C. (205° F.) and is cooled to 37.7° C. (100° F.). This patented process uses lactobacillous bulgaricus incubated at 36.6° C. to 37.7° C. (98° F. to 100° F.). Since the lactobacillous bulgaricus is immediately added after cooling, the frit yogurt is incubated at the factory.
[0008] U.S. Pat. No. 3,563,760 to Kuwabara et al. discloses the production of fermented milk product. Sterilization is needed to get rid of yeast. First milk is fermented with yeast at 25° C. to 30° C. for 15 to 20 hours, sterilized at 100° C. and then fermented with yogurt culture at 25° C. to 30° C. until acidity level is reached. Fermentation by yeast is said to prevent alcohol separation. The yogurt cultures include Lactobacillus acidophilus, Lactobacillus bulgarucus, Lactobacillus casei, Streptococcus thermophillus or Streptococcus diacetlactis . The yogurt fermentation occurs at a central factory location due to the fermentation temperature requirements.
[0009] U.S. Pat. No. 4,210,672 to Hata discloses preparation of yogurt. Yogurt is prepared with a mixture of milk powder and novel Lactobacillus thermophilus (also known as bacillus coagulans) spores that have specific characteristics of requiring nourishment at the time of spore formation, being capable of high speed acid formation, taking a short time for transition into germ cells after budding and being highly thermobiotic so as to kill or inhibit during yogurt fermentation the growth of undesirable saprophytes including spore forming saprophytes present in yogurt which serve to putrify or spoil the yogurt. To prepare yogurt, boiling water is added to the mixture to kill or inhibit the growth of saprophytes and the mixture is permitted to ferment for a relatively short period of time. The spores of yogurt microbes can tolerate boiling at 100° C. and ferment the yogurt at 50° C. within 5 hours. The spores are sporiferous lactic acid bacteria of type Bacillus EC-1, Species No. 2,930. Boiling water is added to milk powder and this high temperature sterilization and fermentation prevents the growth of saprophytes which cause purification of the yogurt. The yogurt culture is not a standard yogurt forming culture and is not fermented at 38° C. to 42° C.
[0010] U.S. Pat. No. 4,339,464 to Vedamuthu discloses a stabilizer producing Streptococcus thermophilus . Naturally stabilized fermented milk products are prepared with a concentrate of Streptococcus thermophilus cells that produce a stabilizer in situ when cultured in milk. The concentrate is obtained by culturing the stabilizer-producing Streptococcus thermophilus in a growth medium including milk solids to obtain at least about 108 cells per ml. The growth medium preferably contains maltose, sucrose, fructose or lactose, which enhances stabilizer formation. This stabilizer producing Streptococcus thermophilus is a starter culture and does not produce a yogurt.
[0011] U.S. Pat. No. 4,382,097 to Vedamuthu et al. discloses a method for the preparation of naturally thickened and stabilized fermented milk products and products produced thereby. A method for the preparation of naturally stabilized, thick bodied, fermented milk products by fermentation is described and uses mixed cultures of milk fermenting, non-slime, lactic acid producing bacteria and slime producing Streptococcus lactis, Streptococcus cremoris or mixtures thereof in milk. Streptococcus cremoris NRRL-B-12,361, 12,362 or 12,363 are used, preferably in addition with a diacetyl producing bacterium for flavor. The fermented milk products are thick bodied without any ropiness or sliminess and are stable to separation of whey from curd upon storage at refrigeration temperatures, with little or no added stabilizing agents such as gums and starches or thickening agents such as added non-fat milk solids. The preferred product is a thick-bodied buttermilk. The yogurt has a pH of 4.2 to 4.7. The inoculated milk is fermented with the mixed culture at temperature between about 10° C. to 32° C., preferably 24° C. The fermentation is generally conducted for between about 12 to 18 hours. The milk usually contains less than nine percent (9%) milk solids. The yogurt is not indicated to be freshly fermented at the yogurt dispensing retail location.
[0012] U.S. Pat. No. 4,410,549 to Baker discloses preparation of a low calorie, low fat fruit-containing yogurt. A low calorie, low fat fruit-containing yogurt is prepared by a process including steps of admixing skim milk, stabilizers and an amount of heat modified nonfat dry milk solids effective to improve texture and flavor, and processing the mixture by heating, homogenizing, fermenting with a culture mixture of Lactobacillus acidophilus, Lactobacillus bulgaricus and Streptococcus thermophilus , blending with low calorie fruit preserves and cooling. The heat modified nonfat dry milk solids are derived from a process in which condensed skim milk is subjected to non-coagulative direct steam heating prior to spray drying. The resultant yogurt product has the appearance, texture and taste of conventional fruit-containing yogurt. In this process, the low fat milk with dry milk solids is heated 87.7° C. to 90.6° C. to sterilize the milk, cooling the homogenized mixture to 32.3° C. to 48.9° C. adding immediately yogurt cultures of 0-50% Lactobacillus acidophilus , balance Lactobacillus bulgaricus and Streptococcus thermophilus in approximately equal proportions fermenting until pH reaches 3.8 to 4.8 and cooling to 1.6° C. to 9.4° C. (35° F. to 49° F.). The yogurt is homogenized with fruits. Due to the immediate addition of yogurt cultures to cooled milk and the homogenization of the yogurt with fruit, the yogurt is made at the yogurt manufacturing facility.
[0013] U.S. Pat. No. 4,416,905 to Lundstedt et al. discloses a method of preparing cultured dairy products. A method for the production of cultured dairy products, such as buttermilk, yogurt or sour cream, by the controlled fermentation of a liquid medium consisting of a major portion of light cream, milk, low-fat milk or skim milk or reconstituted skim milk powder or buttermilk powder, or a mixture of these two components. The liquid medium is fermented using a bacterial fermentation culture. The fermentation of the medium is allowed to proceed for sufficient time to achieve a pH in the range of between 6.2 to about 4.9, at which point the liquid medium is then cooled to a fermentation rate-reducing temperature and acidulated to a pH of 4.7 or below using food grade acids such as those selected from the group consisting of lactic, citric or acetic acid. The yogurt aciditity is provided by adding acid additives. This yogurt is produced at the yogurt manufacturing facility.
[0014] U.S. Pat. No. 4,425,366 to Sozzi et al. discloses production of yogurt. Yogurt having a reduced increase in acidity and bitterness during storage at ambient temperature is produced by fermenting milk with Streptococcus thermophilus and a Lactobacillus bulgaricus strain which has low proteolytic activity and allows a DNA-DNA hybridization of from 80 to 100%. A thickening strain of Streptococcus thermophilus may be used. The yogurt may be packed under sterile conditions and stored at about 20° C. The milk is fermented with a combination of strains in which the Lactobacillus bulgaricus strain has a low proteolytic activity and allows a level of DNA-DNA hybridization of from 80 to 100% with one of the strains of L. bulgaricus CNCM I-179, I-180 and I-181. Some strains of Lactobacillus bulgaricus possess the property of ceasing to produce lactic acid at a pH, which is higher than normal, notably at a pH approaching 5. Moreover, it is known that Streptococcus thermophilus produces lactic acid very rapidly, but stops production at a pH approaching 4.5. It was then found that a combination of Lactobacillus bulgaricus which ceases acidification at a pH approaching 5 and of Streptococcus thermophilus allowed the production of a yogurt having improved keeping properties with respect to increase in acidity and bitterness. The yogurt produced can be stored at 20° C. due to the low acid production capability possessed by special yogurt cultures of Lactobacillus bulgaricus and Streptococcus thermophilus . This yogurt is fermented in a factory.
[0015] U.S. Pat. No. 4,734,361 to Murao et al. discloses a low temperature-sensitive variant of Lactobacillus bulgaricus and a selection method therefor. The novel variant Lactobacillus bulgaricus sensitive at a lower temperature, that is, showing a weak tendency towards formation of lactic acid in a range of the lower temperature, and the method for the selection of the variant, are disclosed. By employing the variant, it is possible to produce a fermented milk or lactic acid beverage in which the rate of increase in the sour taste after preservation at a lower temperature is significantly lowered. The yogurt is produced by a low temperature variant of Lactobacillus bulgaricus.
[0016] U.S. Pat. No. 4,748,026 to Keefer et al. discloses process for production of a no-starch shelf stable yogurt product. This invention provides a method for producing shelf-stable yogurt product which exhibits a smooth, non-gritty texture and enhanced storage stability and the yogurt product produced by such a method. A yogurt product that is storage stable is that which does not have to be refrigerated, i.e., can be stored at room temperature for a period in excess of a few weeks without undergoing spoilage or a substantial breakdown in texture. Incubation is effected by inoculating the pasteurized dairy base within the temperature range of 35° C. to 46.1° C. (95° F. to 115° F.) with a culture of a yogurt producing microorganism, for example, streptococcus thermophilus and Lactobacillus bulgaricus . The microorganisms are allowed to incubate until the pH of the yogurt product is about 3.5 to 5.0. Preferably, the pH of the yogurt is about 4.2 to 4.3, a result obtained after about 3 to 4 hours of incubation. This long term stability is achieved by first pasteurizing/denaturing the milk proteins of the dairy base by high temperature treatment followed by fermentation at 37.8° C. to 46.1° C. (100° F. to 115° F.) to produce a yogurt. The yogurt, at fermentation temperatures is then mixed with a starch free group of thickeners and other additives comprising at least one calcium binding vegetable gum. The admixed yogurt product is then subjected to a pre-conditioning or denaturation step at temperatures within the range of about 54.4° C. to 65.6° C. (130° F. to 150° F.), homogenized, and pasteurized. The yogurt contains vegetable gum. The yogurt is pasteurized and the beneficial yogurt cultures are thus killed.
[0017] U.S. Pat. No. 4,797,289 to Reddy discloses enhancement of Lactobacillus acidophilus growth and viability in yogurt and other cultured dairy products. Lactobacillus acidophilus or bifidus does not grow and survive in yogurt for a long period of time. A differential inoculation procedure has been developed whereby Lactobacillus acidophilus is first inoculated into heat treated milk or milk-sugar-fiber base and incubated until its population builds up sufficiently.
[0018] Later, the regular yogurt cultures Streptococcus thermophilus and Lactobacillus bulgaricus are inoculated into the acidophilus growing yogurt mix. This procedure enables making of a yogurt with significantly high concentration of L. acidophilus bacteria in yogurt. Also dietetic fiber was introduced into the fruit base and then mixed with yogurt, which enhances the population of L. acidophilus and thickens the yogurt due to its exceptional hydration properties. Vitamins and minerals are also included into the yogurt both to enhance the population of acidophilus and to supplement the yogurt. Variations of using lactase enzyme to decrease the lactose in yogurt and to enhance the L. acidophilus counts have been employed. In addition, to significantly prolong the viability of L. acidophilus , calcium carbonate and catalase-L have been included in the yogurt. The milk is first fermented with slow growing micro organisms of Lactobacillus acidophilus or bifidus followed by fermentation with usual yogurt culture of Streptococcus thermophilus and Lactobacillus bulgaricus . The yogurt produced has slow growing Lactobacillus acidophilus or bifidus and has several additives including fiber, vitamins and calcium catalase-L. This yogurt is not free from additives and is not indicated to be produced in a retail location.
[0019] U.S. Pat. No. 4,837,036 to Baker et al. discloses a low fat thin-bodied yogurt product and method. A low calorie, low fat, high total solids, high protein content, thin-bodied, fruit-containing yogurt product is prepared by a process including the steps of admixing a butterfat-containing milk product in sufficient amount to provide a butterfat content in the yogurt product of less than about 0.5% by weight, limited quantities of a stabilizer mix, a nutritive sweetener, and non-heat modified nonfat dry milk solids. The mixture is processed by homogenizing, vat pasteurizing, fermenting with a uniquely proportioned three component bacterial yogurt culture mixture consisting essentially of, by weight, 15 to 25% Lactobacillus acidophilus , 30 to 50% Lactobacillus bulgaricus and 30 to 50% Streptococcus thermophilus , blending with low caloric, nutritive sweetener-containing fruit preserves and cooling. The resultant fruited yogurt product has a total solids content of 21.9 to 23.9%, a protein content of at least 4.5%, a caloric content of 150 calories per 6 ounce (170 gram) serving; the body, texture and taste of conventional thin-bodied fruit-containing yogurt. It is resistant to syneresis and exhibits a consumer acceptable appearance characterized by the absence of free moisture on the product surface and within the packaging. The low fat milk with dry milk solids is sterilized at 87.7° C., cooled to 32.2° C. to 48.9° C. and inoculated with 15 to 25% Lactobacillus acidophilus, 30 to 50% Lactobacillus bulgaricus and 30 to 50% Streptococcus thermophilus , and filtered through a screen to produce homogenous custard like yogurt. The yogurt containers are not closed prior to fermentation of the yogurt. The setup of filtration requires the yogurt to be produced at a factory.
[0020] U.S. Pat. No. 4,957,752 to Ivanova et al. discloses a process for producing kefir. This process for producing kefir involves normalization of purified cow milk with respect to the content of dry solids by ultrafiltration of the milk at a temperature of 50° C. to 55° C. until the content of dry solids is increased in the normalized milk by 0.5 to 4.0% by mass, further heat treatment at the temperature of 90° C. to 140° C., introduction into the normalized milk of a leaven prepared using kefir fungi, leavening of the resulting mixture to a pH of 5.0 to 4.7, residence of the leavened mixture at a temperature of 18° C. to 20° C. to a pH of 4.7 to 4.5, followed by packing. The microflora of the fungal leaven for kefir incorporates not only lactic-acid bacteria, but yeast as well; the optimum for the development of the microorganisms included in the composition of the fungal kefir leaven is within the range of from 18° C. to 26° C., which differs substantially from that for yoghurt leaven produced at 40° C. to 42° C., wherefore the character of the development of these cultures in protein-enriched milk after ultra filtration also differs substantially. Furthermore, upon elevation of the protein content in milk to over 7 to 15% by mass an adequate growth of the cultures incorporated in the kefir leaven (yeast) is not ensured. The fermentation process becomes extended in time, the product acquires a non-pronounced “empty” taste. Moreover, due to the long duration of the fermentation process in the final product proteolytic flaws appear: bitterness, foreign after-tastes. In this patent disclosure, the kefir is produced by fermenting a microflora of the fungal leaven at a temperature in the range of 18° C. to 26° C. and ultra filtered to remove kefir leavening. Kefir fungi comprise a natural symbiosis of the following microorganisms: lactic-acid streptococci, acetic-acid bacteria, lactic-acid bacilli and yeast both fermenting and non-fermenting lactose. This fermentation is done at the kefir factory due to the filtration requirement.
[0021] U.S. Pat. No. 5,827,552 to Mainzer et al. discloses production of fermented food products. This method of making fermented food products such as yogurt uses Lactobacillus bulgaricus organisms for making fermented food products which are conditionally sensitive, that is, operate to metabolize a desired compound normally under the processing conditions for fermented food products but slow or decrease in activity beyond what is normal under the routine storage temperatures for the fermented food products. Such fermented food products exhibits improved shelf life and long-term taste. The yogurt culture is a mutant Lactobacillus bulgaricus organism that has about 20% reduction of growth rate below 20° C. thereby reducing the formation of foul taste and texture in the cultured yogurt during storage.
[0022] U.S. Pat. No. 6,033,691 to Cravero discloses a process for manufacturing a biologically active fermented milk product and product obtained by the process. Lactobacillus casei (ATCC 55544) and Lactobacillus acidophilus (ATCC 55543) are simultaneously inoculated in milk previously added with Streptococcus , and then fermented at a temperature of 43° C. Fermentation results in the formation of a biologically active milk product. After fermentation, the resulting product can be stores between 4° C. and 10° C. for up to 30 days. Storage of the product does not require any special container. The product can also be lyophilized and stored at 20° C. to 25° C. (relative humidity 40 to 65%) for a minimum of four months. When reconstituted, the powdered product has a pH close to liquid and is palatable. The milk contains maltodextrin, non-fatty powder milk and sugar as well as carboxymethylcellulose stabilizers. The first simultaneous yogurt culture used is Lactobacillus casei (ATCC 55544) and Lactobacillus acidophilus (ATCC 55543) followed by Streptococcus . The milk used has maltodextrin, non-fatty powder milk and sugar as well as carboxymethylcellulose stabilizers and the yogurt formed can stay for four months without degradation at 20° C. to 25° C. The milk used is not free from additives and the yogurt formed does not need low temperature refrigeration.
[0023] U.S. Pat. No. 6,399,122 to Vandeweghe et al. discloses a yogurt production process. This process is for decreasing the time required for incubation of the yogurt. The acidity of yogurt decreases as the fermentation proceeds. The decrease in time is accomplished by merely adding acids chosen from citric acid, lactic acid, malic acid, gamma delta lactone, tartartic acid, and their combinations, instead of waiting for the completion of fermentation, thereby decreasing the yogurt formation time or production of yogurt without compromise to the final product quality. The yogurt fermentation is carried out at about 40.6° C. to 46.1° C. (105° F. to 115° F.) followed by direct acidification. The yogurt composition is directly acidified when the pH of the composition reaches a pH of about 4.8 to about 5.2. The yogurt fermentation uses Streptococcus thermophilus and Lactobacillus bulgaricus bacteria. The composition can be acidified while the temperature is at about 40.6° C. to 46.1° C. (105° F. to 115° F.), or the composition can be acidified during or after cooling. The acidification is carried out by adding citric acid, lactic acid, malic acid, gamma delta lactone, tartaric acid, and their combinations. This is a factory produced yogurt with acidifying additives.
[0024] U.S. Pat. No. 7,615,367 to De Vuyst et al. discloses Streptococcus thermophilus strains producing stable high-molecular-mass exopolysaccharides. The exopolysaccharide mass is produced by a lactic acid bacteria. The method uses culture media for producing large amounts of exopolysaccharides in safe and simple fermentation conditions. The Streptococcus thermophilus ST 111 strain produces a stable high-molecular-mass heteropolysaccharide, for use in functional starter cultures and for use in food fermentation processes such as processes producing milk products, yoghurt and cheese for texture improvement and decreasing syneresis during fermentation and in the fermented product. This high-molecular-mass exopolysaccharides is used as a starter culture for the inoculation of yogurt forming milk and fermentation of other food precuts. The '367 patent does not disclose incubation of yogurt or kefir.
[0025] Non-Patent Publication “Effect of Mixing During Fermentation in Yogurt Manufacturing” authors Aguirre-Ezkauriatza et al. from Journal of Dairy Science Dec. 1, 2008 available at http://jds.fass.org/cgi/reprint/92/9/4112.pdf discloses effect of mixing during fermentation in yogurt manufacturing. The yogurt starters, Lactobacillus delbrueckii ssp. bulgaricus and Streptococcus thermophilus , are well known facultatively anaerobic bacteria that can grow in oxygenated environments. Removing dissolved oxygen (DO) in a yogurt mix as the fermentation progressed is shown to retarded the production of acid. Yogurt fermentation was carried out at 43° C. or 37° C. both after the DO reduction treatment and without prior treatment. Nitrogen gas was mixed and dispersed into the yogurt mix after inoculation with yogurt starter culture to reduce the DO concentration in the yogurt mix. The combination of reduced DO concentration in the yogurt mix beforehand and incubation at a lower temperature (37° C.) is said to result in a superior set yogurt with a smooth texture and strong curd structure.
[0026] There remains a need in the art for a fresh yogurt or kefir product that is available to customers in a retail location wherein the yogurt or kefir has a high concentration of beneficial cultures. There is a need for a process and method of delivering to retail locations a completely sealed unfermented mixture that is capable of setting into a high quality tasty fresh yogurt having excellent texture when incubated at the retail location.
SUMMARY OF THE INVENTION
[0027] The present invention provides a freshly cultured yogurt or kefir at a retail location that has undiminished content of active beneficial cultures. The yogurt has a fresh taste, free from bad flavors, and has an excellent texture representative of a superior ‘Grade A’ sealed yogurt or kefir product, and preferably is free from additives, thickeners or antibiotics or microbial growth retarding agents.
[0028] Briefly stated, the first embodiment of the invention involves a process that produces fresh yogurt in situ. More specifically, the process for producing fresh yogurt generally comprises the steps of: (i) sterilizing milk at a temperature in the range of 85° C. to 95° C. to kill all yeast present and to denature the protein structure of the milk suitable for culturing yogurt if sterilized milk is unavailable; (ii) cooling the milk to a low temperature in the range of 4° C. to 10° C.; (iii) adding a yogurt culture capable of long life in the 4° C. to 10° C. temperature range to cold milk; (iv) mixing said culture with said cold milk to form a mixture; (v) filling and sealing the mixture in a sterile container; (vi) transporting the containers with cold milk with yogurt culture to the retail store location and storing said containers at a temperature range of 4° C. to 10° C. for a time period ranging typically from one day to 30 days; (vi) removing the cold containers as needed from cold storage and heating the container in an oven to a temperature in the range of 40° C. to 45° C. for a period of 4 to 10 hours depending on the time and temperature setting properties of the yogurt culture; and (vii) placing said set yogurt in a refrigerating environment at a temperature of 4° C. to 10° C. for sale to customers at the retail store location. The yogurt thus produced is preferably free from antibiotics, acidifiers, thickeners bacterial growth retarding agents and other artificial additives. The process may further include a cooling and incubation chamber that can both cool for refrigeration and heat for setting the yogurt milk-yogurt culture mixture. The first embodiment requires the yogurt culture mixed in milk to tolerate 4° C. to 10° C. for prolonged time periods without producing off flavors or stringy yogurt. This property is met by Lactobacillus bulgaricus and Streptococcus thermophilus.
[0029] The second embodiment of the invention for producing fresh yogurt or kefir generally comprises the steps of: (i) sterilizing milk at a temperature in the range of 85° C. to 95° C. to kill all yeast present and to denature the protein structure of the milk suitable for culturing yogurt of kefir when sterilized milk is unavailable; (ii) cooling the milk to a low temperature in the range of 4° C. to 10° C.; (iii) filling and sealing the mixture in a sterile container with a lid having a separate compartment that contains yogurt of kefir culture kept away from the cold milk; (iv) transporting the sealed yogurt containers with cold milk with separated yogurt or kefir culture to the retail store location and storing said containers at a temperature range of 4° C. to 10° C. for a time period ranging up to 30 days; (v) removing the cold containers as needed from cold storage, shaking the contents to distribute the yogurt or kefir culture into the cold milk and heating the container in an oven to a temperature in the range of 33° C. to 45° C. for a period of 4 to 10 hours depending on the time and temperature yogurt setting properties of the yogurt or 18° C. to 25° C. for 10 to 20 hours for a kefir culture; and (vii) placing said set yogurt or kefir in a refrigerating environment at a temperature of 4° C. to 10° C. for sale to customers at the retail store location. Since the yogurt or kefir culture is separated from cold milk within the container, no off flavors or stringy texture are generated, and the yogurt culture can be any culture including low temperature setting Lactobacillus acidophilus and Lactobacillus bifidus.
[0030] Significant advantages are realized by practice of the present invention. In a preferred embodiment, the Process and System for Delivering Fresh Yogurt or Kefir of the present invention comprises the steps of:
1) heating the milk to sterilization temperature in the range of 85° C. to 95° C. when sterilized milk is unavailable; 2) cooling the sterilized milk to a temperature in the range of 4° C. to 10° C.; 3) In the first embodiment, mixing the cooled milk with yogurt forming cultures of Lactobacillus bulgaricus and Streptococcus thermophilus , both being selected for low growth characteristics in the temperature range of 4° C. to 10° C.;
a. filling cold milk-yogurt culture mixture in sterile yogurt containers and sealing with a lid; b. transporting sealed containers of milk-yogurt culture mixture in refrigerated trucks held at 4° C. to 10° C. to retail store outlets; c. retail stores storing said sealed yogurt containers of milk-yogurt culture mixture in a refrigeration equipment set at a temperature range of 4° C. to 10° C.; d. when fresh yogurt is needed transferring the containers milk-yogurt culture mixture to an oven set at a temperature in the range of 33° C. to 45° C. and incubating the yogurt mixture for 4 to 10 hours, completely setting the yogurt; e. transferring said set yogurt to a refrigeration equipment set at a temperature range of 4° C. to 10° C. for sale to customers at the retail location;
4) In the second embodiment, filling said cooled milk into sterile sealed containers, said containers having an internal second compartment;
a. said compartment receiving high temperature incubating or low temperature incubating yogurt culture and being kept separate from cold milk in a open top or breakable/dissolvable top containment for dispensing yogurt or kefir culture into cold milk prior to incubation; b. transporting sealed containers of milk-separated yogurt culture in refrigerated trucks held at 4° C. to 10° C. to retail store outlets; c. storing said sealed containers of milk-separated yogurt culture in refrigeration equipment set at a temperature range of 4° C. to 10° C.; d. when fresh yogurt is needed transferring the containers milk-separated yogurt culture and shaking the contents to form a mixture and transferring to an oven set at a temperature in the range of 18° C. to 25° C. for kefir yogurt culture or 33° C. to 45° C. for Lactobacillus bulgaricus and Streptococcus thermophilus or other yogurt culture, and incubating the yogurt mixture for 10-15 hours for kefir or 4 to 10 hours for yogurt, completely setting the kefir or yogurt product; e. transferring said set yogurt to refrigeration equipment set at a temperature range of 4° C. to 10° C. for sale to customers at the retail location;
[0045] whereby the fresh yogurt or kefir is freshly prepared with no additives such as antibiotics, thickeners, vegetable gums, corn starch or other additives with digestive friendly cultures available at full concentration without culture cell count reduction due to age of yogurt.
BRIEF DESCRIPTION OF THE DRAWING
[0046] The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description of the preferred embodiments of the invention and the accompanying drawing, in which:
[0047] FIG. 1 schematically illustrates the flow chart for the manufacturing and dispensing of fresh yogurt at a retail location according to the first embodiment of the invention;
[0048] FIG. 2 schematically illustrates the second embodiment of the invention wherein the yogurt or kefir culture is maintained separate from the cold milk during transportation and storage at the retail location;
[0049] FIG. 3 illustrates a commercial refrigeration unit that provides heating for yogurt or kefir incubation and cooling for storage of cultured yogurt or kefir prior to sale.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Yogurt is actually a fermented milk product. The milk is fermented using bacteria such as Lactobacillus bulgaricus . In some yogurt production there might be involved more than one type of bacteria such as Streptococcus thermophilus . The Lactobacillus bacteria are fermentative bacteria that convert lactose, the sugar in the milk, into lactic acids causing the characteristic curd to form. They can tolerate the presence of oxygen. The acid also restricts the growth of food poisoning bacteria. During the yogurt fermentation some flavors are produced, which give yogurt its characteristic acetaldehyde flavor. Yogurt is a fermented food derived from the fermentation of milk. A commercially produced yogurt is made up of milk, sugars, stabilizers, fruits and flavors, and a bacterial culture Lactobacillus bulgaricus. The fermentation of yogurt is approximately about 4 hours. A completely fermented yogurt has a pH of about 4.4, which value is within the acid range. The process for manufacturing prior art commercial yogurt typically involves the following steps:
1. Whole milk or partially skimmed milk fortified with nonfat dry milk (up to 3%) is pasteurized or heat treated and then cooled to 37.8° C. to 43.3° C. (100° F. to 110° F.). 2. The heat treated milk is inoculated with coccus ( Streptococcus thermophilus ), and rod ( Lactobacillus bulgaricus ) culture. Preferably, the coccus to rod ratio of the culture prior to inoculation is 1:1. Also, most generally the starter culture used is a frozen concentrate purchased from a commercial source. In some commercial preparation plants, a bulk starter medium is prepared by reconstituting nonfat dry milk solids in water, heating to 87.8° C. (190° F.) for 1 hour, cooling to 37.8° C. to 43.3° C. (100° F. to 110° F.), and inoculating coccus and rod frozen culture. The medium is incubated until pH drops to from 4.2 to 4.5 and then cooled to 4.4° C. to 7.2° C. (40° F. to 45° F.). This bulk culture is inoculated into yogurt mix at the rate of 1 to 2%. 3. The coccus and rod inoculated mix is incubated at 37.8° C. to 45° C. (100° F. to 113° F.). until pH drops from 6.6 to 6.0. At this stage, the yogurt mix is pumped into a dispenser and it is dispensed into a cup with fruit preserve at the bottom. 4. The cups are sealed and moved into a warm room 37.8° C. to 45.6° C. (100° F. to 114° F.) and held until pH drops to 4.8. Then the cups are placed in a cooler environment until the yogurt is cooled to 4.4° C. (40° F.). By then the pH of the final product is 4.0 to 4.4.
[0055] The most important component in controlling the quality of yogurt fermentation is temperature. Temperature affects the yogurt fermentation by controlling the growth rate of the microorganism. If the temperature is too low, the culture grows too slowly to adequately acidify milk and to achieve a good texture. The commercial starter is a mixed culture of Streptococcus thermophilus and Lactobacillus bulgaricus . If the temperature is too high, it might end up killing the cultures. Temperature will affect the taste of the yogurt produced at the formation and secretion of metabolites which contribute to the overall taste are dependent on the growth rate. The window of proper fermentation is quite small, i.e. from 42° C. to 44° C. In general, as the temperature is raised up to 44° C., the rate of culture metabolism is higher, and the yogurt is sweeter. Faster growth also prompts the yogurt to set faster. When the desired acidity is reached, yogurt is quickly cooled to halt further fermentation and metabolic activity. This cooling step is quite critical in industrial yogurt production; it must be done quickly to control tightly the acidity of the yogurt, which has a profound effect on the taste. The yogurt cultures are varied and some representative strains are Streptococcus lactis, Streptococcus cremoris, Streptococcus thermophilus, Lactobacillus bulgaricus, Lactobacillus acidophilus , and Lactobacillus plantarum . Commercial yogurt production is composed of pretreatment of milk (standardization, fortification, lactose hydrolysis), homogenization, heat treatment, cooling to incubation temperature, inoculation with starter, fermentation, cooling, post-fermentation treatment (flavoring, fruit addition, pasteurization), refrigeration/freezing, and packaging. For set yogurt, the packaging into individual containers is carried out before fermentation.
[0056] Typically, yogurt is produced in a plant that mixes cooled sterilized milk with bacteria. The yogurt bacteria mixture is incubated for several hours and allowed to cool. The milk is first sterilized by heating to approximately 93° C. and is kept at this temperature for 10-30 minutes, depending upon the yogurt thickness desired. For thicker yogurt, the milk is heated longer evaporating more of the water content. Next, the milk is rapidly cooled to approximately 44° C. and mixed with a yogurt starter, which contains the necessary bacteria. This dairy mixture is placed in clean containers and incubated for a minimum of four hours at 37° C. To stop the incubation, the yogurt is placed in a cool environment such as a refrigerator. Yogurt produced by this process is packaged and delivered to various stores and is stored in a refrigerator, where it is offered for sale. The bacteria containing yogurt has a shelf life of approximately 60 days. Bacteria content present in yogurt decreases significantly after 7 days. For this reason, fresh yogurt is healthier for the consumer. The higher bacteria count is better for the upper and lower digestive system. Often times, due to shipping and delivery of yogurt products, by the time it gets to the store or point of purchase, the yogurt is no longer fresh. Consequently, there is a need in the art for a process that would provide yogurt having the ability to be served fresh. An objective of this invention is to provide a process that yields fresh yogurt. The process of the present invention enables yogurt to be produced at lower cost (less need to ship every day) and less handling of the yogurt containing cups is required. Yogurt produced by the process of this invention is fresher. It therefore not only tastes better, but also is healthier.
[0057] This invention relates to a method of providing freshly cultured yogurt or kefir with a high level of healthy probiotic bacterial cultures. The incubation of the yogurt is carried out at the retail yogurt dispensing location just prior to sale of the yogurt contained within a sealed container. Since the milk prior to yogurt or kefir incubation is sterilized by high temperature heating and is sealed and stored in a sterile container throughout the product cycle, the sealed containers of fresh yogurt or kefir receives a ‘Grade A’ rating. The first embodiment of the process takes advantage of thermophillic yogurt such as Streptococcus thermophilus and Lactobacillus bulgaricus cultures that tolerate high incubation temperatures in the range of 33° C. to 45° C. and have very little yogurt culture growth and formation of bad taste and texture when shipped and/or stored as an intimate mixture in a sealed container at temperatures in the range of 4° C. to 10° C. The second embodiment of the process takes advantage of sensitive organisms which may multiply at low temperatures in the range of 4° C. to 10° C. such as kefir culture that grows even at low temperatures and has an incubation temperature in the range of 18° C. to 25° C. for a period of 16 hours and prolonged incubation creates off flavors and texture. In this case, the sterilized cold milk is shipped within the sealed container which has a physically separated region that has the kefir culture and are brought together just prior to incubation of the yogurt. During the time that the yogurt mixture is incubating it must be kept very still, as jostling of the mixture tends to destroy the active culture and causes the yogurt to crack.
[0058] Briefly stated, the first embodiment of the invention involves a process that produces fresh yogurt in situ. More specifically, the process for producing fresh yogurt generally comprises the steps of: (i) sterilizing milk at a temperature in the range of 85° C. to 95° C. to kill all yeast present and to denature the protein structure of the milk suitable for culturing yogurt of kefir if sterilized milk is not available; (ii) cooling the milk to a low temperature in the range of 4° C. to 10° C.; (iii) adding a yogurt culture capable of long life in the 4° C. to 10° C. temperature range to cold milk; (iv) mixing said culture with said cold milk to form a mixture; (v) filling and sealing the mixture in a sterile container; (vi) transporting the containers with cold milk with inoculated yogurt culture to the retail store location and storing said containers at a temperature range of 4° C. to 10° C. for a time period ranging from one day to 30 days; (vi) removing the cold containers as needed from cold storage and heating the container in an oven to a temperature in the range of 33° C. to 45° C. for a period of 4 to 10 hours depending on the time and temperature yogurt setting properties of the yogurt or kefir culture; and (vii) placing said set yogurt or kefir in a refrigerating environment at a temperature of 4° C. to 10° C. for sale to customers at the retail store location. The yogurt thus produced is free from antibiotics, acidifiers, thickeners bacterial growth retarding agents and other artificial additives. The process may further include a cooling and incubation chamber that can both heat for setting the yogurt milk-yogurt culture and cool for refrigerated storage after yogurt setting. The first embodiment requires the yogurt culture mixed in milk to tolerate 4° C. to 10° C. for prolonged time periods without yogurt culture growth producing off flavors or stringy yogurt.
[0059] Briefly stated, the second embodiment of the invention for producing fresh yogurt or kefir generally comprises the steps of: (i) sterilizing milk at a temperature in the range of 85° C. to 95° C. to kill all yeast present and to denature the protein structure of the milk suitable for culturing yogurt of kefir if sterilized milk is unavailable; (ii) cooling the milk to a low temperature in the range of 4° C. to 10° C.; (iii) filling and sealing the cooled milk in a sterile yogurt container with a lid having a separate compartment that contains yogurt of kefir culture kept away from the cold milk; (iv) transporting the yogurt containers with cold milk with separated yogurt or kefir culture to the retail store location and storing said containers at a temperature range of 4° C. to 10° C. for a time period up to 30 days; (v) removing the cold containers as needed from cold storage, shaking the contents to distribute the yogurt or kefir culture into the cold milk and heating the container in an oven to a temperature in the range of 40° C. to 45° C. for a period of 4 to 10 hours for yogurt culture and 18° C. to 25° C. for 10-20 hours for kefir culture depending on the time and temperature yogurt or kefir culture setting properties; and (vii) placing said set yogurt or kefir in a refrigerating environment at a temperature of 4° C. to 10° C. for sale to customers at the retail store location. Since the yogurt or kefir culture is separated from cold milk within the container during transportation and storage at the retail location, no off flavors or stringy textures are generated.
[0060] The storage, heating to incubation temperature and final cooling down after the yogurt or kefir has set can be carried out using three separate units or a single unit capable of cycling through the temperature cycles for specified time periods. In this case, the entire process takes place in situ, with the result that the yogurt is fresh for consumption at the store on the very next day. Quality of the yogurt is improved by eliminating separation which may otherwise occur during portage. Advertising options applicable to this process would include, for example, a sign indicating that the yogurt is incubating, and would be ready in 2 hours. Options exist, such as small heating and cooling units for production of yogurt in situ at the customer's residence.
[0061] FIG. 1 illustrates the flow chart of the first embodiment of the process of the fresh yogurt, shown generally at 100 . The yogurt manufacturing factory is shown at 101 . Step 101 a sterilizes the milk received to kill all the yeast contamination, which can produce sour taste and gassy yogurt. This sterilization step generally requires a temperature in the range of 85° C. to 95° C. If sterilized milk is available this step may be omitted. In step 101 b , the sterilized milk is cooled to 4° C. to 10° C. In step 101 c , the yogurt culture of Streptococcus thermophilus and Lactobacillus bulgaricus which has very little growth rate at 4° C. to 10° C. temperature range is mixed into the milk. In step 101 d , the yogurt mixture containing yogurt culture is fed to individual yogurt cups and sealed in the yogurt factory. This sealed containers of yogurt mixture when incubated at the retail store location produces a ‘Grade A’ certified yogurt, since the yogurt containers have never been opened. The filled sealed yogurt containers are transported to retail store locations in a refrigerated truck maintained at 4° C. to 10° C. temperature as shown in step 102 . Due to the reduced growth characteristic of the Streptococcus thermophilus and Lactobacillus bulgaricus yogurt cultures, the yogurt mixture does not develop foul taste or flavor. The refrigerated truck delivers the sealed yogurt containers with yogurt mixture to retail store locations as shown at step 103 . The retail store uses a refrigerator to store the sealed yogurt containers with yogurt mixture for a period up to 30 days as shown in step 103 a . The merchant of the retail store decides how many yogurt containers must be incubated and transfers the selected yogurt containers into the incubation oven. The yogurt is incubated according to the known yogurt setting characteristics of the yogurt culture, which is typically 33° C. to 45° C. for 4 to 10 hours as shown in step 103 b . The yogurt containers are next transferred to the refrigerated unit maintained at 4° C. to 10° C. and is ready for sale to a customer. The setting characteristics of the yogurt may be verified by opening a sealed yogurt container.
[0062] FIG. 2 illustrates the flow chart of the second embodiment of the process of the fresh yogurt, shown generally at 200 . The yogurt manufacturing factory is shown at 201 . Step 201 a sterilizes the milk received to kill all the yeast contamination, which can produce sour taste and gassy yogurt. This sterilization step generally requires a temperature in the range of 85° C. to 95° C. If sterilized milk is available this step may be omitted. In step 201 b , the sterilized milk is cooled to 4° C. to 10° C. In step 201 c , the cold milk is fed to individual yogurt cups that have a recessed partition portion 201 d with an open top, breakable or dissolvable top that is previously filled with the yogurt or kefir culture. After filling the yogurt container with milk, the container is sealed at the yogurt factory with a lid. Since the yogurt or kefir culture and milk are physically separate there is no possibility of growth of microorganisms in a manner similar to shipped cold milk. This second embodiment can take advantage of all the varieties of yogurt or kefir cultures including the low temperature setting yogurt cultures. Typical yogurt cultures include Lactobacillus acidophilus, Lactobacillus bifidus, Lactobacillus casei, Lactobacillus bulgaricus, Lactobacillus plantarum, Streptococcus thermophilus and mutant cultures. This sealed containers of milk with separated yogurt culture when mixed and incubated at retail store location produces a ‘Grade A’ certified yogurt, since the yogurt containers have never been opened. The filled sealed yogurt containers are transported in a refrigerated truck maintained at 4° C. to 10° C. temperature as shown in step 202 . The refrigerated truck delivers the sealed yogurt containers with milk and separated yogurt or kefir culture to retail store locations as shown at step 203 . The retail store uses a refrigerator to store the sealed yogurt containers for a period up to 30 days as shown in step 203 a . The merchant of the retail store decides how many yogurt containers must be incubated and transfers the selected yogurt containers into the incubation oven after shaking the yogurt containers to mix the yogurt or kefir culture contained in 201 d with the milk intimately. The yogurt mixture is incubated according to the known yogurt setting characteristics of the yogurt culture, which is quite varied. Streptococcus thermophilus and Lactobacillus bulgaricus culture typically requires 33° C. to 45° C. for 4 to 10 hours and Lactobacillus acidophilus and other yogurt cultures requires lower incubation temperatures.
[0063] Kefir culture requires 18° C. to 25° C. for 10 to 20 hours as shown in step 203 b . The yogurt containers are next transferred to the refrigerated unit maintained at 4° C. to 10° C. and is ready for sale to a customer. The setting characteristics of the yogurt may be verified by opening a sealed yogurt container.
[0064] The transportation truck should be vibration isolated to prevent excessive shaking of the yogurt containers produced according to the second embodiment. While FIG. 2 shows the yogurt or kefir containment as an open top partition, other means may be used equally well. This may include a gelatin capsule filled with yogurt or kefir culture wherein the gelatin capsule will dissolve when the yogurt container is shaken at the retail store location. Other separation means may be used equally effectively. In all cases, the sealed cap of the yogurt container must not be opened since this action destroys the ‘Grade A’ rating of the yogurt.
[0065] FIG. 3 illustrates a combination refrigeration incubation unit discussed at web page http://www.startracksmedical.com/solow/ovenfurnace/lrgrefincu.htm. The refrigerator/incubator is programmable and executes time temperature cycle. The combination refrigeration incubation unit may be used for storing received yogurt mixture, incubating and storing finished cooled yogurt or kefir for sale. On the other hand, the combination refrigeration incubation unit may be used only for incubation of yogurt and cooling it for storage or display of finished yogurt or kefir for sale.
[0066] Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.
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A process for delivering to a retail location freshly prepared ‘Grade A’ yogurt or kefir with full undiminished concentration of probiotic microorganisms provides health benefits to customers. The yogurt manufacturing facility mixes cooled sterilized milk with a yogurt culture with low growth at 4° C. to 10° C. forming yogurt mixture fills and seals yogurt containers. Alternatively, the cold milk is separated from any yogurt or kefir culture in the yogurt container by a separation portion. The yogurt containers are then shipped cold to retail locations. The retail location stores yogurt containers at low temperature prior to incubation. When needed, the yogurt container is shaken to mix milk and separated yogurt or kefir culture. The yogurt containers are transferred to incubation oven for appropriate time to set yogurt or kefir, which is then refrigerated for sale to customers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the fiberization of glass or other thermoplastic materials and relates more particularly to fiberization techniques wherein the molten material to be fiberized is centrifugally converted by a rapidly rotating spinner into a multiplicity of glass streams which are attenuated into fibers by a concentric annular gaseous blast from an internal combustion burner adjacent the periphery of the spinner directed perpendicularly to the centrifugal stream, such a fiberization technique being herein referred to as "centrifugal blast attenuation". The fibers, after being sprayed with a binder, are collected on a foraminous conveyor in the form of a blanket or mat, which is then passed through a curing oven.
2. Description of Prior Art
The centrifugal blast attenuation glass fiberization technique generally described above has been used industrially for many years in the production of glass fiber insulation products, and a substantial percentage of glass fiber insulation manufactured at the present time is produced utilizing this technique. Details of various forms of this process are disclosed for example in U.S. Pat. Nos. RE 24,708 2,984,864, 2,991,507, 3,007,196, 3,017,663, 3,020,586, 3,084,381, 3,084,525, 3,254,977, 3,304,164, 3,819,345 and 4,203,745.
In carrying out this technique, substantial amounts of heat energy are required, first for heating the glass into a molten state, and secondly for producing the attenuating blast. The uncertain availability and high cost of energy have created an increasing demand for glass fiber insulation products, while the same factors have caused a substantial increase in the cost of producing such products.
Efforts have accordingly been made to improve the efficiency of the described fiberization process or to utilize alternate fiberization techniques. For example, some glass fiber production has in recent years been carried out utilizing a purely centrifugal fiber attenuation, primarily to avoid the energy requirements of the blast attenuation technique. Such a process is disclosed for example in U.S. Pat. No. 4,058,386.
Centrifugal stream formation coupled with blast attenuation as generally described above remains a preferred technique however, both because of the excellent quality of the fiber blanket obtained therewith as well as the fact that a substantial portion of the insulation industry is equipped at present with apparatus for carrying out such a process. It accordingly follows that any improvement in this technique would be of significant industrial importance. As will be understood from the following disclosure, the present invention provides marked improvements in centrifugal blast attenuation fiberizing techniques with respect to product quality, production rate, and operating costs.
Inasmuch as glass fiberization is in practice an extremely complex technique characterized by a large number of variable parameters, many of the details of known techniques need not be included herein, reference being made to the above patents for such disclosures. However, certain limited aspects of the prior art will be considered, especially concerning those factors respecting which the present invention departs substantially from prior practice.
Among the many variables to be considered, the construction of the spinner and the speed at which it rotates are of particular importance in successfully carrying out a centrifugal fiberization process. In addition, the diameter of the spinner, the size, number and arrangement of the orifices in the peripheral spinner wall, the alloy from which the spinner is made as well as the shape of the spinner wall, the distribution of molten glass to the interior spinner wall and the control of the temperature of various portions of the spinner assembly and the glass flowing therewithin are factors which must be carefully considered.
In the centrifugal blast attenuation process, the blast temperature and velocity, as well as the placement of the blast nozzle and direction of the blast with respect to the spinner wall are important to an optimization of the fiber attenuation. Spinner life is an important factor, particularly in view of the relatively short life of this type of spinner and the extremely high cost of spinner replacement.
The spinners used in early centrifugal blast attenuation equipment were typically of a diameter of about 200 mm and the peripheral wall thereof included typically 4,000 to 6,000 holes through which the molten glass passed to form the primary glass streams subjected to attenuation by the annular blast. It was perceived at an early date that for a spinner of given size and construction, the output or pull rate, conventionally expressed in terms of the weight in tons per day of produced fiber, could be increased only at the expense of a corresponding decrease in fiber quality. It was further perceived that there were practical limits to the pull rate per spinner orifice for maintaining acceptable fiber quality, the maximum rate per orifice ranging between about 1 and 1.4 Kg/day. Nonetheless, the economic demands for increasing production of a given line usually resulted in an increase in pull rate despite the deterioration in product quality. The term "quality" in this sense refers to the product weight per unit of area for a given thermal resistance and nominal product thickness. A lower quality product would hence be a heavier product although with the same insulating value as the better quality product. The lower quality product is thus lower in quality not only since it has a higher density, but also in the sense that it is inherently a more expensive product, requiring more glass for a given area, and is thus more costly to manufacture.
In an effort to increase the output of a spinner of given diameter, the number of holes in the peripheral wall of the spinner was increased. Although some increase in pull rate was achieved, there are practical limits of orifice density controlled by factors such as the necessity of maintaining discrete glass streams emerging from the periphery of the spinner and manufacturing problems. Similar considerations limit the degree to which the spinner peripheral wall can be increased in height to increase its area.
Since the pull rate per orifice, orifice density, and height of the spinner wall could not be further increased without sacrificing fiber quality below acceptable limits, efforts to increase the pull rate were directed toward increase of the spinner diameter, initially to 300 mm and more recently to 400 mm. Although each such increase in diameter produced some increase in pull rate and/or an improvement in fiber quality, the improvements were modest in comparison with those of the present invention.
Another limiting factor is the centrifugal acceleration produced by the high rate of spinner rotation. Although substantial centrifugal forces are required to produce the necessary flow of molten glass through the spinner orifices and to thereby form the primary glass streams, high centrifugal forces foreshorten the life of the spinner.
Since spinner life is substantially inversely proportional to the spinner centrifugal acceleration forces, it has heretofore been considered desirable to restrict rotational speeds of the spinner as much as possible in an effort to extend the spinner life.
Due to the detrimental effects of higher centrifugal acceleration on spinner life and the uncertain effects of higher peripheral speeds on fiber attenuation, the conventional wisdom when increasing spinner diameter has been to decrease or refrain from increasing the centrifugal acceleration and to hold peripheral velocity within a range known to give satisfactory attenuation.
A further factor is of importance, namely the fineness (average diameter) of the fibers. It is well established that for a given density of fiber mat layer, the finer the fibers, the greater the thermal resistance of the layer. An insulating product comprising finer fibers can accordingly be thinner with the same insulating value as a thicker product of coarser fibers. Or, likewise, a product of finer fibers can be less dense than one of coarse fibers of the same thickness and have the same insulating value.
Since sales of insulation products are usually based on a guaranteed thermal resistance (R value) at a nominal thickness, the fiber fineness is an important factor determining the weight of the product per unit of area, known as the basis weight, a product of finer fibers having the lower basis weight and hence requiring less glass and enjoying manufacturing economies.
From an economic standpoint, however, fiber fineness, as with other factors, is normally considered to be a compromise since the attainment of finer fibers is thought to flow principally from higher blast velocities and from the use of softer glass compositions. Increasing the blast velocity results in a direct increase in energy costs, and softer glasses typically require ingredients which are expensive and which, further, usually have undesirable pollutant characteristics.
Fineness, which can be expressed in terms of fiber diameter, in microns, representing the arithmetic mean value of measured fiber diameters, is also conveniently expressed on the basis of a fiber fineness index, or a "micronaire" determination, the latter being a standard measuring technique in the glass wool industry wherein a predetermined mass or sample, for example 5 grams of the fibers, is positioned within a housing of a given volume so as to form a permeable barrier to air passing through the housing under a predetermined pressure and the measurement is made on the air flow through the sample. The measurement thus made depends on the fiber fineness.
In general, the finer the fibers the more resistance offered to the passage of air through the sample. In this manner an indication is given of the average fiber diameter of the sample. The fineness of typical blast attenuated centrifugal glass fiber insulation products ranges from fine types (i.e. micronaire 2.9 (5 g); average diameter 4 μm) to relatively coarse types (i.e. micronaire 6.6 (6 g); average diameter 12 μm).
The insulating value of a blanket of fibers is dependent to a limited although significant degree on the lay-down of the fibers on the collecting conveyor, which determines the orientation of the fibers in the insulation product. The thermal resistance of a fiber blanket will vary depending on the direction of orientation of the fibers to the measured heat flow, the resistance being greater when the fibers are oriented perpendicular to the direction of heat transfer. Accordingly, to maximize the thermal resistance of an insulating blanket, the fibers should be oriented to the maximum degree possible in an attitude parallel to the collecting conveyor and the plane of the blanket formed thereon. Because of the extreme turbulence generated above the collecting conveyor by the decelerating fibers and gaseous currents, there is very little that can be done to control the orientation of the fibers, most efforts in this area of the fiberizing process being directed toward achieving a relatively uniform distribution of fibers across the width of the conveyor.
BRIEF SUMMARY OF THE INVENTION
In an effort to increase fiber production still further while maintaining or possibly improving the quality of the fibers, experiments were undertaken with still larger spinners having diameters of 600 mm and over. Surprising improvements in pull rate and/or quality were achieved although for reasons some of which at the present time are not entirely clear. Particularly unexpected were improvements in the fiber quality which exceeded forecasts by 10-25% depending on the pull rate utilized.
In making the transition from a 400 mm to a 600 mm spinner, the spinner rotational speed was reduced to provide centrifugal accelerating forces on the glass and spinner wall within conventional limits such that the glass feed through the orifices, as well as the stresses placed on the spinner wall structure, would not depart significantly from prior practice. It was feared that the larger spinner diameter would, at the rotational speed necessary to produce such centrifugal force, result in an unacceptably high peripheral speed of the spinner with a consequent degradation of fiber formation and attenuation. Surprisingly, the fiberization was not adversely affected by the higher peripheral speed as evidenced by the improved fiber quality and/or pull rate as compared with lower peripheral speeds.
The present invention in summary comprises techniques including both apparatus and method for producing glass fibers, and fibrous insulation blanket made therefrom, including a spinner mounted for rotation about a substantially vertical axis, the spinner having a diameter substantially greater than 500 mm and preferably within the range of from about 550 or 600 mm to about 1500 mm.
The apparatus additionally includes means for supplying a stream of molten glass to the spinner for centrifugal delivery to the interior surface of the peripheral spinner wall. This wall includes a plurality of orifices through which the molten glass passes and forms a multiplicity of streams. The invention contemplates use of a spinner having orifices of at least 0.7 mm in diameter and contemplates formation of fibers from the centrifugally delivered streams by the use of gas blast attenuation.
The technique of the invention includes an internal combustion burner providing a downwardly directed annular blast adjacent the spinner wall to attenuate the glass streams into fibers. The fibers are delivered downwardly into a receiving hood or receiving chamber and are collected on a substantially horizontal foraminous conveyor disposed at the bottom of the receiving chamber.
Still further the invention contemplates a peripheral spinner velocity substantially higher than heretofore conventionally employed and preferably in the range of about 50 m/s to about 130 m/s.
The invention is further directed to a glass fiber insulation blanket produced by the described process.
Although efforts have been undertaken to isolate the principal factors responsible for the improved performance of the larger spinner, at the present time these efforts have not been conclusive.
The following disclosure will present a detailed description of the apparatus and process utilized in obtaining the improved performance as well as a description of the improved product obtained thereby.
Such theoretical explanations as are set forth in this specification must be recognized to be tentative, subject to further experimental verification, and not taken to be limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional elevational view showing a spinner assembly and burner in accordance with the present invention;
FIG. 2 is a schematic elevational view showing the operation of a conventional small diameter spinner and fiber collecting conveyor, the view being taken transversely through the conveyor and illustrating the uneven distribution and random orientation of fibers on the conveyor in the absence of fiber distribution means;
FIG. 3 is a view similar to FIG. 2 but employing a large diameter spinner operating in accordance with the invention showing the relatively uniform distribution and relatively uniform orientation of fibers on the conveyor in the absence of fiber distribution means;
FIG. 4 is a schematic plan view showing a plurality of spinners and their arrangement with respect to the conveyor;
FIG. 5 is a schematic elevational view of the apparatus shown in FIG. 4;
FIG. 6 is a graph showing fiber quality plotted against spinner diameter for fibers of various degrees of fineness; and
FIG. 7 is a graph showing energy consumption plotted against spinner diameter for fibers produced at constant centrifugal acceleration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIG. 1 thereof, a fiberizing station in accordance with the present invention is illustrated including a spinner 10 having a peripheral wall 12 and a support plate 18. The spinner 10 is mounted by means of a hub portion 20 to a substantially vertical shaft 22. The shaft 22 is rotatably supported in a well known manner by suitable bearin9s attached to a supportin9 frame and is driven in rotation at a relatively uniform predetermined speed by an electric motor and belt drive. The shaft support and drive details are conventional and accordingly are not illustrated.
The shaft 22 is hollow, permitting a stream of molten glass 24 to pass downwardly therethrough into a basket 26 supported beneath the lower end of the shaft by bolts 32.
The basket 26 comprises a substantially cylindrical wall 34 having a plurality of orifices 36 through which the molten glass passes under the influence of centrifugal force in streams 38 which are directed onto the interior of the spinner wall 12. A multiplicity of orifices 40 in the peripheral wall 12 of the spinner serve to form a multiplicity of molten glass streams 41 as the molten glass is forced through the orifices by the centrifugal force acting thereon.
As discussed hereinafter, the diameter of the spinner, the size and density of the orifices 40, as well as the speed of rotation of the spinner are parameters important to the fiberizing process.
An annular internal combustion burner 42 of substantially conventional construction is disposed above the wall of the spinner and includes an annular blast nozzle 44 spaced above the spinner peripheral wall 12 so as to direct an annular blast downwardly adjacent the spinner wall 12 to intercept and attenuate the multiplicity of glass streams 41 issuing from the orifices 40. The burner 42 includes a metal casing 46 enveloping a refractory liner 48 defining an annular combustion chamber 50 into which an air-fuel mixture is introduced at inlet 52. The blast nozzle 44 communicates with the combustion chamber 50 and is formed by inner and outer nozzle lips 54 and 56. The blast nozzle lips 54 and 56 respectively include internal cooling channels 54a and 56a into which a cooling liquid such as water is introduced by inlet 60 for circulation to an outlet (not shown).
In order to maintain the heat content of the spinner and fibers during attenuation, a high frequency induction heating ring 62 is provided just below the spinner in concentric relation thereto and having an internal diameter somewhat larger than the spinner to avoid interference with the downward flow of fibers entrained by the annular blast.
An auxiliary blast is generated by an annular blowing crown 64 disposed outboard of the blast nozzle lips and connected to a source of pressurized gas such as air, steam or combustion products.
The hollow shaft 22 includes several fixed concentric internal tubes. The innermost pair of these tubes defines an annular cooling passage 66 through which cooling water is circulated while the outermost pair define an annular passage 68 through which a combustible mixture can be passed and ignited to preheat the basket 26 prior to startup of the spinner.
The fibers generated by the spinner and the gaseous blast pass downwardly into a receiving chamber or receiving hood 70 and are thence deposited in the form of a blanket 71 on a foraminous conveyor 72 as shown schematically in FIGS. 2, 3 and 5. A suction box 74 beneath the conveyor withdraws the high volume of gases passing through the conveyor in a conventional manner.
As shown in FIGS. 4 and 5, a plurality of fiberizing stations each having a spinner 10 are conventionally employed for the production of the blanket 71 and in the preferred form of the invention are arranged in a line along the longitudinal axis of the conveyor 72. The number of spinners directing fibers onto a conveyor in an industrial installation might typically be six to ten spinners or more.
For operation of the described apparatus, the spinner 10 including the basket 26 thereof is preheated in a well known manner utilizing the combustion of gases passing through passage 68, the heat of the burner 50 and heating ring 62 and similar supplemental sources as may be necessary.
With the spinner rotating at a predetermined speed and the burner adjusted to provide a combustion chamber pressure resulting in a blast velocity sufficient to provide the desired attenuation and fineness of the fibers, the molten glass stream 24 is introduced into the hollow spinner shaft 22 from a forehearth or other source of molten glass disposed above the spinner assembly. The stream of molten glass upon reaching the basket 26 flows along the bottom of the basket under the influence of centrifugal force and passes through the orifices 36 of the basket in the form of glass streams 38 which are directed onto the upper portion of the spinner peripheral wall 12.
Under the influence of the stronger centrifugal force exerted at the wall 12, the glass passes through the multiplicity of small orifices 40 and issues at the exterior of the peripheral wall in the form of a multiplicity of streams 41 which are immediately subject to the attenuating effect of the blast from the internal combustion burner 50 directed across the exterior of the wall. The glass streams 41 are maintained in an attenuable condition by the elevated temperature of the blast for a time sufficient to effect attenuation thereof. The fineness of the attenuated fibers is regulated primarily by the control of the blast velocity which in turn is a function of burner pressure. An increase in burner pressure and blast velocity will result in a greater attenuation and hence finer fibers.
The flow of attenuated fibers into the receiving chamber or receiving hood 70 as shown in FIGS. 3 and 5 is accompanied by the induction of substantial amounts of air as shown by the arrows at the top of the receiving chamber. Although the induced air tends initially to restrict the expansion of the veil of fibers flowing from the spinner, the rapid deceleration of the fibers within the receiving chamber produces a substantial expansion of the fiber veil and, for reasons discussed in more detail herebelow, provides a relatively uniform distribution of the fibers amid the product and across the width of the conveyor. Furthermore, due to a diminution of the turbulence usually present in the conveyor region, the invention produces a more favorable orientation of the fibers during the formation of the fiber blanket with a resultant improvement of the thermal properties of the blanket.
Although a binder spray is applied to the attenuated fibers at the top of the receiving chamber in a conventional manner, the showing of the apparatus for applying the binder has been omitted in FIGS. 2-5 to simplify these figures.
The diameter of the spinner and the speed of spinner rotation are important factors in the present technique.
The largest spinners in industrial use in centrifugal blast attenuated processes have heretofore had a diameter on the order of 400 mm and a peripheral velocity of approximately 44 m/s. An increase in spinner diameter and peripheral velocity had not been deemed feasible, even if centrifugal acceleration were not increased, since peripheral velocity would increase to a degree which was thought to present difficulties in fiber attenuation.
It has been discovered, however, that substantial increases in spinner diameter and peripheral velocity have no adverse effects on fiberization, and in fact, produce fiber of improved quality when operated at the same pull rate per spinner as the 400 mm sized spinner. For example, a spinner of 600 mm in accordance with the present invention can be operated at a pull rate about 50% higher than a 400 mm spinner while producing the same quality fiber. The economic advantages of such an improvement are evident, particularly when it is considered that the output of a given production line can be increased by at least 50% utilizing the invention with modifications requiring a capital outlay in a typical situation of less than 3% of the cost of a new production line.
Considering further the factor of spinner diameter, excellent results have been achieved utilizing a spinner of 600 mm diameter and substantially larger spinners can be used. The benefits of the invention can be attained with spinners having a diameter substantially in excess of 500 mm and within the range of about 550 mm to about 1500 mm. The preferred range of spinner diameter is 600 mm to 1000 mm.
It has been found that fiberization and hence fiber quality is generally improved with increased peripheral speed and increased centrifugal acceleration, although the latter is detrimental to spinner life. By selecting a spinner rotational speed providing centrifugal acceleration forces not significantly departing from those conventionally utilized in smaller spinners, for example within the range of about 8,000 to 14,000 m/s 2 , the peripheral speed with the larger size spinners would be significantly higher than that conventionally employed with smaller spinners with a resultant improved fiber quality. The spinner life would not be decreased, the larger spinners experiencing substantially the same centrifugal forces as the smaller conventional spinners. For example, with a 600 mm spinner operating at a speed producing a centrifugal acceleration of 10,600 m/s 2 , the peripheral speed would be 56.5 m/s, substantially higher than the peripheral speed of 46 m/s of the conventional 400 mm spinner operating at the same centrifugal acceleration.
The present invention contemplates a rotational speed of the spinner which, taking account of the preferred range of spinner diameters as described above, would produce a centrifugal acceleration at the spinner peripheral wall within the range of about 4,000 to about 20,000 m/s 2 and a peripheral speed ranging substantially between about 50 and about 130 m/s. It is expected that the centrifugal acceleration would in practice range between about 6,000 to about 16,000 m/s 2 , particularly in view of the improvement in fiber quality noted within this latter range. Since fiber quality improves with increasing centrifugal acceleration and peripheral speed, the only detriment to operating toward the upper end of the above ranges is the reduced spinner life.
The graph of FIG. 6 illustrates the operation of spinners of various sizes, at a substantially constant centrifugal acceleration of about 10,000 m/sec 2 . It is to be noted that fiber quality, for fiber finenesses of 2.5, 3.0, 3.5 and 4.0 (under 5 grams), significantly and sharply improves, as is graphically shown by the distinct change in the angle of curvature, at spinner diameters substantially in excess of 500 mm.
Taking into account the preferred ranges of spinner diameter and centrifugal acceleration described above, the peripheral velocity of the spinner should in practice range between about 66 m/s and about 90 m/s. The preferred range of peripheral velocity is from about 55 m/s to about 75 m/s.
In view of the foregoing ranges of peripheral speed, spinner diameter and centrifugal acceleration, the spinner rotational speed would range from about 800 rpm to about 2500 rpm.
The diameter of the spinner wall orifices 40 should be at least 0.7 mm and preferably from about 0.8 mm to about 1.2 mm. The density of the orifices should be at least 15 orifices per square centimeter of the perforated part of the wall and preferably between 15 and 30 orifices per square centimeter. A preferred density is about 35 orifices per square centimeter.
Another factor having an important bearing on fiber production is the burner pressure, the control of which directly affects the fiber fineness.
Utilizing a burner of the type shown in FIG. 1, a preferred range of burner pressure is between about 100 and about 900 mm water column with a preferred pressure of 400 mm water column. For reasons not totally understood, the required burner pressure necessary to produce a fiber of a certain fineness decreases with increasing spinner diameter, even though the centrifugal acceleration is not increased. This factor may be a cause of the improved fiber quality as well as the energy saving noted with the larger spinners since the lower burner pressure results in longer fibers with less fiber breakage.
The width of the burner nozzle 44 preferably is within the range of about 5 mm to about 15 mm with a preferred width of about 8 mm. The burner temperature preferably ranges between about 1300° C. and 1700° C. with a preferred temperature of about 1500° C.
With spinners contemplated by the present invention, it has been found that an improved distribution of the fibers on the conveyor as well as an improved orientation of the fibers within the blanket could be obtained.
Measurements were made on products obtained according to the prior technique and products obtained with the technique of the present invention.
There are several methods of measuring the distribution within the product. One of the more simple ones involves cutting the product into a series of small parallelipipeds or "cubes" (for example of 25×25×45 mm in size) which are individually weighed. The various weights, which can be expressed in local densities related to the center of gravity of each "cube", give a three dimensional image of the distribution. To facilitate the comparisons the coefficient of variation C v of the distribution is calculated by the quadratic differential (square root of the mean value of the differentials squared) to the mean value of the weight of the "cubes".
For example, a very significant differential was found between a product obtained with the prior technique (C v =6.1%) and that obtained with the technique of the present invention (C v =2.6%).
In the example of the invention illustrated in FIG. 3, the relatively large diameter of the spinner results in a veil of fibers which expands before reaching the conveyor and the width of which is greater than the width of the conveyor, the fibers around the edge of the veil at each side of the conveyor encountering the sides of the receiving hood 70 and being redirected inwardly to produce a blanket 71 of relatively uniform thickness. The lay-down of the fibers occurs with a minimal amount of turbulence and accordingly results in a fiber orientation predominately parallel to the direction of the conveyor.
In contrast, an example of the prior art is shown in FIG. 2 wherein the fiber veil is seen to be too narrow to reach the walls of the receiving hood and, as a result, due to the typical concentration of fibers in the center of the veil, the blanket is nonuniform, being disproportionately thick in the center and thin at the sides. Furthermore, in contrast to the lay-down of the fibers with the larger spinner shown in FIG. 3, a substantial turbulence occurs around the edge of the veil proximate the conveyor, which turbulence results in a disorganized lay-down of the fibers, the fiber orientation being substantially less parallel to the conveyor than that produced with the present apparatus and method.
Because of the poor distribution attainable with the conventional smaller spinners operating under conventional parameters, various auxiliary means have been employed in an effort to improve the fiber distribution.
With the wide conveyors it is possible to place transversely two, three or more fiberizing units in a transverse direction to the conveyor. However, even if theoretically this arrangement enables a uniform distribution, it presents the major disadvantage that for any stoppage of a single unit of the row, for example to change the spinner, the disorganization of the distribution resulting from this stoppage leads to the rejection of the product formed by all the other units during the span of the intervention. For this reason it is generally preferable to arrange the fiberizing units in a single line longitudinally to the conveyor, since, in this case, any stoppage of a unit would not appreciably alter the distribution and it would be possible to continue to produce--production only being minimized by the lower pull rate of the halted unit.
With the units arranged in this manner, various types of auxiliary distribution means are employed in an effort to improve the fiber distribution. These distribution means include for example jet nozzles in the side of the receiving hood (U.S. Pat. No. 3,030,659), oscillating or alternately fed blower rings, baffles controlling induced air (U.S. Pat. No. 3,255,943), oscillating conduits for the fiber veils (U.S. Pat. No. 3,830,638) and the oscillation of the spinner assembly (U.S. Reissue Pat. No. RE 30,192). Although such devices may achieve an improved fiber distribution, they generally introduce even more turbulence into the receiving chamber, thereby causing an even less favorable orientation of the fibers in the blanket. Since the fiber orientation is extremely important in a fiber insulating medium, with a fiber orientation parallel to the conveyor providing improved thermal resistance characteristics, it can be understood that the larger veil produced by the large spinners in accordance with the invention is an important factor in optimizing the quality of the fibrous blanket. Furthermore, the expense of auxiliary distribution devices and the cost of their operation can be minimized or eliminated with the present invention.
The shape of the veil of fibers directly beneath the spinner can be seen to be more favorable in FIG. 3 than in FIG. 2, the veil in FIG. 3 having relatively little contraction beneath the spinner whereas that of FIG. 2 is substantially contracted in this region. The cause of this improvement is not as yet known but may be a result of the increased spinner peripheral speed which in some manner counteracts the constricting effect of the induced air.
The significant decrease in energy consumption with increased spinner diameter can be readily seen from the graph of FIG. 7. The curve of the graph represents fiberization at constant centrifugal acceleration of 10,000 m/s 2 . This curve was obtained utilizing conditions of similitude wherein the glass, the spinner height, orifice density, orifice size, orifice pull rate, and fiber quality were held constant for production of a fiber blanket having an insulating value of R=2 W/m 2 K at 297° K.
Although it is expected that the present apparatus and method can be effectively utilized with any of the glass compositions conventionally employed for producing glass fibers by centrifugal blast attenuation, the glass composition preferably falls within the following ranges:
______________________________________SiO.sub.2 61 to 72%Al.sub.2 O.sub.3 2 to 8%Fe.sub.2 O.sub.3 0.2 to 1%CaO 4.7 to 7.5%MgO 0 to 5%Na.sub.2 O + K.sub.2 O 14 to 18%B.sub.2 O.sub.3 0 to 6%F 0 to 1.5%BaO 0 to 2.5%ZrO.sub.2 0 to 2.5%Misc ≦1______________________________________
The heat transfer characteristics of a fibrous material are usually expressed in terms of its apparent conductivity which is derived essentially from the sum of the conduction of the gas contained in the material, the solid conduction of the fibers and the radiation through the material. For fibrous insulation materials used in a confined space such as blankets of fibrous material used as building insulation, for the temperature ranges encountered, the heat transfer by convection is negligible and can be ignored. The apparent thermal conductivity can thus be expressed as follows:
λ=A+B(ρ)+C/ρ
where
λ=apparent conductivity W/m°K.
A=conductivity of the gas
B=Coefficient of conductivity related to the solid part of the fibrous material
C=fiber surface area factor
ρ=density of the fibrous material.
We have found that in the carrying out of the invention, suitable values for these factors are as follows:
A=25.89×10 -3
B=0.02×10 -3 to 0.2×10 -3 , preferably 0.075×10 -3
C=0.100 to 0.300, preferably 0.190
ρ=8 to 75
The apparent conductivity for fibrous insulation materials typically ranges between 30×10 -3 to 55 at 24° C. with the fiber fineness ranging between about 2 (5 g) to about 5 (5 g).
SPECIFIC EXAMPLES
The following are examples of operating parameters utilized in successfully carrying out the present technique.
______________________________________ Example No. I II III______________________________________Spinner Diameter (mm) 600 600 1000Pull rate per spinner 20 20 20(metric Tons/day)Number of orifices per spinner 20,000 20,000 20,000Pull rate per orifice 1 1 1(average) (Kg/day)Burner nozzle width (mm) 7.7 7.7 6.5Burner pressure (mm water) 350 430 420Burner temperature °C. 1500 1500 1500Centrifugal acceleration (m/s.sup.2) 10,600 10,600 7888Peripheral velocity (m/s) 56.5 56.5 62.8Fineness (micronaire under 5 g) 3.5 3.0 2.5Density for R = 2 at 24° C. (Kg/m.sup.3) 11.1 10.5 8Nominal Thickness (mm) 90 90 90______________________________________
The glass composition utilized in the Examples is as follows:
SiO 2 : 64.10
Al 2 O 3 : 3.40
Fe 2 O 3 : 0.45
CaO: 7.20
MgO: 3.00
Na 2 O: 15.75
K 2 O: 1.15
B 2 O 3 : 4.50
Misc.: 0.20
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Glass fibers for insulation uses are produced by means of a centrifugal spinner which introduces glass streams into an annular attenuating blast adjacent the periperhy of the spinner. An improved product quality and/or production rate as well as prolonged spinner life are obtained by selection and utilization of a novel combination of structural and operating parameters characterized in particular by a spinner diameter and peripheral speed substantially greater than conventionally employed. The present technique further provides reduced turbulence in the receiving chamber and hence an improved distribution and orientation of the fibers on the collecting conveyor.
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This is a division of application Ser. No. 07/691,798 filed Apr. 26, 1991, now U.S. Pat. No. 5,221,694.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to novel N-benzyl-N-phenoxyethylamines and salts thereof, and to novel bactericides for agricultural and horticultural use.
(2) Description of the Prior Art
Inorganic copper-containing agents, organic copper-containing agents and antibiotic agents such as streptomycin have been used as bactericides for combating pathogenic bacteria causing blights in agricultural plants.
However, these conventional bactericides are defective in that the effect is practically insufficient and phytotoxicity is caused. Accordingly, development of a bactericide having strong bacteriostatic and bactericidal actions (both of the actions will be collectively called "antibacterial action" hereinafter) and having reduced phytotoxicity is desired at the present.
SUMMARY OF THE INVENTION
The present inventors have conducted a study in an effort to solve the above-mentioned problems inherent in the prior art and have arrived at the present invention which is capable of forming novel N-benzyl-n-phenoxyethylamines and salts thereof that exhibit antibacterial action that is strong enough for practical use with virtually no phytotoxicity.
According to the present invention, there is provided an N-benzyl-N-phenoxyethylamine selected from the group consisting of the N-benzyl-N-phenoxyethylamine represented by the following formula (I): ##STR3## and an agriculturally acceptable acid addition salt represented by the following formula (II): ##STR4## wherein m represents a number of 1 or 2 with a proviso that when m is 1 and a chlorine atom in the ring A is present at the para(4)-position of the ring A, two chlorine atoms in the ring B are present at 2,3-, 2,5-, 2,6-, 3,4- or 3,5-positions of the ring B, and HX represents an acid.
According to another embodiment of the present invention, there is provided an agricultural and horticultural bactericide comprising, as an active ingredient, an N-benzyl-N-phenoxyethylamine selected from the group consisting of the N-benzyl-N-phenoxyethylamine represented by the following formula (I'): ##STR5## and an agriculturally acceptable acid addition salt represented by the following formula (II'): ##STR6## wherein n is a number of 1 or 2.
DT-OS 2429523 discloses an N-(4-chlorobenzyl)-N-(2,4-dichlorophenyl)-ethylamine which is a compound that resembles the N-benzyl-N-phenoxyethylamine of the present invention. As for the application of the above compound, however, the above publication simply describes to use the compound as an intermediate for synthesizing imidazole derivatives that are useful as bactericides. Namely, utilizability of the compounds of the general formulas (I) and (II) as bactericides was found by the present inventors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The N-benzyl-N-phenoxyethylamine represented by the general formula I of the first invention is prepared, for example, as follows: ##STR7##
Namely, phenol III is reacted with dibromoethane IV in the presence of a base such as sodium hydroxide in a solvent such as water, an alcohol, dimethylsulfoxide or dimethylformamide to give phenoxyethyl bromide V, which is reacted with amine VI preferably in the presence of a hydrogen bromide scavenger in a solvent such as an alcohol, dimethylsulfoxide or dimethylformamide to give the N-benzyl-N-phenoxyethylamine I of the present invention.
The N-benzyl-N-phenoxyethylamine salt of the first invention represented bygeneral formula II is prepared, for example, by reacting the above-mentioned N-benzyl-N-phenoxyethylamine I with an acid. Though there is no particular limitation on the kind of acid that is used, typical examples include hydrochloric acid, bromic acid, iodic acid, sulfuric acid, nitric acid, phosphoric acid, formic acid, acetic acid, propionic acid, butyric acid, isobutyric acid, valeric acid, pivalic acid, decanoic acid, lauric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, maleic acid, fumaric acid, benzoic acid, phthalic acid,isophthalic acid, terephthalic acid, substituted benzoic acid, naphthoic acid, cinnamic acid, furancarboxylic acid, thiophenecarboxylic acid, pyrrolecarboxylic acid, pyridinecarboxylic acid, methanesulfonic acid, benzenesulfonic acid, p-methylbenzenesulfonic acid (p-toluenesulfonic acid), monobutylphosphoric acid ester, dibutylphosphoric acid ester, monobenzylphosphoric acid ester, dibenzylphosphoric acid, i, ester, 2-ethylhexylphosphoric acid ester, di(2-ethylhexyl)phosphoric acid ester, 3-phenyl-5-methylisoxazol-4-carboxylic acid and the like. Further, the acid may be used in either the gaseous state or the liquid state.
In the general formula II, HX corresponds to the acid used in the preparation.
In the preparation of salt, use of a reaction solvent is not absolutely necessary, but a solvent ordinarily used as a reaction solvent, such as, an alcohol, an ether or an ester, or water, can be used as the reaction solvent. Though there is no particular limitation on the reaction temperature, when, for example, a mineral acid is used in the gaseous form, the loss of mineral can be decreased by maintaining the temperature as low as, for example, at 0° C.
The N-benzyl-N-phenoxyethylamine salt of the first invention is solid or liquid at room temperature or normal temperature, and, in the case of solid, the salt can be recovered from the reaction product liquor by ordinary solid-liquid separating means such as filtration or centrifugal separation and if desired, the recovered crystals can be purified by washing or recrystallization from an alcohol or water.
The physical properties of the N-benzyl-N-phenoxyethylamine represented by general formula I and the N-benzyl-N-phenoxyethylamine salt represented bygeneral formula II of the present invention are shown in Tables 1 and 2, respectively.
TABLE 1______________________________________Physical properties of N-benzyl-N-phenoxyethylamines.______________________________________First line; compound No. Cl(phenoxy group), Cl.sub.mSecond and subsequent line; 1 state, melting point 2 NMR values .sup.1 H-NMR(CDCL.sub.3) δppm 1 2,4-Cl.sub.2 2-Cl1 colorless columnar crystal m.p. 54˜55° C.2 2.05(s, 1H), 3.01(t, J=5Hz, 2H), 3.93(s, 2H), 4.07(t, J=5Hz, 2H), 6.73(d, J=9Hz, 1H), 7.11(dd, J=9, 2Hz, 1H), 7.2-7.5(m, 5H) 2 2,4-Cl.sub.2 3-Cl1 colorless oil m.p. (hydrochloride) 135˜137° C.2 1.76(s, 1H), 3.01(t, J=5Hz, 2H), 3.85(s, 2H), 4.09(t, J=5Hz, 2H), 6.79(d, J=9Hz, 1H), 7.14(dd, J=9, 2Hz, 1H), 7.20(s, 4H), 7.32(d, J=2Hz, 1H) 3 2,4-Cl.sub.2 3,4-Cl.sub.21 colorless needle crystal m.p. 42˜43° C.2 1.87(s, 1H), 2.99(t, J=5Hz, 2H), 3.81(s, 2H), 4.07(t, J=5Hz, 2H), 6.75(d, J=8Hz, 1H), 7.0-7.4(m, 5H) 4 3,4-Cl.sub.2 2-Cl1 colorless columnar crystal m.p. 64˜66° C.2 1.91(s, 1H), 3.00(t, J=5Hz, 2H), 3.93(s, 2H), 4.07(t, J=5Hz, 2H), 6.67(dd, J=9, 2.5Hz, 1H), 6.93(d, J=2.5Hz, 1H), 7.1-7.5(m, 5H) 5 3,4-Cl.sub.2 3-Cl1 colorless oil m.p. (hydrochloride) 180˜182° C.2 1.75(s, 1H), 2.97(t, J=5Hz, 2H), 3.81(s, 2H), 4.01(t, J=5Hz, 2H), 6.68(dd, J=9, 2.5Hz, 1H), 6.95(d, J=2.5Hz, 1H), 7.1-7.3(m, 5H) 6 3,4-Cl.sub.2 4-Cl1 colorless needle crystal m.p. 63˜65° C.2 1.76(s, 1H), 2.96(t, J=5Hz, 2H), 3.80(s, 2H), 4.00(t, J=5Hz, 2H), 6.69(dd, J=9, 2.5Hz, 1H), 6.94(d, J=2.5Hz, 1H), 7.23(s, 4H), 7.29(d, J=9Hz, 1H) 7 3,4-Cl.sub.2 2,4-Cl.sub.21 colorless columnar crystal m.p. 37˜39° C.2 1.83(s, 1H), 3.00(t, J=5Hz, 2H), 3.82(s, 2H), 4.06(t, J=5Hz, 2H), 6.73(dd, J=9, 2.5Hz, 1H), 6.98(d, J=2.5Hz, 1H), 7.1-7.4(m, 4H) 8 3,4-Cl.sub.2 3,4-Cl.sub.21 colorless oil m.p. (hydrochloride) 154˜156° C.2 1.76(s, 1H), 2.97(t, J=5Hz, 2H), 3.80(s, 2H), 4.05(t, J=5Hz, 2H), 6.67(dd, J=8, 2Hz, 1H), 6.9-7.4(m, 5H) 9 2,5-Cl.sub.2 3,4-Cl.sub.21 colorless needle crystal m.p. 34˜36° C.2 2.61(s, 1H), 3.00(t, J=5Hz, 2H), 3.81(s, 2H), 4.08(t, J=5Hz, 2H), 6.7-7.5(m, 6H)10 2.6-Cl.sub.2 3,4-Cl.sub.21 colorless oil m.p. (hydrochloride) 162˜164° C.2 2.10(s, 1H), 2.98(t, J=5Hz, 2H), 3.80(s, 2H), 4.13(t, J=5Hz, 2H), 6.7-7.5(m, 6H)11 2.3-Cl.sub.2 3,4-Cl.sub.21 colorless columnar crystal m.p. 52˜53° C.2 1.84(s, 1H), 2.97(t, J=5Hz, 2H), 3.81(s, 1H), 4.10(t, J=5Hz, 2H), 6.73(dd, J=8, 3.5Hz, 1H), 7.0-7.5(m, 5H)12 3.5-Cl.sub.2 3,4-Cl.sub.21 colorless columnar crystal m.p. 29˜30° C.2 1.40(s, 1H), 2.97(t, J=5Hz, 2H), 3.80(s, 2H), 4.05(t, J=5Hz, 2H), 6.73(d, J=1.5Hz, 2H), 6.89(t, J=1.5Hz, 1H), 7.13(dd, J=8, 1.5Hz, 1H), 7.29(d, J=1.5Hz, 1H), 7.34(d, J=8Hz, 1H)13 2.3-Cl.sub.2 2,4-Cl.sub.21 colorless columnar crystal m.p. 84˜86° C.2 1.97(s, 1H), 3.03(t, J=5Hz, 2H), 3.92(s, 2H), 4.13(t, J= 5Hz, 2H), 6.25(dd, J=7, 3Hz, 1H), 7.0-7.5(m, 5H)14 3.5-Cl.sub.2 2,4-Cl.sub.21 colorless columnar crystal m.p. 36˜38° C.2 2.02(s, 1H), 2.93(t, J=5Hz, 2H), 3.75(s, 2H), 3.97(t, J=5Hz, 2H), 6.68(d, J=1.5Hz, 2H), 6.81(t, J=1.5Hz, 1H), 7.06(dd, J=9, 1.5Hz, 1H), 7.24(d, J=9Hz, 1H), 7.36(d, J=1.5Hz, 1H)15 3,4-Cl.sub.2 2.6-Cl.sub.21 colorless oil m.p. (hydrochloride) 196˜198° C.2 2.06(s, 1H), 2.97(t, J=5Hz, 2H), 3.97(t, J=5Hz, 2H), 4.09(s, 2H), 6.66(dd, J=9, 3Hz, 1H), 6.91(d, J=3Hz, 1H), 7.0-7.3(m, 4H)16 2,3-Cl.sub.2 2.6-Cl.sub.21 colorless needle crystal m.p. 77˜78° C.2 1.33(s, 1H), 3.05(t, J=5Hz, 2H), 4.10(t, J=5Hz, 2H), 4.15(s, 2H), 6.71(dd, J=6, 4Hz, 1H), 6.9-7.4(m, 5H)17 3,5-Cl.sub.2 2.6-Cl.sub.21 colorless columnar crystal m.p. 46˜47° C.2 2.04(s, 1H), 3.00(t, J=5Hz, 2H), 4.00(t, J=5Hz, 2H), 4.13(s, 2H), 6.08(d, J=1.5Hz, 1H), 6.90(t, J=1.5Hz, 1H), 7.23(m, 3H)18 2,6-Cl.sub.2 2.6-Cl.sub.21 colorless columnar crystal m.p. 50˜52° C.2 2.39(s, 1H), 3.07(t, J=5Hz, 2H), 4.18(t, J=5Hz, 2H), 4.19(s, 2H), 6.8-7.4(m, 3H)19 2,5-Cl.sub.2 2.6-Cl.sub.21 colorless needle crystal m.p. 71˜73° C.2 2.30(s, 1H), 3.06(t, J=5Hz, 2H), 4.09(t, J=5Hz, 2H), 4.15(s, 2H), 6.7-7.0(m, 2H), 7.1-7.4(m, 2H)20 2,4-Cl.sub.2 2.6-Cl.sub.21 colorless oil m.p. (hydrochloride) 190˜192° C.2 2.33(s, 1H), 3.03(t, J=5Hz, 2H), 4.05(t, J=5Hz, 2H), 4.12(s, 2H), 6.71(d, J=9Hz, 1H), 7.0-7.3(m, 5H)21 3.4-Cl.sub.2 2,3-Cl.sub.21 colorless oil m.p. (hydrochloride) 175˜177° C.2 1.98(s, 1H), 3.00(t, J=5Hz, 2H), 3.96(s, 2H), 4.05(t, J=5Hz, 2H), 6.71(dd, J=9.2Hz, 1H), 6.98(d, J=2Hz, 1H), 7.1-7.5(m, 4H)22 2,3-Cl.sub.2 2.3-Cl.sub.21 colorless columnar crystal m.p. 105˜106° C.2 1.98(brs, 1H), 3.04(t, J=5Hz, 2H), 4.01(s, 2H), 4.16(t, J=5Hz, 2H), 6.7-7.5(m, 6H)23 2,6-Cl.sub.2 2,3-Cl.sub.21 colorless oil m.p. (hydrochloride) 148˜150° C.2 2.21(s, 1H), 3.07(t, J=5Hz, 2H), 4.01(s, 2H), 4.20(t, J=5Hz, 2H), 6.8-7.4(m, 6H)24 2,4-Cl.sub.2 2,3-Cl.sub.21 colorless oil m.p. (hydrochloride) 189˜191° C.2 2.96(s, 1H), 3.05(t, J=5Hz, 2H), 4.00(s, 2H), 4.12(t, J=5Hz, 2H), 6.82(d, J=9Hz, 1H), 7.0-7.5(m, 5H)25 3,5-Cl.sub.2 2,3-Cl.sub.21 colorless oil m.p. (hydrochloride) 172˜174° C.2 1.90(s, 1H), 3.00(t, J=5Hz, 2H), 3.96(s, 2H), 4.05(t, J=5Hz, 2H), 6.76(d, J=2Hz, 2H), 6.92(t, J=2Hz, 1H), 7.30(m, 3H)26 2,5-Cl.sub.2 2.3-Cl.sub.21 colorless columnar crystal m.p. 67˜69° C.2 2.08(s, 1H), 3.05(t, J=5Hz, 2H), 3.99(s, 2H), 4.12(t, J=5Hz, 2H), 6.7-7.5(m, 6H)27 3,4-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 199˜201° C.2 1.80(s, 1H), 2.97(t, J=5Hz, 2H), 3.80(s, 2H), 4.03(t, J=5Hz, 2H), 6.67(dd, J=9, 2.5Hz, 1H), 6.98(d, J=2.5Hz, 1H), 7.23(s, 3H), 7.34(d, J=9Hz, 1H)28 2.3-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 163˜165° C.2 1.77(s, 1H), 2.99(t, J=5Hz, 2H), 3.83(s, 2H), 4.06(t, J=5Hz, 2H), 6.79(d, J=1.8Hz, 2H), 6.97(d, J=1.8Hz, 1H), 7.25(s, 3H)29 2,4-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 171˜172° C.2 1.90(s, 1H), 3.00(t, J=5Hz, 2H), 3.84(s, 2H), 4.11(t, J=5Hz, 2H), 6.81(d, J=9Hz, 1H), 7.18(dd, J=9, 2.5Hz, 1H), 7.24(s, 3H) 7.35(d, J=2.5Hz, 1H)30 3,5-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 171˜172° C.2 1.83(s, 1H), 3.03(t, J=5Hz, 2H), 3.87(s, 2H), 4.14(t, J=5Hz, 2H), 6.7-7.2(m, 3H), 7.25(s, 3H)31 2,6-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 154˜156° C.2 2.07(s, 1H), 3.03(t, J=5Hz, 2H), 3.86(s, 2H), 4.20(t, J=5Hz, 2H), 6.8-7.4(m, 6H)32 2,5-Cl.sub.2 3,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 186˜187° C.2 1.99(s, 1H), 3.04(t, J=5Hz, 2H), 3.86(s, 2H), 4.13(t, J=5Hz, 2H), 6.8-7.0(m, 2H), 7.28(s, 3H), 7.29(d, J=9Hz, 1H)33 3,4-Cl.sub.2 2,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 153˜155° C.2 1.94(s, 1H), 3.01(t, J=5Hz, 2H), 3.90(s, 2H), 4.05(t, J=5Hz, 2H), 6.72(dd, J=9, 3Hz, 1H), 6.98(d, J=3Hz, 1H), 7.2-7.5(m, 4H)34 2,4-Cl.sub.2 2,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 204˜205° C.2 2.04(s, 1H), 3.00(t, J=5Hz, 2H), 3.90(s, 2H), 4.11(t, J=5Hz, 2H), 6.73(d, J=9Hz, 1H), 7.0-7.4(m, 5H)35 2,5-Cl.sub.2 2,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 191˜192° C.2 2.22(s, 1H), 3.06(t, J=5Hz, 2H), 3.93(s, 2H), 4.02(t, J=5Hz, 2H), 6.8-6.9(m, 2H), 7.2-7.3(m, 3H), 7.46(d, J=2Hz, 1H)36 2,3-Cl.sub.2 2,5-Cl.sub.21 colorless columnar crystal m.p. 58˜60° C.2 2.05(s, 1H), 3.05(t, J=5Hz, 2H), 3.92(s, 2H), 4.17(t, J=5Hz, 2H), 6.76(dd, J=7, 4Hz, 1H), 7.0-7.3(m, 4H), 7.45(d, J=2Hz, 1H)37 2,6-Cl.sub.2 2,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 192˜193° C.2 2.22(s, 1H), 3.02(t, J=5Hz, 2H), 3.90(s, 2H), 4.16(t, J=5Hz, 2H), 6.7-7.3(m, 5H), 7.15(d, J=2Hz, 1H)38 3,5-Cl.sub.2 2,5-Cl.sub.21 colorless oil m.p. (hydrochloride) 48˜49° C.2 1.92(s, 1H), 3.00(t, J=5Hz, 2H), 3.89(s, 2H), 4.04(t, J=5Hz, 2H), 6.73(d, J=2Hz, 2H), 6.89(t, J=2Hz, 1H), 7.18(m, 2H), 7.41(d, J=2Hz, 1H)______________________________________
TABLE 2______________________________________Physical properties of N-benzyl-N-phenoxyethylamine salts ClCompound (phenoxyNo. group) Cl.sub.m HX mp (°C.)______________________________________39 2,4-Cl.sub.2 3-Cl HCl 135˜13740 3,4-Cl.sub.2 2-Cl HCl 179˜18141 3,4-Cl.sub.2 3-Cl HCl 188˜19042 3,4-Cl.sub.2 4-Cl HCl 183˜18543 3,4-Cl.sub.2 2,4-Cl.sub.2 HCl 182˜18644 3,4-Cl.sub.2 3,4-Cl.sub.2 HCl 154˜15645 3,4-Cl.sub.2 3,4-Cl.sub.2 HBr 187˜18846 3,4-Cl.sub.2 3,4-Cl.sub.2 HI 192˜19347 3,4-Cl.sub.2 3,4-Cl.sub.2 HNO.sub.3 189˜19048 3,4-Cl.sub.2 3,4-Cl.sub.2 H.sub.2 SO.sub.4 159˜16049 3,4-Cl.sub.2 3,4-Cl.sub.2 H.sub.3 PO.sub.4 164˜16750 2,6-Cl.sub.2 3,4-Cl.sub.2 HCl 162˜16451 2,3-Cl.sub.2 3,4-Cl.sub.2 HCl 184˜18652 3,5-Cl.sub.2 3,4-Cl.sub.2 HCl 166˜16753 2,3-Cl.sub.2 2,4-Cl.sub.2 HCl 188˜19054 3,5-Cl.sub.2 2,4-Cl.sub.2 HCl 168˜17055 3,4-Cl.sub.2 2,6-Cl.sub.2 HCl 196˜19856 2,3-Cl.sub.2 2,6-Cl.sub.2 HCl 187˜18957 3,5-Cl.sub.2 2,6-Cl.sub.2 HCl 194˜19658 2,6-Cl.sub.2 2,6-Cl.sub.2 HCl 196˜19859 2,5-Cl.sub.2 2,6-Cl.sub.2 HCl 202˜20460 2,4-Cl.sub.2 2,6-Cl.sub.2 HCl 190˜19261 3,4-Cl.sub.2 2,3-Cl.sub.2 HCl 175˜17762 2,3-Cl.sub.2 2,3-Cl.sub.2 HCl 171˜17363 2,6-Cl.sub.2 2,3-Cl.sub.2 HCl 148˜15064 2,4-Cl.sub.2 2,3-Cl.sub.2 HCl 189˜19165 3,5-Cl.sub.2 2,3-Cl.sub.2 HCl 172˜17466 2,5-Cl.sub.2 2,3-Cl.sub.2 HCl 159˜16167 3,4-Cl.sub.2 3,5-Cl.sub.2 HCl 199˜20168 2,3-Cl.sub.2 3,5-Cl.sub.2 HCl 163˜16569 2,4-Cl.sub.2 3,5-Cl.sub.2 HCl 171˜17270 3,5-Cl.sub.2 3,5-Cl.sub.2 HCl 171˜17271 2,6-Cl.sub.2 3,5-Cl.sub.2 HCl 154˜15672 2,5-Cl.sub.2 3,5-Cl.sub.2 HCl 186˜18773 3,4-Cl.sub.2 2,5-Cl.sub.2 HCl 153˜15574 2,4-Cl.sub.2 2,5-Cl.sub.2 HCl 204˜20675 2,5-Cl.sub.2 2,5-Cl.sub.2 HCl 191˜19276 2,3-Cl.sub.2 2,5-Cl.sub.2 HCl 161˜16377 2,6-Cl.sub.2 2,5-Cl.sub.2 HCl 192˜19378 3,5-Cl.sub.2 2,5-Cl.sub.2 HCl 180˜18279 2,3-Cl.sub.2 3,4-Cl.sub.2 * 188˜18980 2,3-Cl.sub.2 3,4-Cl.sub.2 ** 97 9881 3,4-Cl.sub.2 2-Cl * 164 16682 3,4-Cl.sub.2 4-Cl * 94 9583 3,4-Cl.sub.2 3,4-Cl.sub.2 * 173 17584 3,4-Cl.sub.2 3,4-Cl.sub.2 *** 112 11385 3,4-Cl.sub.2 3,4-Cl.sub.2 **** 94 9586 3,4-Cl.sub.2 3,4-Cl.sub.2 Benzoic acid 108 11087 3,4-Cl.sub.2 3,4-Cl.sub.2 *** 134 13588 3,4-Cl.sub.2 3,4-Cl.sub.2 Propionic acid 64 6589 3,4-Cl.sub.2 3,4-Cl.sub.2 Acetic acid 72 7490 2,5-Cl.sub.2 3,4-Cl.sub.2 * 168 17091 3,5-Cl.sub.2 3,4-Cl.sub.2 * 140 14692 3,5-Cl.sub.2 3,4-Cl.sub.2 ** 111 11393 3,5-Cl.sub.2 3,4-Cl.sub.2 Benzoic acid 89 91______________________________________*p-toluenesulfonic acid**2thiophene carboxylic acid***3phenyl-5-methylisoxazol-4-carboxylic acid****mtrifluoromethyl benzoic acid
According to the second invention, furthermore, there is provided an agricultural and horticultural bactericide which comprises as an active ingredient at least one of the N-benzyl-N-phenoxyethylamine compounds represented by the general formula I' and a salt of the N-benzyl-N-phenoxyethylamine represented by the general formula II': ##STR8##wherein in the general formulas I' and II', n is 1 or 2, and in the generalformula II', HX represents an acid.
The N-benzyl-N-phenoxyethylamine represented by the general formula I' and N-benzyl-N-phenoxyethylamine salt represented by the general formula II' (hereinafter the N-benzyl-N-phenoxyethylamine and a salt thereof are oftencollectively referred to as N-benzyl-N-phenoxyethylamines) exhibit strong antibacterial action against bacteria belonging to the genus Xanthomonas such as bacteria causing citrus canker and bacteria belonging to the genusClavibacter such as bacteria causing tomato canker, as well as against bacteria causing blights in agricultural plants. Phytotoxicity when these compounds are used is smaller than that of when conventional chemical agents are used. Further, the N-benzyl-N-phenoxyethylamines all remain chemically stable and can be preserved for extended periods of time.
Therefore, the agricultural and horticultural bactericide of the second invention that comprises these N-benzyl-N-phenoxyethylamine as active ingredients, exhibits strong antibacterial action against a variety of pathogenic bacteria with little phytotoxicity, and can be preserved for extended periods of time.
The agricultural and horticultural bactericide of the second invention is effective for controlling a variety of blights caused by various pathogenic bacteria such as citrus canker, bacterial leaf blight of rice, bacterial shot hole of peach, black rot of cabbage, bacterial blight of lettuce, bacterial spot of melon, leaf blight of soy bean, and tomato canker.
A preferred example of the active ingredient of the agricultural and horticultural bactericide of the second invention is a salt of the N-benzyl-N-phenoxyethylamine that exhibits stronger antibacterial action and that is more stable than the N-benzyl-N-phenoxyethylamine, and that can be easily recovered during preparation.
The agricultural and horticultural bactericide of the second invention can be formed into an optional preparation of an agricultural and horticultural agent, such as a wettable powder, a liquid, an emulsifiable concentrate, a flowable (sol) preparation, a powder, a driftless (DL) dustor a granule by the method known per sex using the novel compound of the first invention. The carrier to be used for such preparations is not particularly critical, and any of carrier customarily used in this field can be used. As typical examples of the solid carrier, there can be mentioned mineral powders such as kaolin, bentonire, clay, talc and vermiculite, plant powders such as wood meal, starch and crystalline cellulose, and polymeric compounds such as a petroleum resin, polyvinyl chloride, a ketone resin and dammar gum. As typical examples of the liquidcarrier, there can be mentioned water, alcohols such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, butanol, ethylene glycol and benzyl alcohol, aromatic hydrocarbons such as toluene, benzene,xylene, ethylbenzene and methylnaphthalene, halogenated hydrocarbons such as chloroform, carbon tetrachloride, dichloromethane, chloroethylene, monochlorobenzene, trichlorofluoromethane and dichlorofluoromethane, ethers such as ethyl ether, ethylene oxide and dioxane, ketones such as acetone, methyl ethyl ketone, cyclohexanone and methyl isobutyl ketone, esters such as ethyl acetate, butyl acetate and ethylene glycol acetate, acid amides such as dimethylformamide and dimethylacetamide, sulfoxides such as dimethylsulfoxide, alcohol ethers such as ethylene glycol monomethylether and ethylene glycol monoethyl ether, aliphatic and alicyclic hydrocarbones such as n-hexane and cyclohexane, gasolines of theindustrial grade such as petroleum ether and solvent naphtha, paraffins, and petroleum fractions such as kerosene and gas oil.
Various surface active agents can be used. As typical instances of the surface active agent, there can be mentioned nonionic surface active agents such as polyoxyethylene alkyl ether and polyoxyethylene alkyl ester, anionic surface active agents such as alkyl benzene-sulfonate and alkyl sulfate, cationic surface active agents such as lauryl and stearyltrimethyl ammonium chlorides, and amphoteric surface active agents such as betaine type carboxylic acid and sulfuric acid esters.
The content of the compound of the first invention in a preparation as mentioned above is not particularly critical, but from a practical viewpoint, the content of the compound is generally about 0.001 to about 95% by weight (expressed as the compound of general formula I; the same will apply hereinafter) and preferably about 0.01 to about 90% by weight. Practically, in the case of a powder, a DL dust and a granule, the contentof the compound of the present invention is about 0.01 to about 5% by weight, and in the case of a wettable powder, a liquid and an emulsifiableconcentrate, the content of the compound of the present invention is about 1 to 75% by weight.
The so-formed preparation, for example, a powder, a driftless dust or a granule, is directly applied, and a wettable powder, a liquid, an emulsifiable concentrate or a flowable agent is applied after it has been diluted with water or an appropriate solvent.
The rate of application of the agricultural and horticultural bactericide of the second invention varies depending on the kind of the disease to be controlled, the degree of the disease, the kind of the plant to be treated, the region of application, the method of application, the season of application and the kind of preparation, and cannot be exclusively specified. However, the active ingredient or the compound represented by the general formula I of the first invention (or the compound that is represented by the general formula II of the first invention is reckoned as that of the general formula I) is used in an amount of 2 to 6 kg per 10ares in the case of a powder, driftless dust or granule (the concentration of the active ingredient is 3% by weight) or in an amount of 0.05 to 3 kg being diluted in 100 to 500 liters of water in the case of a wettable powder, liquid, emulsifiable concentrate or flowable agent (the concentration of the active ingredient is 20% by weight).
The compound of the first invention and, particularly, the compound represented by the general formula II exhibits strong antibacterial actionand improved stability, and can be applied over extended periods of seasons, and can be desirably used as an agricultural and horticultural agent.
Examples
The present invention will now be concretely described with reference to the following examples that by no means limit the scope of the invention.
EXAMPLE 1
Synthesis of N-3,4-dichlorobenzyl-N-2-(3,4-dichlorophenoxy)ethylamine (compound No. 8).
5.40 Grams (20.0 mmol) of 2-(3,4-dichlorophenoxy)ethyl bromide was dissolved in 50 ml of isopropyl alcohol, followed by addition of 4.26 g (40.0 mmol) of anhydrous sodium carbonate and 6.30 g (35.8 mmol) of 3,4-dichlorobenzylamine. The mixture was refluxed for 8 hours on an oil bath. After cooling, the reaction mixture was poured into 200 ml of water and was extracted with chloro form (4 0 ml×3).
The organic layer was dried over with magnesium sulfate and the solvent wasremoved by distillation, and the residue was purified by silica gel column chromatography (developing agent: ethyl acetate/chloroform=4/6) to give the captioned compound in an amount of 5.89 g (yield; 81%) in the form of a colorless oil.
The compound exhibited the following properties. 13 C-NMR (CDCl 3 );
47.90(t), 52.47(t), 68.21(t), 1 14.46(d), 116.44(d), 124.09(s), 127.24(d) ,129.80(d), 130.22(d), 130.59(d), 130.74(s), 132.36(s), 132.78(s), 140.53(s), 157.76(s)ppm
Infrared absorption spectrum (liquid film method);
νmax=2820 m , 1580 s , 1560 s , 1445 s , 1255 s , 1220 s , 1115 s , 1020 s , 800 s , 655 s cm -1
Mass spectrum;
m/e=369(M + +6.1% ), 368(M + +5.1%), 367(M + +4.4% ), 366(M + +3.2%), 365(M + +2.8% ), 364(M + +1.1% ), 363(M + +6% ), 204(3%), 202(5%), 192(11%), 191(7%), 190(64%), 189(11%), 188(98%), 163(13%), 162(7%), 161(70%), 160(9%), 159(100%), 126(3%), 124(6%), 123(8%).
Ultraviolet absorption spectrum (EtOH);
νmax=202(60,900), 219 sh (17,100), 228 sh (15,000), 276 sh (1,230), 282(1,830), 291(1,460)nm
Elementary analysis;
calculated as C 15 H 13 Cl 4 NO C:49.35 H:3.59 N:3.84(%) Found;C:49.59 H:3.53 N:4.09(%)
EXAMPLE 2
Synthesis of N-3-chlorobenzyl-N-2-(2,4-dichlorophenoxy)ethylamine (compoundNo. 2).
2.70 Grams (10.0 retool) of 2-(2,4-dichlorophenoxy)ethyl bromide was dissolved in 30 ml of ethanol, followed by the addition of 1.06 g (10.0 mmol) of anhydrous sodium carbonate and 4.25 g (30.0 mmol) of 3-chlorobenzylamine. The mixture was refluxed for 6 hours on an o il bath.After cooling, the reaction mixture was poured into 100 ml of water and wasextracted with chloroform (20 ml×3).
The organic layer was d ried over with magnesium sulfate and the solvent was removed by distillation, and the residue was purified by silica gel column chromatography (developing agent: ethyl acetate/chloroform=1/1) to give the captioned compound in an amount of 2.51 g (yield; 76% ) in the form of a colorless oil.
The compound exhibited the following properties.
13 C-NMR (CDCl 3 );
47.75(t), 53.02(t), 69.30(t), 114.37(d), 123.88(s), 125.99(d), 126.75(s), 127.02(d), 127.51(d), 128.00(d), 129.55(d), 129.86(d), 134.25(s), 142.30(s), 153.09(s)ppm
Infrared absorption spectrum (liquid film method);
νmax=2830 m , 1575 s , 1455 s , 1250 s , 1100 s , 1060 s , 1035 s , 865 s , 800 s , 775 s , 735 s , 680 s cm -1
Mass spectrum;
m/e=330(M + +1.1%), 298(5%), 297(6%), 296(25%), 295(19%), 294(36%), 293(19%), 170(2%), 169(2%), 168(5%), 157(3%), 156(30%), 155(9%), 154(90%),128(3%), 127(34%), 126(10%), 125(100%), 90(5%), 89(13%).
Ultraviolet absorption spectrum (EtOH);
νmax=201(35,000), 217 sh (12,200), 228 sh (8,340), 277 sh (1,120), 285(1,650), 292(1,470)nm
Elementary analysis;
calculated as C 15 H 14 Cl 3 NO C:54.49 H:4.27 N:4.24(%) Found;C:54.61 H:4.38 N:4.01(%)
EXAMPLE 3
Synthesis of N-4-chlorobenzyl-N-2-(3,4-dichlorophenoxy)ethylammonium p-toluene sulfonate (compound No. 82).
The compound was synthesized in two steps as described below.
1) Synthesis of N-4-chlorobenzyl-N-2-(3,4-dichlorophenoxy)ethylamine
2.70 Grams (10.0 mmol) of 2-(3,4dichlorophenoxy)ethyl bromide was dissolvedin 30 ml of ethanol, followed by the addition of 1.06 g (10.0 mmol) of anhydrous sodium carbonate and 4.25 g (30.0 mmol) of 4-chlorobenzylamine. The mixture was heated and refluxed on an oil bath for 7 hours. After cooling, the reaction mixture was poured into 100 ml of water and was extracted with chloroform (20 ml×3).
The organic layer was dried over with magnesium sulfate and the solvent wasremoved by distillation, and the residue was purified by silica gel column chromatography (developing agent: ethyl acetate/chloroform=4/6 ) to give the captioned compound in an amount of 2.99 g (yield, 90%) in the form of a colorless oil.
The compound exhibited the following properties.
Mass spectrum;
m/e=330(M + +1.1%), 298(3%), 297(6%), 296(30%), 295(19%), 294(38%), 293(22%), 170(4%), 168(5%), 157(3%), 156(34% ), 155(8%), 154(92%), 127(44%), 126(8%), 125(100%), 90(7%), 89(20%).
Ultraviolet absorption spectrum (EtOH);
νmax=218 sh (13,200), 230 sh (8,340), 281 sh (1,200), 286(1,700), 292(1,500)nm
Elementary analysis;
calculated as C 15 H 14 Cl 3 NO C:54.49 H:4.27 N:4.24(%) Found;C:54.61 H:4.38 N:4.01(%)
2) Synthesis of N-4-chlorobenzyl- N-2-(3,4-dichlorophenoxy ) e thy lammonium- p-toluene sulfonate
331 Milligrams (1.00 retool) of the amine obtained in the above step 1) wasdissolved in 2 ml of ether followed by the addition of 190 mg (1.00 mmol) of p-toluenesulfonic acid monohydrate. The acid was dissolved by ultrasonic treatment, and the newly precipitated crystals were separated by filtration, washed with ether and then dried to obtain 322 mg (yield, 80%) of the captioned compound in the form of colorless scale-like crystals, m.p., 170-171° C.
______________________________________Preparation Example 1 (Wettable Powder) Amount (partsComponent by weight)______________________________________Compound No. 8 20Lignin-sulfonic acid 3Polyoxyethylene alkylaryl ether 2Diatomaceous earth 75______________________________________
The foregoing components homogeneously mixed to give a wettable powder comprising 20% by weight of the active ingredient.
______________________________________Preparation Example 2 (Powder) Amount (partsComponent by weight)______________________________________Compound No. 8 3Calcium stearate 1Powder of silicic acid anhydride 1Clay 48Talc 47______________________________________
The foregoing components were homogeneously mixed to give a powder comprising 3% by weight of the active ingredient.
Test 1 (Antibacterial Test against Phytopathogenic Bacteria
Antibacterial actions of the N-benzyl-N-phenoxyethylamine and N-benzyl-N-phenoxyethylamine salt against various phytopathogenic bacteriawere examined.
More specifically, the bacterium causing black spot of cabbage, Xanthomonascampestris pv. campestris, the bacterium causing citrus canker, X. Campestris pv. citri, the bacterium causing bacterial leaf blight of rice,X. Campestris pv. oryzae, the bacterium causing bacterial shot hole of peach, X. campestris pv. pruni and the bacterium causing tomato canker, Clavibacter michiganmensis subsp. michiganensis, were used as the bacteriato be tested, and the action of inhibiting the growth of the bacteria on anagar plate was examined.
A sample compound was added to a peptone-added potato extract medium, and a2-fold dilution system having a maximum concentration of 100 ppm was prepared and the culture medium was cast into a Petri dish to form an agarplate.
The agar plate was inoculated with the bacterium to be tested and incubation was carried out at 28° C. for 2 days, and the growth of the bacterium was checked.
The obtained results are shown in Table 3.
The compounds of the present invention showed a strong antibacterial actionagainst all of the pathogenic bacteria.
TABLE 3______________________________________Antibacterial tests against phytopathogenicbacteria of plantsMinimum inhibition concentration (ppm)CompoundNo. Xc Xi Xo Xp Cm______________________________________1 25 25 252 25 25 6.33 50 50 6.34 25 25 255 12.5 12.5 6.3 12.5 12.56 12.5 12.5 12.5 12.5 12.58 50 50 6.39 100 50 12.540 25 25 2542 12.5 12.5 12.5 12.5 6.344 12.5 6.3 3.2 12.5 6.351 12.5 12.5 6.3 12.5 12.5C 25 25 6.3 25 6.3______________________________________C; Streptomycin (commercially available comparative agent)Xc; Bacteria causing black spot of cabbageXi; Bacteria causing citrus cankerXo; Bacteria causing bacterial leaf blight of riceXp; Bacteria causing bacterial shot hole of peachCm; Bacteria causing tomato canker
Test 2 (Test of Preventing Citrus Canker)
Leaf pieces having a square shape of about 1 cm 2 were cut out from summer orange leaves and immersed in a chemical solution having a predetermined concentration for 20 minutes. The leaf pieces were removed from the chemical solution and were then air-dried. Then, the leaf pieces were inoculated with a suspension of cells of the bacterium causing citrusCanker (about 10 8 cells per ml) by using a needle.
The inoculated leaf pieces were placed in a Petri dish on which a sheet of wet filter paper was spread, and incubation was carried out at 28° C. for 10 days and the outbreak of the disease was checked. The disease attack ratio was calculated according to the following formula: ##EQU1##wherein n 0 represents the number of leaf pieces having a disease severity index of 0 (no disease), n 1 represents the number of leaf pieces having a disease severity index of 1 (slight disease), n 2 represents the number of leaf pieces having a disease severity index 2 (medium disease), n3represents the number of leaf pieces having a disease severity index of 3 (violent disease), and N represents the total number of the examined leaf pieces.
Furthermore, the degree of phytotoxicity was visually examined.
The results were as shown in Table 4.
TABLE 4______________________________________Test for preventing citrus cankerCompound Concentration Disease attack Phytotox-No. (ppm) ratio (%) icity**______________________________________ 1 300 23.8 2 300 20.8 - 3 300 7.4 - 4 300 20.8 - 5 300 14.3 - 6 300 16.7 - 7 300 14.3 - 8 300 7.4 - 9 300 9.5 -10 300 14.3 -39 300 16.7 -40 300 13.3 -41 300 16.7 -42 300 7.4 -43 300 0.0 -44 300 0.0 -50 300 4.8 -cocide diluted 26.7 ±wettable to 1/2000powder* 2000untreated 66.7______________________________________*Commercially available comparative agent.**-: No phytotoxicity. ±: Phytotoxic to a slight degree. +: Phytotoxic (hereinafter the same).
Test 3 (Test of Controlling Bacterial Leaf Blight of Rice).
An aqueous solution containing a sample compound at a predetermined concentration was sprayed onto the rice plants of the 5-leaf stage (variety: Koshihikari) grown in a pot having a diameter of 6 cm.
After one day has passed, the rice plants were shear-inoculated with a cellsuspension of the bacterium causing bacterial leaf blight of rice, which had a concentration of 10 8 cells per ml.
Three weeks after the inoculation, the lengths of disease lesions were measured, and the control values were calculated according to the following formula: ##EQU2##
The obtained results were as shown in Table 5.
TABLE 5______________________________________Test for controlling bacterial leaf blight of riceCompound Concentration Control value Phytotox-No. (ppm) (%) icity______________________________________ 3 500 80.5 - 8 500 75.6 - 9 500 88.2 -40 500 83.7 -42 500 90.0 -43 500 95.1 -44 500 96.3 -phenazine diluted 60.1 -wettable to 1/500powder*______________________________________*Commercially available comparative agent.
Test 4 (Test of Controlling Soft Rot)
Radish disks having a diameter of 2 cm and a thickness of 1 cm were prepared and immersed in an aqueous solution containing a sample compound at a predetermined concentration for 1 hour.
The radish disks were taken out from the aqueous solution and air-dried. A bacterium suspension was dropped on central portions of the disks and the disks were maintained at 28° C. for 24 hours. The rotted degree wasexamined and the control values were calculated according to the following formula: ##EQU3##
The results were as shown in Table 6.
TABLE 6______________________________________Test of controlling soft rotCompound Concentration Control value Phytotox-No. (ppm) (%) icity______________________________________ 3 400 90 - 8 400 90 -43 400 100 -44 400 100 -cocide diluted 80 ±wettable to 1/2000powder*______________________________________*Commercially available comparative agent.
Test 5 (Antibacterial Test against phytopathogenic Bacteria
Antibacterial actions of the N-benzyl-N-dichlorophenoxyethylamines and of salts of organic acids against various phytopathogenic bacteria were examined.
More specifically, the bacterium causing black spot of cabbage, Xanthomonascampestris pv. campestris, the bacterium causing citrus canker, X. campestris pv. citri, the bacterium causing bacterial leaf blight of rice,X. campestris pv. oryzae, the bacterium causing bacterial shot hole of peach, X. campestris pv. pruni, and the bacterium causing tomato canker, Clavibacter michiganensis subsp. michiganensis, were tested to examine theaction of inhibiting the growth of the bacteria on an agar plate.
The sample compound was added to a peptone-added potato extract medium, anda 2-fold dilution system having a maximum concentration of 100 ppm was prepared and the culture medium was cast into a Petri dish to form an agarplate.
The agar plate was inoculated with the bacterium to be tested and incubation was carried out at 28° C. for two days to examine the growth of the bacterium.
The results were as shown in Table 7.
The compounds of the present invention exhibited a strong antibacterial action against all of the pathogenic bacteria.
TABLE 7______________________________________Antibacterial tests against phytopathogenicbacteria of plantsMinimum inhibition concentration (ppm)CompoundNo. Xc Xi Xo Xp Cm______________________________________83 12.5 12.5 6.3 6.3 12.586 6.3 6.3 3.2 3.2 6.387 6.3 6.3 3.2 3.2 6.388 6.3 6.3 3.2 3.2 12.589 6.3 6.3 6.3 3.2 6.390 12.5 12.5 12.5 12.5 12.591 12.5 12.5 6.3 6.3 3.292 25 12.5 12.5 12.5 6.393 12.5 12.5 6.3 12.5 6.3strepto- 25 25 6.3 25 6.3mycin*______________________________________*Commercially available comparative agent.Xc; Bacteria causing black spot of cabbageXi; Bacteria causing citrus cankerXo; Bacteria causing bacterial leaf blight of riceXp; Bacteria causing bacterial shot hole of peachCm; Bacteria causing tomato canker
Test 6 (Prevention of Citrus Canker)
Leaf pieces having a square of about 1 cm 2 were cut out from summer orange leaves and immersed in a chemical solution having a predetermined concentration for 20 minutes. The leaf pieces were taken out from the chemical solution and were then air-dried. Then, the leaf pieces were inoculated with a suspension of cells of the bacterium causing citrus canker (about 10 8 cells per ml) by using a needle. The inoculated leaf pieces were placed in a Petri dish on which was spread a sheet of wetfilter paper, and incubation was carried out at 28° C. for 10 days and the outbreak of the disease was examined. The disease attack ratio wascalculated according to the following formula: ##EQU4##wherein n 0 represents the number of leaf pieces having a disease severity index of 0 (no disease), n 1 represents the number of leaf pieces having a disease severity index of 1 (slight disease), n 2 represents the number of leaf pieces having a disease severity index of 2 (medium disease), n 3 represents the number of leaf pieces having a disease severity index of 3 (violent disease), and N represents the total number of the examined leaf. pieces.
Furthermore, the degree of phytotoxicity was visually examined.
The results were as shown in Table 8.
TABLE 8______________________________________Test for preventing citrus cankerCompound Concentration Disease attack Phytotox-No. (ppm) ratio (%) icity**______________________________________79 300 16.7 -80 300 7.4 -81 300 9.5 -82 300 14.3 -84 300 16.7 -85 300 13.3 -86 300 16.7 -87 300 0.0 -88 300 0.0 -89 300 20.8 -90 300 7.4 -92 300 20.8 -93 300 4.8 -cocide diluted 26.7 ±wettable to 1/2000powder* 2000untreated 66.7______________________________________*Commercially available comparative agent.**-: No phytotoxicity. ±: Phytotoxic to a slight degree. +: Phytotoxic (hereinafter the same).
Test 7 (Test of Controlling Bacterial Leaf Blight of Rice)
An aqueous solution containing a sample compound at a predetermined concentration was sprayed onto the rice plants of the 5-leaf stage (variety: Koshihikari) grown in a pot having a diameter of 6 cm.
One day after, the rice plant was shear-inoculated with a cell suspension of the bacterium causing bacterial leaf blight of rice having a concentration of 10 8 cells per milliliter.
Three weeks after the inoculation, the lengths of disease lesions were measured, and the control values were calculated according to the following formula: ##EQU5##
The results were as shown in Table 9.
TABLE 9______________________________________Test for controlling bacterial leaf blight of rice.Compound Concentration Control value Phytotox-No. (ppm) (%) icity______________________________________80 500 83.7 -84 500 95.1 -85 500 80.5 -86 500 75.6 -87 500 90.0 -89 500 88.2 -93 500 96.3 -phenazine diluted 60.1 -wettable to 1/500powder*______________________________________*Commercially available comparative agent.
Test 8 (Test of Controlling Soft Rot)
Radish disks having a diameter of 2 cm and a thickness of 1 cm were prepared and immersed in an aqueous solution containing a sample compound at a predetermined concentration for 1 hour.
The radish disks were taken out from the aqueous solution and were air-dried. A bacterium suspension was dropped on central portions of the disks and the disks were maintained at 28° C. for 24 hours to examine the rotted degree. The control values were calculated according tothe following formula: ##EQU6##
The results were as shown in Table 10.
TABLE 10______________________________________Test of controlling soft rot.Compound Concentration Control value Phytotox-No. (ppm) (%) icity______________________________________80 400 90 -86 400 100 -89 400 90 -93 400 100 -cocide diluted 80wettable to 1/2000powder*______________________________________*Commercially available comparative agent.
The N-benzyl-N-phenoxyethylamines and salts thereof of the present invention are all novel compounds that can be easily prepared, featuring stable properties and exhibiting excellent antibacterial action against various pathogenic bacteria of plants. Therefore, the agricultural and horticultural agent of the present invention can be desirably used for controlling a variety of plant diseases.
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Disclosed is an N-benzyl-N-phenoxyethylamine selected from the group consisting of the N-benzyl-N-phenoxyethylamine represented by the following formula (I): ##STR1## and an agriculturally acceptable acid addition salt represented by the following formula (II): ##STR2## wherein m represents a number of 1 or 2 with a proviso that when m is 1 and a chlorine atom in the ring A is present at para(4)-position of the ring A, two chlorine atoms in the ring B are present at 2,3-, 2,5-, 2,6-, 3,4- or 3,5-positions of the ring B, and HX represents an acid.
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TECHNICAL FIELD OF INVENTION
The present invention relates to a new apparatus and method for use in subterranean exploration. The present invention provides a rapid rig-up and rig-down pipe stand building system that is capable of being retrofit to an existing drilling rig. In particular, the invention relates to a drilling rig mountable horizontal to vertical pipe delivery machine. The pipe delivery machine delivers pipe to a pair of drilling rig mounted elevators. A drill floor mounted pipe racking system receives the drill pipe from the elevators. The pipe racking system is capable of controlled, rapid, and precise movement of multiple connected sections of pipe. The elevator system is mounted in between for make-up of the single pipe joints into a pipe stand.
BACKGROUND OF THE INVENTION
In the exploration of oil, gas and geothermal energy, drilling operations are used to create boreholes, or wells, in the earth. Subterranean drilling necessarily involves the movement of long lengths of tubular sections of pipe. At various intervals in the drilling operation, all of the drill pipe must be removed from the wellbore. This most commonly occurs when a drill bit wears out, requiring a new drill bit to be located at the end of the drill string. It can also be necessary to reconfigure the bottom-hole assembly or replace other downhole equipment that has otherwise failed. When the drill pipe has to be removed, it is disconnected at every second or third connection, depending on the height of the mast. On smaller drilling rigs used in shallower drilling, every other connection is disconnected, and two lengths of drill pipe, known as “doubles,” are lifted off of the drill string, aligned in the fingers of the rack by the derrickman, and then lowered onto the drill floor away from the well center. On larger drilling rigs used for deeper drilling, every third connection is disconnected and three lengths of drill pipe, known as “triples,” are lifted off of the drill string, aligned in the fingers of the rack by the derrickman, and then lowered onto the drill floor away from the well center. The doubles and triples are called a stand of pipe. The stands are stored vertically on the rig floor, aligned neatly between the fingers of the rack on the mast.
Removing all of the drill pipe from the well and then reconnecting it to run back into the well is known as “tripping the pipe” or “making a trip,” since the drill bit is making a round trip from the bottom of the hole to the surface and then back to the bottom of the hole. Tripping the drill pipe is a very expensive and dangerous operation for a drilling rig. Most injuries that occur on a drilling rig are related to tripping the pipe. Additionally, the wellbore is making no progress while the pipe is being tripped, so it is downtime that is undesirable. This is why quality drill bits are critical to a successful drill bit operation. Drill bits that fail prematurely can add significant cost to a drilling operation. Since tripping pipe is “non-drilling time,” it is desirable to complete the trip as quickly as possible. Most crews are expected to move the pipe as quickly as possible. The pipe stands are long and thin (about ninety feet long).
There are a number of variables that contribute to irregular and hostile movement of the pipe stand as it is disconnected and moved to the rack for setting on the drill floor, as well as when it is being picked up for alignment over the wellbore center for stabbing and connection to the drill string in the wellbore. For example, the vertical alignment and travel of the elevator and hoist connection which lift the drill string from the wellbore is cable connected, and capable of lateral movement which is translated to the drill string rising from the wellbore. Also, the drill string is supported from the top, and as the derrickman moves the drill string laterally, the accelerated lateral movement of the long length of the pipe stand away from the well center generates a wave form movement in the pipe itself. As a result of the natural and hostile movement of the heavy drill stand, which typically weighs between 1,500 and 2,000 pounds, and drill collars which weigh up to 20,000 pounds, it is necessary for the crew members to stabilize the drill pipe manually by physically wrestling the pipe into position. The activity also requires experienced and coordinated movement between the driller operating the drawworks and the derrickman and floorhands. Needless to say, many things can and do go wrong in this process, which is why tripping pipe and pipe racking is a primary safety issue in a drilling operation.
Attempts have been made to mechanize all or part of the pipe racking operation. On offshore platforms, where funding is justifiable and where drill floor space is available, large Cartesian racking systems have been employed, in which the pipe stands are gripped at upper and lower positions to add stabilization, and tracked modules at the top and bottom of the pipe stand coordinate the movement of the pipe stand from the wellbore center to a racked position. Such systems are very large and very expensive, and are not suitable for use on a traditional land-based drilling rig.
A previous attempt to mechanize pipe racking on conventional land-based drilling rigs is known as the Iron Derrickman® pipe-handling system. The apparatus is attached high in the mast, at the rack board, and relies on a system of hydraulics to lift and move stands of drill pipe and collars from the hole center to programmed coordinates in the racking board. This cantilever mast mounted system has a relatively low vertical load limit, and therefore requires assistance of the top drive when handling larger diameter collars and heavy weight collars.
The movement of the pipe with this system is somewhat unpredictable and requires significant experience to control. It grasps the pipe from above the center of gravity of the tubular and fails to control the hostile movement of the pipe stand sufficiently to allow for safe handling of the stands or for timely movement without the intervention of drilling crew members. In particular, the system is not capable of aligning the lower free end of the drill stand accurately for stabbing into the drill string in the wellbore. As a result of these and other deficiencies, the system has had limited acceptance in the drilling industry.
An alternative system that is known provides vertical lifting capacity from the top drive and a lateral movement only guidance system located near the rack. The system still requires a floorman for stabbing the pipe to the stump as well as to the set-back position.
A primary difficulty in mechanizing pipe stand racking is the hostile movement of the pipe that is generated by stored energy in the stand, misaligned vertical movement, and the lateral acceleration and resultant bending and oscillation of the pipe, which combine to generate hostile and often unpredictable movements of the pipe, making it hard to position, and extremely difficult to stab.
A conflicting difficulty in mechanizing pipe stand racking is the need to move the pipe with sufficient rapidity so that cost savings are obtained over the cost of manual manipulation by an experienced drilling crew. The greater accelerations required for rapid movement store greater amounts of energy in the pipe stand, and greater attenuated movement of the stand.
Another primary obstacle in mechanizing pipe stand racking is the prediction and controlled management of the pipe stand movement sufficient to permit the precise alignment required for stabbing the pipe to a first target location on the drill floor and to a second target location within the fingers of the racking board.
An even greater obstacle in mechanizing pipe stand racking is the prediction and controlled management of the pipe stand movement sufficient to achieve the precise alignment required for stabbing the tool joint of the tubular held by the racking mechanism into the receiving tubular tool joint connection extending above the wellbore and drill floor.
Another obstacle to land-based mechanizing pipe stand racking is the lack of drilling floor space to accommodate a railed system like those that can be used on large offshore drilling rigs.
Another obstacle to mechanizing pipe stand racking is the several structural constraints that are presented by the thousands of existing conventional drilling rigs, where the need to retrofit is constrained to available space and structure. For example, existing structures require orthogonal movement of the drill stand over a significant distance and along narrow pathways for movement.
Another obstacle to mechanizing pipe stand racking is the need to provide a reliable mechanized solution that is also affordable for retrofit to a conventional drilling rig. Still another obstacle to mechanizing pipe stand racking is the need to grip and lift pipe stands within the narrow confines of parallel rows of pipe stands in a conventional rack.
It is also desirable to minimize accessory structure and equipment, particularly structure and equipment that may interfere with transportation or with manpower movement and access to the rig floor during drilling operations. It is further desirable to ergonomically limit the manpower interactions with rig components during rig-up for cost, safety and convenience.
Thus, technological and economic barriers have prevented the development of a pipe racking system capable of achieving these goals. Conventional prior art drilling rig configurations remain manpower and equipment intensive to trip pipe and rack pipe when tripping. Alternative designs have failed to meet the economic and reliability requirements necessary to achieve commercial application. In particular, prior art designs fail to control the natural attenuation of the pipe and fail to position the pipe with sufficient rapidity and accuracy.
A goal of the present invention is to achieve rapid and accurate unmanned movement of the pipe between the racked position and the over-well position. Thus, the racker of the present invention must avoid storage of energy within the positioning structure. True verticality is critical to limiting the energy storage of the system. Additionally, controlled movement and positional holding of the stand is critical to allowing rapid movement by adding the stiffness to the system.
In summary, the various embodiments of the present invention provide a unique solution to the problems arising from a series of overlapping design constraints, including limited drill floor space, and obtaining sufficient stiffness from a retrofittable assembly to provide a controlled and precise automated movement and racking of drill pipe. More specifically, the various embodiments of the present invention provide for lateral movement of the pipe stand independent of assistance from the top drive, and without extension and retraction of the top drive for handing the pipe stand to the racking system. This provides free time for the top drive to move with the racker system in positioning the pipe without assistance from the top drive. Additionally, the various embodiments of the present invention provide a device capable of precise and accurate stabbing of the drill stand, resulting in faster trip time.
SUMMARY OF THE INVENTION
The present invention provides a new and novel pipe stand building and racking system and method of use. In one embodiment, a horizontal to vertical machine is provided. The horizontal to vertical machine is mountable to a conventional drilling rig. The horizontal to vertical machine has a gripper for gripping the exterior of a tubular (such as drill pipe). The horizontal to vertical machine is capable of grasping and raising a tubular from a horizontal position near the ground to a vertical position proximate to the edge of the drilling floor.
A lower elevator is mounted to the drilling rig for receiving a tubular in a vertical orientation from the horizontal to vertical machine. The lower elevator may be pivotally connected to the drilling rig so that it may be attached in a horizontal position prior to raising the substructure. The lower elevator has at least one gripper that is vertically translatable along the length of the lower elevator. The gripper is capable of clamping onto the exterior of a drilling tubular and supporting the load of the tubular.
An automatic pipe racker is provided, having a base frame connectable to a drill floor of a drill rig and extending upwards at a position offset to a V-door side of a drilling mast that is also connected to the drill floor. In one embodiment, the base frame is a C-frame design. A mast brace may be connected between the base frame and the drilling mast at a position distal to the drill floor for stabilizing an upper end of the base frame in relationship to the mast. In one embodiment, the mast brace is adjustable for tilting the automatic pipe racker slightly towards the mast. A tensioner may be connected between the base frame and the drilling floor for stabilizing the base frame in relationship to the substructure.
The automatic pipe racker is capable of moving stands of pipe between the racked position and the over-well position.
In one embodiment, a lateral extend mechanism is pivotally connectable to the base frame. The lateral extend mechanism is extendable between a retracted position and a deployed position. A rotate mechanism is connected to the lateral extend mechanism and is rotatable in each of the left and right directions. A finger extend mechanism is connected to the rotate mechanism. The finger extend mechanism is laterally extendable between a retracted position and a deployed position.
A vertical grip and stab mechanism is attached to the finger extend mechanism. The gripping mechanism has grippers to hold a tubular or stand of pipe and is capable of moving the pipe vertically to facilitate stabbing. The lateral extend mechanism is deployable to move the rotating finger extend and gripping mechanisms between a position beneath a racking board cantilevered from the mast and a position substantially beneath the mast.
In another embodiment, movement of the lateral extend mechanism between the retracted position and the deployed position moves the rotate mechanism along a substantially linear path. In a more preferred embodiment, movement of the lateral extend mechanism between the retracted position and the deployed position moves the rotate mechanism along a substantially horizontal path.
The rotate mechanism is rotatable in each of a left and right direction. In a more preferred embodiment, the rotate mechanism is rotatable in each of a left and right direction by at least ninety degrees. In another preferred embodiment, the pipe stand gripping mechanism is vertically translatable to vertically raise and lower the load of a stand of pipe.
In another embodiment, the automatic pipe racking system is series nesting. In this embodiment, the finger extend and grip and stab mechanisms are substantially retractable into the rotate mechanism, which is substantially retractable into the pivot frame of the lateral extend mechanism, which is substantially retractable into the base frame.
An upper elevator is pivotally connected to the base frame for receiving a tubular in a vertical orientation from a lower elevator. The upper elevator has an upper gripper and a lower gripper. The upper gripper is vertically translatable along the length of the upper elevator. The upper and lower grippers are both capable of clamping onto the exterior of a drilling tubular and supporting the load of the tubular.
A stand building power tong is provided for rotating tubular to be connected between the upper elevator and the lower elevator.
In operation, the horizontal to vertical machine grips a first tubular, such as a section of drill pipe, and raises it from a horizontal position near the ground to a vertical position proximate to the drill floor. The lower elevator receives the first tubular from the horizontal to vertical machine. The lower elevator raises the first tubular vertically, where the upper elevator grips and vertically raises the first tubular.
The horizontal to vertical machine grips a second tubular and raises it from a horizontal position near the ground to a vertical position proximate to the drill floor. The lower elevator receives the second tubular from the horizontal to vertical machine. The lower elevator raises the second tubular vertically, until the female connection of the second tubular engages the male connection of the first tubular. The stand building power tong rotates the one of the tubular in relation to the other to make-up the threaded connection between them. The upper elevator then grips and vertically raises the connected first and second tubulars.
The horizontal to vertical machine then grips a third tubular and raises it from a horizontal position near the ground to a vertical position proximate to the drill floor. The lower elevator receives the third tubular from the horizontal to vertical machine. The lower elevator raises the third tubular vertically, until the female connection of the third tubular engages the male connection of the second tubular. The stand building power tong rotates the one of the tubular in relation to the other to make-up the threaded connection between them. The upper elevator then grips and vertically raises the connected first, second and third tubulars (referred to as the pipe “stand”) to a position below the racking board.
The automatic pipe racker receives the connected pipe stand from the upper elevator, wherein the upper elevator releases the connected pipe stand. In one embodiment, the upper elevator may then be rotated with respect to the base frame of the automatic pipe racker such that the upper elevator is no longer in the way.
In another embodiment, the automatic pipe racker then tilts the connected pipe stand inside the racking board. The automatic pipe racker may be tilted by actuating linearly adjustable mast braces connected to the drilling mast. The automatic pipe racker is then used to locate the pipe stand in the racking boards, and to move the pipe stand between the racking board and the well.
As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wings may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
FIG. 1 is an isometric view of a drilling rig fitted with an automatic pipe racking system having features in accordance with embodiments of the present invention.
FIG. 2 is an isometric view of the racking mechanism illustrating the mechanism fully retracted within the base frame.
FIG. 3 is an isometric view of the racking mechanism illustrating the lateral extend mechanism partially deployed.
FIG. 4 is an isometric view of the racking mechanism illustrating the lateral extend mechanism partially deployed, and further illustrating the rotate mechanism rotated 90 (ninety) degrees, and the finger extend mechanism partially deployed, such as in position to receive or to set back a stand of drill pipe in a racking board.
FIG. 5 is an isometric view of the base frame of the racking mechanism illustrating the base frame in isolation of the remaining components of the racking mechanism and of the drilling rig.
FIG. 6 is an isometric view of the lateral extend mechanism of the racking mechanism illustrating the lateral extend mechanism in isolation of the remaining components of the racking mechanism and of the drilling rig.
FIG. 7 is an isometric view of the pivot frame illustrated in isolation of the remaining components of the racking mechanism and of the drilling rig.
FIG. 8 is an isometric view of the rotate mechanism, finger extend mechanism and vertical grip and stab mechanism of the racking mechanism.
FIG. 9 is a top view of the rotate mechanism illustrating the rotate mechanism in the non-rotated position, and having the finger extend and gripping mechanisms retracted.
FIG. 10 is a top view of the rotate mechanism illustrating the rotate mechanism rotated 90 (ninety) degrees, and having the finger extend and gripping mechanisms retracted.
FIG. 11 is an isometric view of the finger extend mechanism and vertical grip and stab mechanism of the racking mechanism.
FIGS. 12 through 22 are top views illustrating operation of the automatic pipe racker and illustrating the automatic pipe racker moving from a fully retracted position, to retrieve a stand of pipe (or other tubular) from the pipe rack, to an extended position and delivering the pipe stand into alignment for vertical stabbing into the stump over the wellbore.
FIG. 23 is a side view of the automatic pipe racking mechanism in the position illustrated in the top view of FIG. 13 .
FIG. 24 is a side view of the automatic pipe racking mechanism in the position illustrated in the top view of FIG. 15 .
FIG. 25 is a side view of the automatic pipe racking mechanism in the position illustrated in the top view of FIG. 17 .
FIG. 26 is a side view of the automatic pipe racking mechanism in the position illustrated in the top view of FIG. 22 .
FIG. 27 is a top view illustrating potential paths of a tubular or pipe as manipulated by the pipe racking mechanism.
FIG. 28 is an isometric view of a drilling rig floor fitted with a tubular stand building system having features in accordance with the present invention.
FIG. 29 is an isometric view of a drilling rig floor fitted with a tubular stand building system having features in accordance with the present invention, and generally illustrated from a side opposite that of FIG. 28 , and illustrating only the base frame and braces of the pipe racking mechanism.
FIG. 30 is an isometric exploded view of the horizontal to vertical pipe feeding mechanism of the present invention used to bring a tubular such as a drill pipe section from beneath the drill rig floor for delivery to a lower elevator attached near the edge of the V-door side of the drill rig floor.
FIG. 31 is an isometric view of the horizontal to vertical pipe feeding mechanism, illustrating the mechanism at the bottom of its motion, having gripped a pipe section from a horizontal rack on the ground.
FIG. 32 is an isometric view of the horizontal to vertical pipe feeding mechanism, illustrating the mechanism moving upwards from its bottom position upon extension of the boom cylinder, and illustrating the upward movement of the pipe being retained in a generally horizontal position.
FIG. 33 is an isometric view of the horizontal to vertical pipe feeding mechanism, illustrating the continued upward movement of the mechanism, and the translation of the pipe from a horizontal position to a vertically inclined position.
FIG. 34 is an isometric view of the horizontal to vertical pipe feeding mechanism, illustrating the mechanism in its fully raised position, and with the pipe being fully vertical.
FIG. 35 is an isometric view of the tubular stand building system, illustrating the collective actuator control movements of the system during operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
FIG. 1 is an isometric view of a racking mechanism 100 including features of the automatic stand building system 1 . As it pertains to the present invention, racking mechanism 100 is one component of automatic stand building system 1 . Although significant detail is provided below for racking mechanism 100 , it will be appreciated that many variations and modifications may be considered desirable by those skilled in the art based upon a review of the following description of one preferred embodiment.
As seen in FIG. 1 , a drilling rig 10 is located over a wellbore 12 . Drilling rig 10 has a drill floor 14 and a drilling mast 16 extending upwards above drill floor 14 and located over wellbore 12 . Drilling mast 16 has an open V-door side 18 . A racking board 20 extends horizontally outward on V-door side 18 . Racking board 20 has a plurality of fingers 22 extending horizontally for supporting drill pipe 50 when it is removed from wellbore 12 . Racking mechanism 100 is mounted to drill floor 14 , on V-door side 18 of drilling mast 16 .
FIG. 2 is an isometric view of racking mechanism 100 in accordance with one embodiment of the invention, illustrating racking mechanism 100 in the fully retracted position. Racking mechanism 100 is comprised of a base frame 200 that is connected to drill floor 14 by floor pins 202 . In one embodiment, base frame 200 is a tapered C-frame that extends upwards from drill floor 14 at a position offset to V-door side 18 of drilling mast 16 . A mast brace 204 is connected between base frame 200 and drilling mast 16 at a position distal to drill floor 14 for stabilizing an upper end of base frame 200 in relationship to drilling mast 16 . In one embodiment, a pair of tensioning members 206 is connected between drill floor 14 and base frame 200 . Tensioning members 206 provide further support and stability to the base frame 200 with respect to the drill floor 14 .
In one embodiment, base frame 200 comprises a pair of deployable wings 208 (not shown), pivotally attached to base frame 200 . When wings 208 are deployed outward, deployed ends of wings 208 are connected to base frame 200 by struts 210 (not shown). In this embodiment, mast braces 204 are connected to the deployed ends of wings 208 , increasing the spacing between mast braces 204 to facilitate conflict free operation of racking mechanism 100 . Retraction of wings 208 provides a narrower transport profile for transporting racking mechanism 100 between drilling sites.
As seen in FIG. 2 , wellbore 12 has a vertical well centerline 70 that extends through and above the entrance of wellbore 12 . Well centerline 70 represents the theoretical target location for stabbing drill pipe 50 . Mast brace 204 stabilizes an upper end of base frame 200 in relationship to drilling mast 16 . In a preferred embodiment, the length of mast brace 204 is adjustable to compensate for deflection of racking mechanism 100 under different payloads which vary with the size of the tubular being handled. Adjustment is also advantageous to accommodate non-verticality and settling of drilling rig 10 . Adjustment is also useful for connectivity to other mechanisms that deliver or receive pipe from racking mechanism 100 .
FIG. 3 is an isometric view of racking mechanism 100 , illustrating racking mechanism 100 partially deployed. In FIG. 3 and FIG. 4 , drilling mast 16 of drilling rig 10 has been removed for clarity.
A lateral extend mechanism 300 is pivotally connected to base frame 200 . Lateral extend mechanism 300 is extendable between a retracted position, substantially within base frame 200 , and a deployed position which extends in the direction of well centerline 70 . In FIG. 3 , as compared to FIG. 2 , lateral extend mechanism 300 is partially deployed.
Lateral extend mechanism 300 includes a pivot frame 400 . A rotate mechanism 500 is connected to pivot frame 400 . A finger extend mechanism 700 (not visible) is connected to rotate mechanism 500 . A grip and stab mechanism 800 is connected to rotate mechanism 500 . FIG. 3 illustrates rotate mechanism 500 rotated 90 (ninety) degrees, with finger extend mechanism 700 in the retracted position. This position is intermediate of positions for receiving or setting back a stand of drill pipe in racking board 20 .
In a preferred embodiment (best seen in FIG. 1 ), lateral extend mechanism 300 is particularly configured such that upon deployment towards well centerline 70 , rotate mechanism 500 , finger extend mechanism 700 , and grip and stab mechanism 800 are movable to a position beneath racking board 20 , and further to a position substantially within drilling mast 16 . Also in a preferred embodiment, lateral extend mechanism 300 is particularly configured to be force-balanced, such that upon partial extension, lateral extend mechanism 300 is not inclined to retract or extend, as contrasted to a parallelogram linkage. The benefit of this configuration is that a low pushing force is required to actuate lateral extend mechanism 300 into deployment or retraction.
In another embodiment, racking mechanism 100 is further balanced such that upon failure of the power supply and/or hydraulic pressure, lateral extend mechanism 300 will be slightly more inclined to retract under gravitational force than to extend.
FIG. 4 is an isometric view of racking mechanism 100 , illustrating lateral extend mechanism 300 partially deployed, and further illustrating rotate mechanism 500 rotated 90 (ninety) degrees and finger extend mechanism 700 partially deployed. As best seen in FIG. 2 , finger extend mechanism 700 (not shown) may be retracted into the interior space of rotate mechanism 500 (not shown) to permit passage through the narrow alley formed between stands of pipe 50 stacked on drill floor 14 when tripping drill pipe 50 out of wellbore 12 , such as when changing the drill bit. As contrasted, the position illustrated in FIG. 4 is exemplary of a position for receiving or setting back a stand of drill pipe in racking board 20 .
FIG. 5 is an isometric view of base frame 200 of racking mechanism 100 , illustrating base frame 200 in isolation of the remaining components of racking mechanism 100 and of drilling rig 10 . Base frame 200 is pivotally connected to drill floor 14 (not shown) by floor pins 202 . A mast brace 204 connects each side of base frame 200 to drilling mast 16 (not shown) of drilling rig 10 (not shown). Mast braces 204 stabilize base frame 200 of racking mechanism 100 . In a preferred embodiment, mast braces 204 are adjustable to compensate for verticality of drilling mast 16 and for the variable deflection of racking mechanism 100 when handling different sizes of drill pipe 50 .
In another preferred embodiment, a tensioning member 206 connects each side of base frame 200 to drill floor 14 (not shown) of drilling rig 10 (not shown). Tensioning members 206 stabilize base frame 200 of racking mechanism 100 . In a preferred embodiment, tensioning members 206 are adjustable to compensate for verticality of racking mechanism 100 , and for the variable deflection of racking mechanism 100 when handling different sizes of drill pipe 50 .
FIG. 6 is an isometric view of lateral extend mechanism 300 of FIG. 1 , illustrating lateral extend mechanism 300 in isolation of the remaining components of racking mechanism 100 and of drilling rig 10 . As shown in FIG. 6 , lateral extend mechanism 300 has a mast side 302 and a base connect side 304 . Base connect side 304 of lateral extend mechanism 300 is pivotally connected to base frame 200 (not shown). Mast side 302 of lateral extend mechanism 300 is pivotally connected to pivot frame 400 at connections 420 and 450 .
In the preferred embodiment illustrated, lateral extend mechanism 300 comprises an extend linkage 320 and a level linkage 350 . In a more preferred configuration, lateral extend mechanism 300 comprises an eight bar linkage as illustrated.
In the preferred embodiment illustrated, extend linkage 320 is comprised of an upper link 322 , a lower link 324 , and a long link 326 . Also in this embodiment, level linkage 350 is comprised of an inboard link 352 , an outboard link 354 , and a coupler link 356 .
Extend linkage 320 and level linkage 350 are pivotally connected to base frame 200 (not shown) on base connect side 304 . Extend linkage 320 and level linkage 350 are pivotally connected to pivot frame 400 on mast side 302 . Extend linkage 320 is pivotally connected to pivot frame 400 at connection 420 . Level linkage 350 is pivotally connected to pivot frame 400 at connection 450 . Extend linkage 320 and level linkage 350 are also pivotally connected to each other by coupler link 356 .
A lateral extend cylinder 390 is pivotally connected between base frame 200 (not shown) and extend linkage 320 . Controllable expansion of lateral extend cylinder 390 moves lateral extend mechanism 300 and thus pivot frame 400 between a retracted position substantially internal to base frame 200 (not shown) and an extended position external to base frame 200 . In a preferred embodiment, inboard link 352 and upper link 322 are substantially the same length. The novel kinematic configuration of extend linkage 320 and level linkage 350 generates extension of pivot frame 400 along a stable and substantially horizontal path above drill floor 14 (not shown) when lateral extend mechanism 300 is deployed.
The lateral extend mechanism 300 is useful for other drilling rig applications in which it is desirable to horizontally translate another apparatus in a self-balancing manner in which maintaining the vertical alignment of the apparatus is desired. Such applications include positioning a gripping or torque device.
As seen in FIG. 6 , pivot frame 400 is in the form of a C-frame, with an opening in the direction of mast side 302 for receiving rotate frame 600 (not shown) and its connected contents.
FIG. 7 is an isometric view of lateral extend mechanism 300 from FIG. 6 , shown from the opposite side, with pivot frame 400 in front, and shown from below. Pivot frame 400 has a plurality of sockets for pivotal connection to the linkage of rotate mechanism 500 .
In one embodiment as shown, at the top of pivot frame 400 is a right lock socket 412 , a right drive link socket 414 , and a right cylinder socket 416 which are located near the top of pivot frame 400 . A left lock socket 422 , a left drive link socket 424 , and a left cylinder socket 426 are also located near the top of pivot frame 400 .
A right lock socket 452 , a right drive link socket 454 , and a right cylinder socket 456 are located near the bottom of pivot frame 400 , and in respective axial alignment with right lock socket 412 , right drive link socket 414 , and right cylinder socket 416 at the top of pivot frame 400 .
A left lock socket 462 , a left drive link socket 464 , and a left cylinder socket 466 are located near the bottom of pivot frame 400 , and in respective axial alignment with left lock socket 422 , left drive link socket 424 , and left cylinder socket 426 at the top of pivot frame 400 .
In one embodiment illustrated in FIG. 7 , a notch 490 on pivot frame 400 is receivable of level linkage 350 of lateral extend mechanism 300 . A similarly sized notch 410 (not seen) is located on the corresponding side of the pivot frame 400 . Engagement of notch 490 (and notch 410 ) with level linkage 350 stabilizes pivot frame 400 and other components of racking mechanism 100 when lateral extend mechanism 300 is fully retracted.
FIG. 8 is an isometric view of the components of racking mechanism 100 , shown without lateral extend mechanism 300 and pivot frame 400 . As illustrated in FIG. 9 , a rotate mechanism 500 is shown for connection to pivot frame 400 . A rotate frame 600 comprises the body of the rotate mechanism 500 . A top rotate mechanism 510 and bottom rotate mechanism 560 are also shown connected to the rotate mechanism 500 , and used for connection to the pivot frame 400 . A finger extend mechanism 700 is connected to rotate mechanism 500 . A grip and stab mechanism 800 is connected to rotate mechanism 500 via the finger extend mechanism 700 . FIG. 3 illustrates rotate mechanism 500 rotated 90 (ninety) degrees; with finger extend mechanism 700 in the retracted position. This position is intermediate of positions for receiving or setting back a stand of drill pipe in racking board 20 .
FIG. 9 is a top view of rotate mechanism 500 , illustrating top rotate mechanism 510 (not shown) in the non-rotated position. FIGS. 9 and 10 illustrate one embodiment in which pivot frame 400 (not shown) is operably connected to rotate mechanism 500 .
As best seen in FIG. 9 , top rotate mechanism 500 comprises a right driver 532 pivotally connected to pivot frame 400 (not shown) at right drive socket 414 (not shown) on one end and pivotally connected to a right coupler 534 on its opposite end. Right coupler 534 is pivotally connected between right driver 532 and rotate frame 600 . An expandable right cylinder 536 has one end pivotally connected to pivot frame 400 at right cylinder socket 416 (not shown). The opposite end of right cylinder 536 is pivotally connected to right driver 532 between its connections to pivot frame 400 and right coupler 534 . A right rotate lock pin 530 is provided for engagement with pivot frame 400 at right lock socket 412 .
As also seen in FIG. 9 , top rotate mechanism 500 comprises a left driver 542 pivotally connected to pivot frame 400 at left drive link socket 424 (not shown) on one end and to a left coupler 544 on its opposite end. Left coupler 544 is pivotally connected between left driver 542 and rotate frame 600 . An expandable left cylinder 546 has one end pivotally connected to pivot frame 400 at left cylinder socket 426 . The opposite end of left cylinder 546 is pivotally connected to left driver 542 between its connections to pivot frame 400 and left coupler 544 . A left rotate lock pin 540 is provided for engagement with pivot frame 400 at left lock socket 422 (not shown).
A substantially matching configuration to the linkage and sockets of top rotate mechanism 510 is provided for bottom rotate mechanism 560 . In this manner, top rotate mechanism 510 and bottom rotate mechanism 560 work in parallel relation to turn rotate frame 600 of rotate mechanism 500 in the desired direction.
To provide selectable rotation direction, or non-rotated direction, rotate mechanism 500 is connected to pivot frame 400 , in part, by selectable rotate lock pins 530 and 540 . Rotate frame 600 is clockwise rotatable about a first vertical axis centered on right lock socket 452 of pivot frame 400 . Rotate frame 600 is counterclockwise rotatable about a second vertical axis centered on left lock socket 462 of pivot frame 400 .
As illustrated in FIG. 9 , right rotation of rotate mechanism 500 is caused by actuation of right rotate lock pin 530 into right lock socket 440 (not shown) of pivot frame 400 . Subsequent expansion of right cylinder 536 forces right driver 532 to push right coupler 534 , which pushes out one end of rotate frame 600 . Since the other end of rotate frame 600 is pivotally attached to pivot frame 400 by right rotate lock pin 530 in right lock socket 412 , rotate frame 600 rotates to the right.
Similarly, left rotation of rotate mechanism 500 is caused by actuation of left rotate lock pin 540 into left lock socket 422 (not shown) of pivot frame 400 . Subsequent expansion of left cylinder 546 forces left driver 542 to push left coupler 544 , which pushes out one end of rotate frame 600 . Since the other end of rotate frame 600 is pivotally attached to pivot frame 400 by left rotate lock pin 540 in left lock socket 462 , rotate frame 600 rotates to the left.
Rotate frame 600 can be locked into non-rotated position by actuation of right rotate lock pin 530 into right lock socket 412 of pivot frame 400 , and actuation of left rotate lock pin 540 into left lock socket 422 of pivot frame 400 .
As previously stated, the same kinematic relationships are engaged in top rotate mechanism 510 and bottom rotate mechanism 560 so that they may work in parallel relation to turn rotate frame 600 in the desired direction.
FIG. 10 is a top view of rotate mechanism 500 . Rotate mechanism 500 comprises a rotate frame 600 , a top rotate linkage 510 and a bottom rotate linkage 560 (not shown). Top rotate linkage 510 and bottom rotate linkage 560 pivotally connect rotate frame 600 to pivot frame 400 (not shown). Top rotate linkage 510 and bottom rotate linkage 560 work in parallel relation to turn rotate frame 600 at least 90 (ninety) degrees in a selectable clockwise or counterclockwise direction in relation to pivot frame 400 .
FIG. 11 is an isometric view of finger extend mechanism 700 and vertical grip and stab mechanism 800 . Finger extend mechanism 700 is pivotally connected to rotate frame 600 (not shown). Finger extend mechanism 700 is extendable between a retracted position substantially within rotate frame 600 and a deployed position, which extends outward in the selected direction of rotate mechanism 500 , away from rotate frame 600 . Referring back to FIG. 4 , as compared to FIG. 3 , finger extend mechanism 700 is partially deployed.
In the preferred embodiment, finger extend mechanism 700 is collapsible within rotate frame 600 such that rotate frame 600 , finger extend mechanism 700 and vertical grip and stab mechanism 800 are collectively 180 (one hundred eighty) degrees rotatable within a 48 inch distance.
Finger extend mechanism 700 includes an upper finger extend frame 702 pivotally connected on its upper end to rotate frame 600 and pivotally connected on its lower end to a vertical stab frame 802 of vertical grip and stab mechanism 800 . Finger extend mechanism 700 includes a lower finger extend frame 704 pivotally connected on its upper end to rotate frame 600 and pivotally connected on its lower end to vertical stab frame 802 . A finger extend cylinder 710 is pivotally connected on a first end to vertical stab frame 802 , and connected on a second end to rotate mechanism 500 . Extension of finger extend cylinder 710 causes extension of finger extend mechanism 700 and movement of vertical grip and stab mechanism 800 away from rotate frame 500 to position pipe 50 in the desired position.
As stated, vertical grip and stab mechanism 800 has a vertical stab frame 802 . Vertical stab frame 802 has a lower end and an opposite upper end. A stab cylinder 804 is located on vertical stab frame 802 .
A lower load gripper 820 is mounted in vertically translatable relation to vertical stab frame 802 . A spacer 806 is attached above lower load gripper 820 . An upper load gripper 830 is mounted above spacer 806 , in vertically translatable relation to vertical stab frame 802 . Load grippers 820 and 830 are capable of clamping onto the exterior of a drilling tubular and supporting the load of the tubular. Extension of stab cylinder 804 moves lower load gripper 820 , spacer 806 , and upper load gripper 830 vertically upwards in relation to vertical stab frame 802 .
A spring assembly 808 is located between stab cylinder 804 and centering gripper 840 . Spring assembly 808 is preloaded with the weight of the lower load gripper 820 and upper load gripper 830 . The spring is further loaded when lower load gripper 820 and upper load gripper 830 are used to grip pipe 50 , and stab cylinder 804 is extended. This reduces the power required for extending stab cylinder 804 to raise pipe 50 . In one embodiment, spring assembly 808 is designed to achieve maximum compression under a weight of approximately 2,000 pounds, which is approximately the weight of a standard drill string.
Preloading spring assembly 808 allows for a gradual load transfer of the vertical forces from stab cylinder 804 to the target support of pipe 50 , being either a receiving toll joint of drill pipe stump 52 located in wellbore 12 , or on drill floor 14 for setting back the stand of drill pipe 50 .
A centering gripper 840 is located on the lower end of vertical stab frame 802 . Centering gripper 840 stabilizes pipe 50 , while allowing it to translate vertically through its centering grip.
In an alternative embodiment (not illustrated), a gripper assembly is mounted in vertically translatable relation to vertical stab frame 802 . At least one load gripper 830 is mounted on the gripper assembly. In this embodiment, extension of stab cylinder 804 moves the gripper assembly, including load gripper 830 , vertically upwards in relation to vertical stab frame 802 .
FIGS. 12 through 22 are top views illustrating the operation of racking mechanism 100 and illustrating racking mechanism 100 moving from a fully retracted position to retrieve a stand of pipe 50 (or other tubular) from pipe rack 20 , and delivering pipe stand 50 into alignment for vertical stabbing into drill pipe stump 52 located over wellbore 12 . In each of FIGS. 12 through 22 , substantial structure has been removed for the purpose of more clearly illustrating the operation of racking mechanism 100 , with emphasis of the relationship between racking mechanism 100 , pipe rack 20 , pipe stand 50 , and drill pipe stump 52 .
In FIG. 12 , racking mechanism 100 is illustrated in the fully retracted position. In this position, the lateral extend mechanism 300 (not seen), rotate mechanism 500 , finger extend mechanism 700 (not seen), and grip and stab mechanism 800 are all fully retracted. In this position, racking mechanism 100 can be serviced. Rotate mechanism 500 can also be rotated and lateral extend mechanism 300 can be extended to permit racking mechanism 100 to be used to lift other drilling rig equipment. It is possible to replace grip and stab mechanism 800 with an alternative gripping device for this purpose.
FIG. 13 illustrates racking mechanism 100 having lateral extend mechanism 300 partially extended. In this position, racking mechanism 100 can be parked for immediate access to pipe 50 in racking board 20 when needed.
FIG. 14 illustrates racking mechanism 100 in a partially extended position as racking mechanism 100 progresses towards pipe 50 which is resting in racking board 20 . In this position, the lateral extend mechanism 300 is partially extended and rotate mechanism 500 , finger extend mechanism 700 , and grip and stab mechanism 800 are extended to a position beneath diving board 24 .
FIG. 15 illustrates racking mechanism 100 with rotate mechanism 500 partially rotated to the right towards pipe 50 . FIG. 16 illustrates rotate mechanism 500 rotated 90 (ninety) degrees and now orienting grip and stab mechanism 800 such that grippers 820 , 830 , and 840 are open and facing pipe 50 .
FIG. 17 illustrates racking mechanism 100 having finger extend mechanism 700 fully extended to position grip and stab mechanism 800 adjacent to pipe 50 . Grippers 820 , 830 , and 840 are closed around pipe 50 . Stab cylinder 804 is extended and pipe 50 is raised off of drilling floor 10 , suspended vertically by upper load gripper 830 and lower load gripper 820 . Centering gripper 840 resists undesirable bending and oscillation of pipe 50 .
FIG. 18 illustrates racking mechanism 100 having finger extend mechanism 700 retracted to position pipe 50 between diving board 24 and the ends of fingers 22 of racking board 20 . Rotate mechanism 500 remains rotated clockwise. A corridor 26 is formed in this space through which pipe 50 must be navigated to avoid conflict with the structure of racking board 20 .
FIG. 19 illustrates racking mechanism 100 having the lateral extend mechanism 300 further extended to guide pipe 50 through corridor 26 towards drill pipe stump 52 in wellbore 12 .
FIG. 20 illustrates racking mechanism 100 having delivered pipe 50 along a substantially horizontal path by the extension of lateral extend mechanism 300 . In this position, pipe 50 is now past diving board 24 in the direction of wellbore 12 . Rotate mechanism 500 is now rotated counterclockwise to position pipe 50 in alignment with drill pipe stump 52 in wellbore 12 .
FIG. 21 illustrates racking mechanism 100 having rotate mechanism 500 returned to the forward and non-rotated position, thus aligning pipe 50 for delivery to a position directly above drill pipe stump 52 . It is possible to simultaneously actuate rotate mechanism 500 while lateral extend mechanism 300 continues to extend in the direction of drill pipe stump 52 in wellbore 12 to save delivery time.
FIG. 22 illustrates racking mechanism 100 having delivered pipe 50 in a vertical position directly above drill pipe stump 52 in wellbore 12 . In this position, stab cylinder 804 of grip and stab mechanism 800 is lowered to vertically lower upper load gripper 830 and lower load gripper 820 , and thus pipe 50 , until the male pin connection of pipe 50 (or other tubular) engages female box connection of drill pipe stump 52 . In this position, pipe 50 may be fully connected by rotation and the proper torque into drill pipe stump 52 .
FIGS. 23 through 26 are selected side views that correspond to the top views provided in FIGS. 12 through 22 .
FIG. 23 is a side view of racking mechanism 100 in the position illustrated in the top view of FIG. 13 . In this view, racking mechanism 100 is mostly retracted.
FIG. 24 is a side view of racking mechanism 100 in the position illustrated in the top view of FIG. 15 . In this view, lateral extend mechanism 300 is partially extended in the direction of pipe 50 , and rotate mechanism 500 is partially rotating to the right towards pipe 50 .
FIG. 25 is a side view of racking mechanism 100 in the position illustrated in the top view of FIG. 17 , in which racking mechanism 100 has finger extend mechanism 700 fully extended to position grip and stab mechanism 800 adjacent to pipe 50 . Grippers 820 , 830 , and 840 are closed around pipe 50 . Stab cylinder 804 is extended and pipe 50 is raised off of drilling floor 14 , suspended vertically by upper load gripper 830 and lower load gripper 820 . Centering gripper 840 resists undesirable bending and oscillation of pipe 50 .
FIG. 26 is a side view of racking mechanism 100 in the position illustrated in top view of FIG. 22 , in which automatic pipe racking mechanism 100 has delivered pipe 50 in a vertical position directly above stump 52 in wellbore 12 . In this position, stab cylinder 804 of grip and stab mechanism 800 is lowered to vertically lower upper load gripper 830 and lower load gripper 820 , and thus pipe 50 , until the male pin connection of pipe 50 (or other tubular) engages female box connection of drill pip stump 52 . In this position, pipe 50 may be fully connected by rotation and the proper torque into drill pipe stump 52 .
FIG. 27 is a top view illustrating potential paths of pipe racking mechanism 100 with the dotted line representing the path of drill pipe 50 . As seen in FIG. 27 , pipe racking mechanism 100 is capable of navigating the narrow space between diving board 10 (see FIG. 24 ) and fingers 20 .
FIG. 28 is an isometric view of a drilling rig floor 14 fitted with automatic stand building system 1 having features in accordance with the present invention. As seen in FIG. 28 , automatic stand building system 1 comprises a horizontal to vertical mechanism 900 , which feeds sections of drill pipe 50 to a lower elevator 1000 .
Lower elevator 1000 has at least one gripper 1002 for supporting the load of drill pipe 50 . Gripper 1002 of lower elevator system 1000 is vertically translatable along lower elevator 1002 . This capability allows gripper 1002 to vertically raise drill pipe 50 to an upper elevator 1100 . In one embodiment, the upper end of lower elevator 1000 is pivotally connected to drill rig 10 along a horizontal axis. This connection permits horizontally positioned attachment of lower elevator 1000 in a horizontal position to drill rig 10 prior to raising the substructure of drill rig 10 during rig up. After raising the substructure, lower elevator 1000 may be pivoted into its normal, vertical position.
In one embodiment, upper elevator 1100 is pivotally connected to base frame 200 of pipe racking mechanism 100 along a vertical axis of upper elevator 1100 . Upper elevator 1100 has a lower gripper 1102 and an upper gripper 1104 . Lower gripper 1104 is vertically translatable along the length of upper elevator 1100 . Each of the grippers 1102 and 1104 is capable of supporting the load of three sections of pipe 50 . Grippers 1102 and 1104 are independently operable.
A torquing mechanism such as a power tong 1200 may be used to rotate a first section of drill pipe 50 in upper elevator 1100 in respect to a second section of drill pipe 50 in lower elevator 1000 . By this procedure, the upper section of the second section of drill pipe 50 and the lower section of the first section of drill pipe 50 are threadedly connected. In an alternative embodiment, one or both of lower elevator 1000 and upper elevator 1100 are fitted with spinning grippers, which are capable of rotating a first section of drill pipe 50 in upper elevator 1100 with respect to a second section of drill pipe 50 in lower elevator 1000 .
In one embodiment, the verticality of automatic pipe racking mechanism 100 is controllable in relationship to the mast 16 of drilling rig 10 , such as by controllable length adjustment of the mast braces 204 . In this embodiment, tipping base frame 200 of automatic pipe racking mechanism 100 , and thus also upper elevator 1100 towards mast side 302 of base frame 200 permits entry of a pipe stand 50 into the confines of the racking board 20 of drilling rig 10 .
FIG. 29 is an isometric view of the automatic stand building system 1 shown in FIG. 28 , as it appears from the opposite side. In this view, the lower elevator 1000 may be more clearly seen as located underneath the drill floor 14 . Furthermore, the overall positional relationship between the horizontal to vertical mechanism 900 , the lower elevator 1000 , the upper elevator 1100 , and the racking mechanism 100 are more clearly illustrated in FIG. 29 .
FIG. 30 is an isometric exploded view of the horizontal to vertical pipe feeding mechanism 900 of the present invention, used to bring tubulars such as drill pipe 50 from beneath drill rig floor 14 for delivery to lower elevator 1000 attached at the edge of the V-door side drill rig floor 14 . In the view provided by FIG. 30 , the various components which make up the horizontal to vertical mechanism 900 are illustrated in detail, and are further described below.
Horizontal to vertical mechanism 900 has a base 910 . In the embodiment shown, base 910 has a flange 912 for connection to drill rig 10 . Base 910 is pivotally connected to a boom 930 , a cylinder 950 and a link 952 . In one embodiment, base 910 has a boom flange 922 with a boom pivot 924 . Base 910 has a link flange 914 with a link pivot 916 . Link flange 914 extends outward from flange 912 further than boom flange 924 . Base 910 has a cylinder flange 918 with a cylinder pivot 920 .
Horizontal to vertical mechanism 900 has an angular boom 930 . In the embodiment shown, boom 930 has a base connect end 934 for pivotal connection to base 910 at boom pivot 924 . Boom 930 has a yoke 936 on its opposite end. Yoke 936 has a brace pivot 944 and an arm pivot 942 . In the embodiment illustrated, boom 930 is pivotally connectable to cylinder 950 at a cylinder pivot 940 .
Horizontal to vertical mechanism 900 has a lever 960 . Lever 960 is pivotally connected to boom 930 , link 952 , and arm 980 . In the embodiment shown, lever 960 has an outer lobe 962 and an inner lobe 964 . In this embodiment, inner lobe 964 is shorter than outer lobe 962 . Outer lobe 962 has a pivot connection 966 for pivotal connection to link 952 . A pivot connection 968 is provided between outer lobe 962 and inner lobe 964 for pivotal connection to boom 930 at pivot connection 942 . A pivot connection 970 is provided between outer lobe 962 and inner lobe 964 for pivotal connection to arm 980 at pivot connection 988 .
Horizontal to vertical mechanism 900 has a brace 954 . Brace 954 is pivotally connected between boom 930 and arm 980 . In the embodiment shown, brace 954 is pivotally connected at one end to pivot point 944 on yoke 936 of boom 930 . Brace 954 is pivotally connected at its opposite end to pivot 990 of arm 980 .
Horizontal to vertical mechanism 900 has an arm 980 . Arm 980 is pivotally connected to lever 960 and to boom 930 through brace 954 . In the embodiment shown, arm 980 is pivotally connected to lever 960 between inner lobe 964 and outer lobe 962 at pivot point 968 . Arm 980 is pivotally connected to brace 954 at pivot 990 .
Arm 980 has an upper arm portion 982 and a lower arm portion 984 . Lower arm 984 is angularly disposed to upper arm 982 in a direction that extends beneath inner lobe 964 of lever 960 . Arm 980 has a gripper head 986 on the free end of lower arm 984 . Gripper head 986 has attached at least one gripper 992 capable of clamping onto the exterior of a drilling tubular such as a section of drill pipe 50 and of supporting the load of the tubular 50 . In the embodiment shown, a second gripper 994 is provided for increased lifting and support capability. In another embodiment, not shown, grippers 992 and 994 are controllably and rotatably attached to arm 980 , for additional positioning control of drill pipe 50 .
Cylinder 950 is pivotally connected between base 910 and boom 930 . Cylinder 950 is pivotally connected at one end to base 910 at cylinder pivot 920 on cylinder flange 918 . Cylinder 950 is pivotally connected at its opposite end to boom 930 at cylinder pivot 940 .
Link 952 is pivotally connected between base 910 and lever 960 . Link 952 is pivotally connected at one end to base 910 at link pivot 916 on link flange 914 . Link 952 is pivotally connected at its opposite end to lever 960 at pivot point 966 on outer lobe 962 .
Although the above description discloses horizontal to vertical mechanism 900 as a six-bar mechanism, it has been recognized that an eight-bar mechanism may also be developed for this purpose by taking advantage of the unique geometry and kinematic relationships disclosed for horizontal to vertical mechanism 900 . This may be preferred depending upon other variables such as the height of the drilling floor 14 of a particular drilling rig 10 , or the total length of the stand of drill pipe 50 being utilized. In particular, such mechanism could include an additional linkage between base 910 and boom 930 . An example of this mechanism is illustrated in FIG. 35 for comparison.
FIG. 31 is an isometric view of the horizontal to vertical pipe feeding mechanism 900 , illustrating mechanism 900 at the bottom of its motion, having gripped a section of drill pipe 50 from a horizontal rack near the ground.
FIG. 32 is an isometric view of the horizontal to vertical pipe feeding mechanism 900 , illustrating mechanism 900 moving upwards from its bottom position upon extension of cylinder 950 , and illustrating the upward movement of drill pipe 50 , being advantageously retained in a generally horizontal position at this stage of the movement, thus clearing an optional V-door ramp, and accommodating variable heights of conventional drill floors 14 .
FIG. 33 is an isometric view of the horizontal to vertical mechanism 900 , illustrating the mechanism's continued upward movement, and the translation of drill pipe 50 from a horizontal position to a vertically inclined position.
FIG. 34 is an isometric view of the horizontal to vertical mechanism 900 , illustrating mechanism 900 in its fully raised position, and with drill pipe 50 being fully vertical for gripping by gripper 1002 of lower elevator 1000 (see FIG. 35 ).
FIG. 35 is an isometric view of the tubular stand building system 1 , illustrating the collective actuator control movements of tubular stand building system 1 in operation, as is described further below. In FIG. 35 , the internal components of the racking mechanism 100 are excluded for visibility of the remaining components of tubular stand building mechanism 1 , illustrating only base frame 200 of racking mechanism 100 . In this view it is seen that upper elevator 1100 can be pivotally attached to base frame 200 with hinge-type or other pivots 1106 . It can also be seen that extendable mast braces 204 can be used to alter the verticality of base frame 200 with respect to mast 16 (not shown) via extension or retraction of the mast braces 204 .
Operation of the Invention
Referring to FIG. 35 , lower elevator 1000 is mounted to drilling rig 10 for receiving a section of drill pipe 50 in a vertical orientation from horizontal to vertical mechanism 900 . Lower elevator 1000 may be pivotally attached to drilling rig 10 so that it may be attached in a horizontal position prior to raising the substructure. Lower elevator 1000 has at least one gripper 1002 that is vertically translatable along the length of lower elevator 1000 . Gripper 1002 is capable of clamping onto the exterior of drilling tubular 50 and supporting the load of tubular 50 .
Referring back to FIGS. 28-29 , racking mechanism 100 is provided, having base frame 200 connectable to a drill floor 14 of a drill rig 10 and extending upwards at a position offset to a V-door side 18 of a drilling mast 16 that is also connected to drill floor 14 . In one embodiment, the base frame 200 is a C-frame design. A mast brace 204 is connected between base frame 200 and drilling mast 16 at a position distal to drill floor 14 for stabilizing an upper end of base frame 200 in relationship to mast 16 . In one embodiment, mast brace 204 is adjustable for tilting racking mechanism 100 slightly towards mast 16 . A tensioning member 206 may be connected between base frame 200 and drilling floor 14 for stabilizing base frame 200 in relationship to the substructure.
The racking mechanism 100 is capable of moving stands of pipe between a racked position within the racking board 20 and the over-well position such as well centerline 70 .
In one embodiment, a lateral extend mechanism 300 is pivotally connectable to base frame 200 . Lateral extend mechanism 300 is extendable between a retracted position and a deployed position. A rotate mechanism 500 is connected to lateral extend mechanism 300 and is rotatable in each of a left and right direction. A finger extend mechanism 700 is connected to rotate mechanism 500 . Finger extend mechanism 700 is laterally extendable between a retracted position and a deployed position.
A grip and stab mechanism 800 is attached to finger extend mechanism 700 . Grip and stab mechanism 800 has grippers 820 , 830 , 840 to hold a drill pipe 50 or stand of pipe and is capable of moving the pipe 50 vertically to facilitate stabbing. Lateral extend mechanism 300 is deployable to move finger extend mechanism 700 and grip and stab mechanism 800 between a position beneath a racking board 20 cantilevered from mast 16 to a position substantially beneath mast 16 , and back.
In another embodiment, movement of lateral extend mechanism 300 between the retracted position and the deployed position moves rotate mechanism 500 along a substantially linear path. In a more preferred embodiment, movement of lateral extend mechanism 300 between the retracted position and the deployed position moves the rotate mechanism along a substantially horizontal path.
Rotate mechanism 500 is rotatable in each of a left and right direction. In a more preferred embodiment, the rotate mechanism is rotatable in each of a left and right direction by at least 90 (ninety) degrees. In a preferred embodiment, grip and stab mechanism 800 is vertically translatable to vertically raise and lower the load of a stand of pipe 50 .
In another embodiment, racking mechanism 100 may be series nesting. In this embodiment, finger extend mechanism 700 and grip and stab mechanism 800 are substantially retractable into rotate mechanism 500 , which is substantially retractable into pivot frame 400 of lateral extend mechanism 300 , which is substantially retractable into base frame 200 .
An upper elevator 1100 is pivotally connected to base frame 200 for receiving a drill pipe 50 in a vertical orientation from a lower elevator 1000 . Upper elevator 1100 has a lower gripper 1102 and an upper gripper 1104 . Upper gripper 1104 is vertically translatable along the length of upper elevator 1100 . Upper gripper 1104 and lower gripper 1102 are both capable of clamping onto the exterior of a drill pipe 50 and supporting the load of the drill pipe.
A stand building power tong 1200 is provided for rotating drill pipe 50 to be connected between upper elevator 1100 and the lower elevator 1000 .
Remaining on FIGS. 28-29 , in operation, the horizontal to vertical machine 900 grips a first tubular 60 , such as a section of drill pipe 50 , and raises it from a horizontal position near the ground to a vertical position proximate to drill floor 14 and adjacent to lower elevator 1000 . Lower elevator 1000 receives the first tubular 60 from the horizontal to vertical machine 900 . Lower elevator 1000 raises the first tubular 60 vertically, wherein upper elevator 1100 grips and continues to vertically raise the first tubular 60 .
The horizontal to vertical machine 900 grips a second tubular 62 and raises it from a horizontal position near the ground to a vertical position proximate to drill floor 14 and adjacent the lower elevator 1000 . Lower elevator 1000 receives second tubular 62 from the horizontal to vertical machine 900 and raises the second tubular 62 vertically until the female connection of second tubular 62 engages the male connection of first tubular 60 . Stand building power tong 1200 rotates one of the tubulars in relation to the other to make-up the threaded connection between them. Upper elevator 1100 then grips and vertically raises the connected first tubular 60 and second tubular 62 .
Depending on the needs of a well operator and the requirements on the length of a pipe stand, horizontal to vertical machine 900 may grip a third tubular 64 and raise it from a horizontal position near the ground to a vertical position proximate to drill floor 14 and adjacent to the lower elevator 1000 . Lower elevator 1000 receives the third tubular 64 from the horizontal to vertical machine 900 and raises the third tubular 64 vertically until the female connection of third tubular 64 engages the male connection of the second tubular 62 . Stand building power tong 1200 then rotates one of the tubulars in relation to the other to make-up the threaded connection between them. Upper elevator 1100 then grips and vertically raises the connected first, second and third tubulars 60 , 62 , 64 , which collectively make up a connected pipe stand 66 .
The racking mechanism 100 receives the connected pipe stand 66 from upper elevator 1100 , whereupon, the upper elevator 1100 releases the connected pipe stand 66 . In one embodiment, upper elevator 1100 may then be rotated with respect to base frame 200 of racking mechanism 100 such that upper elevator 1100 is no longer in the way.
In another embodiment, racking mechanism 100 then tilts the connected pipe stand 66 inside racking board 20 . Racking mechanism 100 may be tilted by actuating linearly adjustable mast braces 204 connected to drilling mast 16 . (See FIG. 35 ). The racking mechanism 100 is then used to locate connected pipe stand 66 in racking boards 20 , and to move pipe stand 66 between racking board 20 and the wellbore 12 .
The references and relationship between first, second and third tubulars 60 , 62 , 64 are illustrated in FIG. 28 , which shows first, second and third tubulars 60 , 62 , 64 threaded together as connected pipe stand 66 , and positioned over stump 52 by racking mechanism 100 .
As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wings may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
As described, the relationship of these elements has been shown to be extremely advantageous in providing a racking mechanism 100 that can be mounted to a conventional drill floor, and that is capable of lifting and moving drill pipe between a racked position within a largely conventional racking board and a stabbed position over a wellbore.
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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The present invention provides a rapid rig-up and rig-down pipe stand building and racking system that is capable of being retrofit to an existing drilling rig. In particular, the invention relates to a horizontal to vertical pipe delivery machine that is mountable to a drilling rig. The horizontal to vertical machine delivers sections of pipe to a pair of drilling rig mounted elevators. The elevators receive and vertically translate the sections of pipe. A power tong may be used to make connections between the sections of pipe to form a pipe stand, and may also break the connections of the pipe stand. A drill floor mounted pipe racking system receives the connected drill pipe from the elevators. A pipe racking system that may be used in conjunction with the stand building system is capable of controlled, rapid, and precise movement of multiple connected sections of pipe.
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RELATED APPLICATION DATA
This application is a divisional application of U.S. application Ser. No. 11/265,797, filed Nov. 2, 2005, which claims priority under 35 U.S.C. §119 and/or §365 to Swedish Application No. 0402693-6, filed Nov. 5, 2004, the entire contents of each of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a coated cutting tool insert designed to be used in metal machining. The substrate is a cemented carbide, cermet, ceramics or cBN on which a hard and wear resistant coating is deposited. The coating exhibits an excellent adhesion to the substrate covering all functional parts thereof. The said coating is composed of one or more refractory layers of which at least one layer is a strongly textured alpha-alumina (α-Al 2 O 3 ) deposited in the temperature range of from about 750 to about 1000° C.
A crucial step in the deposition of different Al 2 O 3 polymorphs is the nucleation step. κ-Al 2 O 3 can be grown in a controlled way on {111} surfaces of TiN, Ti(C,N) or TiC having the fcc structure. TEM has confirmed the growth mode which is that of the close-packed (001) planes of κ-Al 2 O 3 on the close-packed {111} planes of the cubic phase with the following epitaxial orientation relationships: (001) κ //(111) TiX ; [100] κ //[112] TiX . An explanation and a model for the CVD growth of metastable κ-Al 2 O 3 have proposed earlier (Y. Yoursdshahyan, C. Ruberto, M. Halvarsson, V. Langer, S. Ruppi, U. Rolander and B. I. Lundqvist, Theoretical Structure Determination of a Complex Material: κ-Al 2 O 3 , J. Am. Ceram. Soc. 82(6)(1999)1365-1380).
When properly nucleated, κ-Al 2 O 3 layers can be grown to a considerable thickness (greater than about 10 μm). The growth of even thicker layers of κ-Al 2 O 3 can be ensured through re-nucleation on thin layers of, for example TiN, inserted in the growing κ-Al 2 O 3 layer. When nucleation is ensured, the κ→α transformation can be avoided during deposition by using a relatively low deposition temperature (less than about 1000° C.). During metal cutting, the κ→α a phase transformation has confirmed to occur resulting in flaking of the coating. In addition, there are several other reasons why α-Al 2 O 3 should be preferred in many metal cutting applications. As shown earlier α-Al 2 O 3 exhibits better wear properties in cast iron (U.S. Pat. No. 5,137,774).
However, the stable α-Al 2 O 3 phase has been found to be more difficult to be nucleated and grown at reasonable CVD temperatures than the metastable κ-Al 2 O 3 . It has been experimentally confirmed that α-Al 2 O 3 can be nucleated, for example, on Ti 2 O 3 surfaces, bonding layers of (Ti,Al)(C,O) or by controlling the oxidation potential using CO/CO 2 mixtures as shown in U.S. Pat. No. 5,654,035. The bottom line in all these approaches is that nucleation must not take place on the 111-surfaces of TiC, TiN, Ti(C,N) or Ti(C,O,N), otherwise κ-Al 2 O 3 is obtained.
It should also be noted that in the prior-art methods higher deposition temperatures (about 1000° C.) are usually used to deposit α-Al 2 O 3 . When the nucleation control is not complete, as is the case in many prior-art products, the produced α-Al 2 O 3 layers have, at least partly, been formed as a result of the κ-Al 2 O 3 →α-Al 2 O 3 phase transformation. This is especially the case when thick Al 2 O 3 layers are considered. These kinds of α-Al 2 O 3 layers are composed of larger grains with transformation cracks. These layers exhibit much lower mechanical strength and ductility than the α-Al 2 O 3 layers that are composed of nucleated α-Al 2 O 3 . Consequently, there is a need to develop techniques to control the nucleation step of α-Al 2 O 3 .
The control of the α-Al 2 O 3 polymorph in industrial scale was achieved in the beginning of the 1990's with commercial products based on U.S. Pat. No. 5,137,774. Later modifications of this patent have been used to deposit α-Al 2 O 3 with preferred coating textures. In U.S. Pat. No. 5,654,035, an alumina layer textured in the (012) direction and in U.S. Pat. No. 5,980,988 in the (110) direction are disclosed. In U.S. Pat. No. 5,863,640, a preferred growth either along (012), or (104) or (110) is disclosed. U.S. Pat. No. 6,333,103 describes a modified method to control the nucleation and growth of α-Al 2 O 3 along the (10(10)) direction. US20020155325A1 describes a method to obtain a strong (300) texture in α-Al 2 O 3 using a texture modifying agent (ZrCl 4 ) The processes discussed above use all high deposition temperatures of about 1000° C.
US 2004/0028951A1 describes a new state-of-the-art technique to achieve a pronounced (012) texture. The commercial success of this kind of product demonstrates the importance to refine the CVD process of α-Al 2 O 3 towards fully controlled textures.
It is well established that the water gas shift reaction, in the absence of H 2 S or other dopants, is the critical rate-limiting step for Al 2 O 3 formation, and to a great extent, controls the minimum temperature at which Al 2 O 3 can be deposited. Further it is well established that the water-gas shift reaction is very sensitive for deposition pressure.
Extensive work has been done to deposit CVD Al 2 O 3 at lower temperatures. Several Al 2 O 3 layers using other than AlCl 3 —CO 2 —H 2 system have been investigated, including AlCl 3 —CO—CO 2 , AlCl 3 -C 2 H 5 OH, AlCl 3 —N 2 O—H 2 , AlCl 3 —NH 3 —CO 2 , AlCl 3 —O 2 —H 2 O, AlCl 3 —O 2 —Ar, AlX 3 —CO 2 (where X is Cl, Br, I), AlX 3 —CO 2 —H 2 (where X is Cl, Br, I), AlBr 3 —NO—H 2 —N 2 and AlBr 3 —NO—H 2 —N 2 . It is emphasised that these studies have been carried out without dopants (such as H 2 S) and the effect of the deposition pressure has not been elucidated.
It is worth noting that none of these systems have been commercially successful. Consequently, to provide a CVD process for depositing Al 2 O 3 layers at temperatures below those currently used on a commercial scale is therefore highly desirable.
U.S. Pat. No. 6,572,991 describes a method to deposit γ-Al 2 O 3 at low deposition temperatures. This work clearly shows that it is possible to obtain Al 2 O 3 layers in the medium temperature range from the AlCl 3 —CO 2 —H 2 system. However, in this work it was not realised that nucleation surface controls the phase composition of Al 2 O 3 and that deposition of α-Al 2 O 3 is thus possible at lower deposition temperatures. In the prior-art, it was considered impossible to deposit α-Al 2 O 3 at low temperatures and it was believed that γ-Al 2 O 3 and κ-Al 2 O 3 were the unavoidable low temperature phases.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention is to provide a new, improved alumina layer where the α-Al 2 O 3 phase is of nucleated α-Al 2 O 3 with a strong, fully controlled (104) growth texture. According to the present invention, α-Al 2 O 3 with the controlled (104) texture can be obtained within a wide temperature range from about 750 to about 1000° C., which can be considered surprising.
In one aspect of the invention, there is provided a cutting tool insert of a substrate at least partially coated with a coating with a total thickness of from about 10 to about 40 μm, of one or more refractory layers of which at least one layer is an alumina layer, said alumina layer being composed of columnar α-Al 2 O 3 grains with texture coefficients
a) TC(104) greater than about 2.0; b) TC(012), TC(110), TC(113), TC(024) all less than about 1.0.; c) TC(116) less than about 1.2;
The texture coefficient TC(hkl) is defined as
TC
(
hkl
)
=
I
(
hkl
)
I
O
(
hkl
)
{
1
n
∑
I
(
hkl
)
I
O
(
hkl
)
}
-
1
where
I(hkl)=measured intensity of the (hkl) reflection I o (hkl)=standard intensity according to JCPDS card no 46-1212 n=number of reflections used in the calculation (hkl) reflections used are: (012), (104), (110), (113), (024), (116).
In another aspect of the invention, there is provided a method of coating a substrate with an Al 2 O 3 layer wherein the α-Al 2 O 3 layer is composed of columnar α-Al 2 O 3 grains with a texture coefficient TC (104) greater than about 2 comprising depositing a (Ti,Al)(C,O,N) bonding layer on said substrate to provide a nucleation surface for said Al 2 O 3 , subjecting said nucleation surface to a modification treatment of a pulse treatment with a mixture of TiCl 4 , AlCl 3 and H 2 , a purge with a neutral gas and an oxidizing pulse of a gas mixture including N 2 and CO 2 in a ratio of from about 450 to about 650, repeating the modification treatment and depositing α-Al 2 O 3 having a texture coefficient TC(104) greater than about 2 at a temperature of from about 750 to about 1000° C.
The alumina layer with strong texture outperforms the prior art with random or other less developed and incompletely controlled textures. Further, increased toughness can be obtained when deposition is carried out at lower temperatures. Compared with prior-art products the α-Al 2 O 3 layer according the present invention is essentially free from transformation stresses, consisting of columnar, defect free, α-Al 2 O 3 grains with low dislocation density and with improved cutting properties. The texture-controlled α-Al 2 O 3 layers deposited at medium temperature (about 800° C.) show enhanced toughness.
DESCRIPTION OF THE DRAWINGS AND FIGURES
FIG. 1 shows a cross-section SEM image (magnification 5000×) of a typical alumina layer according to the present invention deposited on a MTCVD-Ti(C,N) layer. The alumina layer is composed of columnar grains. It is dense with no detectable porosity.
FIG. 2 shows a cross-section SEM image of a typical layer according the prior-art (magnification 6000×) deposited on a MTCVD-Ti(C,N) layer. The alumina layer is composed of large nearly equiaxed grains. Porosity is visible in the alumina layer. Interfacial porosity between the alumina layer and the Ti(C,N) layer is also visible.
DETAILED DESCRIPTION OF THE INVENTION
A method to deposit α-Al 2 O 3 with a strong (104) texture in a temperature range of from about 750 to about 1000° C. is described. The invention utilizes short pulses of precursors followed by purging steps with an inert gas such as Ar. After the purge another precursor is applied as a short pulse. In addition to the texture control, the method can be used to produce finer grain sizes by increasing the number of nucleation sites.
Al 2 O 3 layers according to the present invention outperform the prior-art and are especially suitable be used in toughness demanding stainless steel application such as interrupted cutting, turning with coolant and especially intermittent turning with coolant. The other area is cast iron where the edge strength of this kind of alumina layer is superior to the prior art.
Ti(C,N) is used as an intermediate layer, which can be obtained either by conventional CVD or MTCVD, preferably by MTCVD. The present invention makes it possible to deposit α-Al 2 O 3 at same temperature as is used to deposit the intermediate MTCVD Ti(C,N) layer. Consequently, the heating-up period can be omitted after MTCVD.
To nucleate α-Al 2 O 3 with the specified texture, several steps are needed. First, on the Ti(C,N) layer a bonding layer characterised by the presence of an Al concentration gradient is deposited. Nitrogen and CH 3 CN are applied during deposition of this bonding layer. The aluminium content on the surface of this layer is considerably, about 30%, higher than in the bonding layer according to U.S. Pat. No. 5,137,774 (prior-art) and the bonding layer is obviously containing nitrogen. The surface of this bonding layer is subjected to an additional treatment(s).
Nucleation is started with a AlCl 3 /TiCl 4 /H 2 pulse with a duration of 5 minutes. After that an Ar purge (duration about 5 minutes) is applied in order to remove excess Cl − from the surface. After this, an oxidizing pulse is applied using a CO 2 /H 2 /N 2 /Ar (Co 2 =about 0.15%, H 2 =about 10%, N 2 about 25%, Ar=balance) gas mixture at a pressure of from about 50 to about 500 mbar, to a temperature of from about 750° to about 1000° C., depending on the temperature of the subsequent alumina deposition. In addition to a relatively low oxidation potential of the gas mixture, the oxidizing step has to relatively short, from about 0.5 to about 5 minutes to secure (104) nucleation. These steps should be repeated several times, preferably from about 2 to about 5 times in sequence to increase the amount of α-Al 2 O 3 nuclei. It is noted that if pulsating nucleation is used, one has to find an optimized combination between the duration of the individual steps and the amount of the steps, otherwise too low or excessive oxidization may be obtained. A person skilled in the art can find the correct procedure by trial and error.
The key to obtain the specified growth texture is the control of the oxidation potential of the CO 2 /H 2 /N 2 /Ar mixture by adjustment of the N 2 :CO 2 ratio. This ratio should be from about 450 to about 650, preferably from about 450 to about 550. The use of controlled oxygen potential in combination with the correct time and number of pulses enables the correct nucleation mode. Typical pulse times may range from about 10 seconds to about 5 minutes depending on the duration of the pulse. The oxidising pulse is again followed by an Ar purge. These steps should be repeated several times, preferably from about 2 to about 5 times, in sequence to increase the amount of α-Al 2 O 3 nuclei. Excessive oxidisation must be avoided. A person skilled in the art can find the best and optimised combination between the duration and the amount of the steps.
Detailed Description of the Nucleation Steps
1. Depositing a bonding layer from about 0.1 to about 1 μm thick in a gas mixture of from about 2 to about 3% TiCl 4 , AlCl 3 increasing from about 0.5 to about 5%, from about 3 to about 7% CO, from about 1 to about 3% CO 2 , from about 2 to about 10% N 2 and balance H 2 at from about 750 to about 1000° C., preferably at about 800° C. and at a pressure of from about 50 to about 200 mbar. 2. Purging by Ar for about 5 min. 3. Treating the bonding layer in a gas mixture of from about 1 to about 2% TiCl 4 and from about 2 to about 4% AlCl 3 in hydrogen for about 2 to about 60 min at from about 750 to about 1000° C., preferably at about 800° C. and at a pressure of from about 50 to about 200 mbar. 4. Purging by Ar for 5 about min. 5. Treating in a gas mixture of from about 0.1 to about 0.15% CO 2 (preferably about 0.15%), from about 10 to about 30% N 2 (preferably from about 22.5 to about 30% when the CO 2 content is about 15%), about 10% H 2 , balance Ar at a pressure of from about 50 to about 200 mbar for about 0.5 to about 5 minutes at a temperature of from about 750 to about 1000° C., depending on the temperature for the subsequent deposition of the alumina layer. 6. Purging by Ar for about 5 min. 7. Repeating steps 3-6 to obtain the an optimum oxidation level. 8. Depositing an alumina layer at a temperature of from about 950 to about 1000° C. and a pressure of from about 50 to about 200 mbar with desired thickness according to known technique or depositing an alumina layer at from 5 about 750 to about 950 using higher deposition pressures (from about 200 to about 500 mbar) together with higher amounts (from about 0.5 to about 1.5%) of catalysing precursors such as H 2 S or SO x , preferably H 2 S. The growth of the alumina layer onto the nucleation layer is started by sequencing the reactant gases in the following order: CO, AlCl 3 , CO 2 . The process temperatures of from about 750 to about 1000° C. can be used since the texture is determined by the nucleation surface.
The present invention also relates to a cutting tool insert of a substrate at least partially coated with a coating with a total thickness of from about 15 to about 40 μm, preferably from about 20 to about 25 μm, of one or more refractory layers of which at least one layer is an alpha alumina layer. The α-Al 2 O 3 layer deposited according to the present invention is dense and exhibits a very low defect density. It is composed of columnar grains with a strong (104) texture. The columnar grains have a length/width ratio of from about 2 to about 12, preferably from about 4 to about 8.
The texture coefficients (TC) for the α-Al 2 O 3 according to the present invention layer is determined as follows:
TC
(
hkl
)
=
I
(
hkl
)
I
O
(
hkl
)
{
1
n
∑
I
(
hkl
)
I
O
(
hkl
)
}
-
1
where
I(hkl)=intensity of the (hkl) reflection
I o (hkl)=standard intensity according to JCPDS card no 46-1212
n=number of reflections used in the calculation (hkl) reflections used are: (012), (104), (110), (113), (024), (116). The texture of the alumina layer is defined as follows: TC(104) greater than about 2.0, preferably greater than about 3. Simultaneously TC(012), TC(110), TC(113), TC(024) should be all less than about 1.0, preferably less than about 0.5. Note that the related (012) and (024) reflections are also low. However, for this growth mode TC(116) is somewhat higher than the other background reflections. TC(116) should be less than about 1.2, preferably less than about 1.
The substrate comprises a hard material such as cemented carbide, cermets, ceramics, high speed steel or a super hard material such as cubic boron nitride (CBN) or diamond, preferably cemented carbide or CBN. With CBN is herein meant a cutting tool material containing at least about 40 vol-% CBN. In a preferred embodiment, the substrate is a cemented carbide with a binder phase enriched surface zone.
The coating comprises a first layer adjacent the body of CVD Ti(C,N), CVD TiN, CVD TiC, MTCVD Ti(C,N), MTCVD Zr(C,N), MTCVD Ti(B,C,N), CVD HfN or combinations thereof preferably of Ti(C,N) having a thickness of from about 1 to about 20 μm, preferably from about 1 to about 10 μm, and said α-Al 2 O 3 layer adjacent said first layer having a thickness of from about 1 to 40 μm, preferably from about 1 to about 20 μm, most preferably from about 1 to about 10 μm. Preferably, there is an intermediate layer of TiN between the substrate and said first layer with a thickness of less than about 3 μm, preferably from about 0.5 to about 2 μm.
In one embodiment, the α-Al 2 O 3 layer is the uppermost layer.
In another embodiment, there is a layer of carbide, nitride, carbonitride or carboxynitride of one or more of Ti, Zr and Hf, having a thickness of from about 0.5 to about 3 μm, preferably from about 0.5 to about 1.5 μm, atop the α-Al 2 O 3 layer. Alternatively this layer has a thickness of from about 1 to about 20 μm, preferably from about 2 to about 8 μm.
In yet another embodiment, the coating includes a layer of κ-Al 2 O 3 and/or γ-Al 2 O 3 preferably atop the α-Al 2 O 3 . with a thickness of from 0.5 to 10, preferably from 1 to 5 μm.
The invention is additionally illustrated in connection with the following examples, which are to be considered as illustrative of the present invention. It should be understood, however, that the invention is not limited to the specific details of the examples.
EXAMPLE 1
Cemented carbide cutting inserts with a composition of 5.9% Co and balance WC (hardness about 1600 HV) were coated with a layer of MTCVD Ti(C,N). The thickness of the MTCVD layer was about 2 μm. On to this layer two different layers consisting of about 10 μm α-Al 2 O 3 were deposited:
Layer a) contained a (104) textured layer and was deposited according to the present invention at 1000° C. The detailed process data is given in Table 1.
Layer b) was deposited according to the prior art.
Layer c) contained a (104) textured layer and was deposited according to the present invention at 800° C. The detailed process data is given in Table 2.
TABLE 1
Deposition process for a Layer a) with (104) texture at
1000° C.:
Step 1: Bonding layer
Gas mixture
TiCl 4 = 2.8%
AlCl 3 = 0.8-4.2%
CO = 5.8%
CO 2 = 2.2%
N 2 = 5-6%
Balance: H 2
Duration
60 min
Temperature
1000° C.
Pressure
100 mbar
Step 2: Purge
Gas
Ar = 100%
Duration
5 min
Temperature
1000 C.
Pressure
50 mbar
Step 3: Pulse 1
Gas mixture
TiCl 4 = 1.6%
AlCl 3 = 2.8
H 2 = Balance
Duration
2-5 min depending on the
amount of pulses.
Temperature
1000 C.
Pressure
50 mbar
Step 4: Purge
Gas
Ar = 100%
Duration
5 min
Temperature
1000 C.
Pressure
50 mbar
Step 5: Pulse 2
Gas mixture
CO 2 = 0.05%
N 2 = 25%
Balance: H 2
Duration
0.5-1 min depending on the
amount of pulses.
Temperature
1000° C.
Pressure
100 mbar
Step 6: Purge
Gas
Ar = 100%
Duration
5 min
Temperature
1000 C.
Pressure
50 mbar
Step 7: Nucleation step
Gas mixture
AlCl 3 = 3.2%
HCl = 2.0%
CO 2 = 1.9%
Balance H 2
Duration
60 min
Temperature
1000° C.
Pressure
210 mbar
Step 8: Deposition
Gas mixture
AlCl 3 = 4.2%
HCl = 1.0%
CO 2 = 2.1%
H 2 S = 0.2%
Balance: H 2
Duration
520 min
Temperature
1000° C.
Pressure
50 mbar
It should be noted that the steps 3-7 can be repeated 5-10 times in sequence in order to obtain grain refinement and the strong desired texture. The amount of pulses can be even higher if the duration of step 6 is reduced. In this example the steps 3-7 were repeated 3 times with durations of 0.6 minutes.
TABLE 2 Deposition process for a Layer c) with (104) texture at 780° C.: Step 1: Bonding layer Gas mixture TiCl 4 = 2.8% CH 3 CN = 0.7% AlCl 3 = increasing from 0.8 to 4.2% CO = 5.8% CO 2 = 2.2% N 2 = 5% Balance: H 2 Duration 40 min Temperature 780° C. Pressure 100 mbar Step 2: Purge Gas Ar = 100% Duration 5 min Temperature 780° C. Pressure 50 mbar Step 3: Pulse 1 Gas mixture TiCl 4 = 1.6% AlCl 3 = 2.8 H 2 = Balance Duration 5 min. Temperature 780° C. Pressure 50 mbar Step 4: Purge Gas Ar = 100% Duration 5 min Temperature 780° C. Pressure 50 mbar Step 5: Pulse 2 Gas mixture CO 2 = 0.05% N 2 = 25% H 2 = 10% Balance: Ar Duration 2 min Temperature 780° C. Pressure 100 mbar Step 6: Purge Gas Ar = 100% Duration 5 min Temperature 780° C. Pressure 50 mbar Step 7: Nucleation step Gas mixture AlCl 3 = 3.2% HCl = 2.0% CO 2 = 1.9% Balance H 2 Duration 60 min Temperature 780° C. Pressure 50 mbar Step 8: Deposition Gas mixture AlCl 3 = 4.1% HCl = 1.0% CO 2 = 2.3% H 2 S = 0.9% Balance: H 2 Duration 600 min Temperature 780° C. Pressure 350 mbar
Steps 3-6 were repeated three times.
EXAMPLE 2
Layers a, b and c were studied using X-ray diffraction. The texture coefficients were determined are presented in Table 3. As clear from Table 3 the layer according to the present invention exhibits a strong (104) texture when deposited either at 1000° C. or 780° C. Typically, for this growth mode the (116) reflection is somewhat more profound than the other background reflections.
TABLE 3
Hkl
Invention, layer a
Prior art, layer b,
Invention, layer c
012
0.24
0.97
0.49
104
4.30
1.14
3.13
110
0.06
0.95
0.49
113
0.19
0.99
0.41
024
0.27
0.86
0.49
116
0.94
1.09
0.99
EXAMPLE 3
Layers a) and b) were studied using Scanning Electron Microscopy. The cross section images of the layers are shown in FIGS. 1 and 2 , respectively. The differences in microstructure and morphology are clear.
EXAMPLE 4
The layers a) and b) from the Example 1 were tested with respect to edge chipping in longitudinal turning of cast iron.
Work piece:
Cylindrical bar
Material:
SS0130
Insert type:
SNUN
Cutting speed:
400 m/min
Feed:
0.4 mm/rev
Depth of cut:
2.5 mm
Remarks:
dry turning
The inserts were inspected after 2 and 4 minutes of cutting, As clear from Table 4 the edge toughness of the prior art product was considerably enhanced when the layer was produced according to the present invention.
TABLE 4
Flaking of the edge
Flaking of the edge
line (%) after 2 minutes
line (%) After 6 minutes
Layer a (Invention)
0
6
Layer b
12
22
EXAMPLE 5
The layer produced according to the present invention was compared with a market leader, referred here as Competitor X. This coating is composed of MTCVD Ti(C,N) and α-Al 2 O 3 . XRD was used to determine the texture coefficients for these competitor coatings. Two inserts from Competitor X were randomly chosen for XRD. Table 5 shows the obtained TCs for the Competitor X. The coatings from Competitor X exhibit a random texture and can be compared with the present invention, Table 1.
TABLE 5 Hkl TC(hkl) 012 0.71 0.57 104 0.92 0.86 110 1.69 1.92 113 0.48 0.40 024 1.16 1.14 116 1.04 1.11
The X-rayed inserts from the competitor X were compared with inserts produced according to the present invention, Layer a).
Two inserts produced according to the present invention were compared with the two Competitor X inserts with respect to flank wear resistance in face turning of ball bearing material:
Work piece:
Cylindrical tubes (Ball bearings)
Material:
SS2258
Insert type:
WNMG080416
Cutting speed:
500 m/min
Feed:
0.5 mm/rev
Depth of cut:
1.0 mm
Remarks:
Dry turning
Tool life criterion:
Flank wear >0.3 mm, three edges of each
variant were tested.
Results:
Tool life (min)
Layer a
25.0 (invention)
Layer a
23.5 (invention)
Competitor 1
14.5 (prior art)
Competitor 2
15.5 (prior art)
EXAMPLE 6
Layer a), b) and c) deposited on Co-enriched substrates were tested with respect to toughness in longitudinal turning with interrupted cuts.
Work piece:
Cylindrical slotted bar
Material:
SS1672
Insert type:
CNMG120408-M3
Cutting speed:
140 m/min
Feed:
0.1, 0.125, 0.16, 0.20, 0.25, 0.315, 0.4,
0.5, 0.63, 0.8 mm/rev gradually increased after 10 mm
length of cut
Depth of cut:
2.5 mm
Remarks:
dry turning
Tool life criteria:
Gradually increased feed until edge
breakage. 10 edges of each variant were tested.
TABLE 6
Mean feed at breakage (mm/rev)
Layer a (invention)
0.24
Layer b (prior art)
0.12
Layer c (invention)
0.32
The test results show (Table 6) that layers according to the present invention exhibited clearly better toughness behaviour than the prior-art (layer b).
EXAMPLE 7
Cubic boron nitride (CBN) insert containing about 90% of polycrystalline CBN (PCBN) were coated according to the present invention and according to prior art layer discussed in Example 1. The coated CBN was compared with uncoated CBN insert in cutting of steel containing ferrite. It is known that B has a high affinity to ferrite and diffusion wear occurs at high cutting speeds. As shown in Table 7 the layer according to the present invention is superior to the prior art.
Work piece:
Cylindrical bar
Material:
SS0130
Insert type:
SNUN
Cutting speed:
750 m/min
Feed:
0.4 mm/rev
Depth of cut:
2.5 mm
Remarks:
dry turning
TABLE 7
Life time (min)
Coated CBN (Invention)
26
Coated according to prior art
11
Uncoated CBN
9
Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.
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A new and refined method to produce α-Al 2 O 3 layers in a temperature range of from about 750 to about 1000° C. with a controlled growth texture and substantially enhanced wear resistance and toughness than the prior art is disclosed. The α-Al 2 O 3 layer of the present invention is formed on a bonding layer of (Ti,Al)(C,O,N) with increasing aluminium content towards the outer surface. Nucleation of α-Al 2 O 3 is obtained through a nucleation step being composed of short pulses and purges consisting of Ti/Al-containing pulses and oxidising pulses. The α-Al 2 O 3 layer according to the present invention has a thickness ranging from about 1 to about 20 μm and is composed of columnar grains. The length/width ratio of the alumina grains is from about 2 to about 12, preferably from about 4 to about 8. The layer is characterized by a strong (104) growth texture, measured using XRD, and by low intensity of (012), (110), (113), (024) and (116) diffraction peaks.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Patent Provisional Application No. 61/718,288, filed Oct. 25, 2012, the entire contents of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to coated medical devices, in particular, to covered stents and to methods of using a tacky polymeric material in a patient's body lumen to prevent stent migration from a treatment site.
[0003] Stents, grafts, stent-grafts, vena cava filters and similar implantable medical devices, collectively referred to hereinafter as stents, are radially expandable or self-expanding endoprostheses which are intravascular or endoscopic implants capable of being implanted transluminally either percutaneously or endoscopically. Stents may be implanted in a variety of body lumens or vessels such as within the vascular system, urinary tracts, bile ducts, gastro-intestinal tract, airways, etc. Stents may be used to reinforce body vessels and to prevent restenosis following angioplasty in the vascular system. They may be self-expanding, mechanically expandable or hybrid expandable. In general, self-expanding stents are mounted on a delivery device consisting of two tubes. The stent is delivered by sliding the outer tube to release the stent.
[0004] Stents are typically tubular members that are radially expandable from a reduced diameter configuration for delivery through a patient's body lumen to an expanded configuration once deployed at the treatment site.
[0005] Stents may be constructed from a variety of materials such as stainless steel, Elgiloy, nickel, titanium, nitinol, polymers, shape memory polymers, etc.
[0006] Typically, the stent is formed from a tubular member in which a pattern is subsequently formed by etching or cutting material from the tubular member or it is made from wires using techniques such as braiding, knitting or weaving
[0007] Desirable stent properties thus include sufficient flexibility to be able to conform to the tortuous body lumen during delivery, yet sufficiently rigid to resist migration once deployed at the treatment site.
[0008] In some stents, the compressible and flexible properties that assist in stent delivery may also result in a stent that has a tendency to migrate from its originally deployed position. Stent migration affects many endoscopic stents including esophageal, duodenal, colonic, pancreatic, biliary and airway stents. It is thus desirable to provide a stent configuration that resists migration following deployment.
[0009] Commonly assigned US Patent Publication No. 20090098176, the entire content of which is incorporated by reference herein, discloses medical devices with triggerable bioadhesives.
[0010] Moreover, fully covered stents prevent tissue ingrowth and are easier to remove than bare or partially covered stents. However, these stents are even more prone to migration.
[0011] It is thus desirable to provide a stent configuration that resists migration following deployment.
[0012] Many techniques have been developed to prevent stent migration including adding barbs and flares to the stent itself or using clips or sutures to attach the stent to the vessel wall.
[0013] There remains a need in the art for an improved stent that is resistant to migration.
SUMMARY OF THE INVENTION
[0014] In one embodiment, the present invention relates to a stent, the stent having an inner surface and an outer surface, at least a portion of the outer surface of the stent including a tacky biocompatible coating comprising a tacky silicone.
[0015] In another embodiment, the present invention relates to a stent, the stent having an inner surface and an outer surface, at least a portion of the outer surface of the stent including a tacky biocompatible coating comprising a tacky polymer material having a peel adhesion of about 20 to about 50 grams per inch, the tacky polymer having a tackiness that is not compromised by the presence of moisture.
[0016] In another embodiment, the present invention relates to a method of delivering a stent to a body lumen, the method including depositing a tacky biocompatible polymer material at a treatment site in a body lumen, delivering the stent to the treatment site and deploying the stent at the treatment site, wherein the tacky biocompatible polymer material hinders migration of the stent from the treatment site.
[0017] These and other aspects, embodiments and advantages of the present disclosure will become immediately apparent to those of ordinary skill in the art upon review of the Detailed Description and Claims to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a side view of an embodiment of a stent according to the invention.
[0019] FIG. 2 is a cross-sectional view taken at 2 in FIG. 1 illustrating the tacky polymeric coating on the stent according to the invention.
[0020] FIG. 3 is a cross-sectional view of an alternative embodiment of a stent similar to that shown in FIG. 1 having the tacky polymeric coating and a hydrophilic coating or biodegradable coating disposed on the tacky polymeric coating.
[0021] FIG. 4 is a cross-sectional view of a covered stent according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] While embodiments of the present invention may take many forms, there are described in detail herein, specific embodiments of the present disclosure. This description is an exemplification of the principles of the present disclosure and is not intended to limit the disclosure to the particular embodiments illustrated herein.
[0023] The present invention is directed to implantable medical devices such as stents having a tacky coating thereon to prevent stent migration and to methods of using a tacky polymeric material in a patient's body lumen to prevent stent migration from a treatment site.
[0024] The term “tacky” is a well know term in the adhesives art. As used herein, the term “tacky” shall refer to a material that retains a sticky or slightly sticky feel to the touch. These materials can also be referred to as pressure sensitive polymer materials. The tacky materials employed herein can have peel strengths from about 20 grams/inch to about 1000 grams/inch as measured per ASTM D3330 Standard Test Method for Peel Adhesion of Pressure-Sensitive Tape, suitably about 20 grams/inch to about 500 grams/inch, and more suitably about 20 grams/inch to about 100 grams/inch. In some embodiments, the tacky materials employed herein have a low peel strength of about 20 grams/inch to about 50 grams/inch.
[0025] The tacky polymeric materials employed herein are selected to as to provide gentle adhesion to human tissue. However, the adhesion is not permanent and the materials can be readily removed when desired.
[0026] It is also desirable that the tackiness or adhesion of the tacky polymeric material is not compromised upon exposure to moisture such as would be the case upon insertion in a patient's body.
[0027] Turning now to the drawings, FIG. 1 is a side view of one embodiment of a stent on which the coatings according to the invention be employed. In this embodiment, stent 10 is a self-expanding stent formed of a shape memory metal such as nitinol having a silicone covering. The stent has a braided wire construction. In this embodiment, stent 10 is shown having a silicone covering 12 . Stent 10 is disposed on silicone covering 12 and is partially embedded therein. FIG. 2 is a partial cross-sectional view of the stent taken at section 2 in FIG. 1 . Stents of this type are described in commonly assigned US Patent Publication Nos. 2006/0276887 and 2008/0009934, each of which is incorporated by reference herein in its entirety.
[0028] While in the embodiment shown in FIGS. 1 and 2 , the stent is formed from nitinol, stents may be constructed of any suitable stent material including, but not limited to stainless steel, Elgiloy, nickel, titanium, nitinol, shape memory polymers, other polymeric materials, etc.
[0029] Any stent can have a covering and the coverings are thus not limited to nitinol stents. Moreover, the stent need not be covered whatsoever, may be partially covered or may be fully covered.
[0030] Other suitable covering materials can be employed as well. Examples of other suitable covering materials include, but are not limited to, polyethylene, polypropylene, polyvinyl chloride, polytetrafluoroethylene, including expanded polytetrafluoroethylene (ePTFE), fluorinated ethylene propylene, fluorinated ethylene propylene, polyvinyl acetate, polystyrene, poly(ethylene terephthalate), naphthalene, dicarboxylate derivatives, such as polyethylene naphthalate, polybutylene naphthalate, polytrimethylene naphthalate and trimethylenediol naphthalate, polyurethane, polyurea, polyamides, polyimides, polycarbonates, polyaldehydes, polyether ether ketone, natural rubbers, polyester copolymers, styrene-butadiene copolymers, polyethers, such as fully or partially halogenated polyethers, and copolymers and combinations thereof. See, for example, commonly assigned U.S. Pat. No. 8,114,147, the entire content of which is incorporated by reference herein.
[0031] Stent 10 further has a tacky coating as shown in cross-section in FIG. 3 . In this embodiment, tacky coating 14 comprises a tacky silicone.
[0032] Tacky or pressure sensitive silicone materials are commercially available from a variety of sources such as MED 6300 series of heat cured silicone materials and MED 6381 moisture cured silicone available from Nusil located in Santa Barbara, Calif.
[0033] In some embodiments, the tacky silicone is a moisture cured silicone.
[0034] In some embodiments, the tacky silicone gel is a polydimethylsiloxane.
[0035] While tacky silicone is one desirable tacky polymeric material that may be employed herein, other tacky polymeric materials may be used as well including, but not limited to, styrenic block copolymers such as styrene-isobutylene-styrene (SIBS), styrene-ethylene/butylene-styrene (SEBS), styrene-ethylene/propylene-styrene (SEPS) and styrene-isoprene-styrene (SIS), acrylics, polyvinyl ether, polyurethanes, copolymers of ethylene such as ethylene vinyl acetate (EVA), etc.
[0036] The silicone gels have a similar feel to that of a hydrogel. However, the tackiness or adhesion of a hydrogel is compromised in the presence of moisture. Hydrogels are known to become “slippery” when wet, making them ideally suited for delivery of medical devices in a patient's body lumen where lubricity is desirable.
[0037] In some embodiments, a biocompatible dye is added to the tacky polymeric material to make it readily visible to a physician.
[0038] The tacky polymeric material may be applied to the entire outer surface of the stent, or to portions of the stent such as to the distal, proximal and central portions of the stent.
[0039] If the tacky polymeric material is applied to the stent, it may be desirable to dispose a hydrophilic or biodegradable coating over the tacky polymeric material to facilitate delivery through a patient's body lumen for a balloon expandable stent or to decrease the friction force between the outer tube of the delivery device and the stent for a self-expanding stent. FIG. 4 is a cross-sectional view of a stent 10 including a covering 12 , a tacky polymeric coating 14 and a hydrophilic or biodegradable coating 16 disposed on the tacky polymeric coating 14 . Once the stent is positioned and deployed at the treatment site, the biodegradable or hydrophilic coating will erode, exposing the underlying tacky polymeric coating which is now positioned between the patient's vessel wall and the stent in order to hinder stent migration.
[0040] Examples of suitable hydrogels include, but are not limited to, polyvinylpyrrolidone (PVP), poly(meth)acrylic acid and copolymers of (meth)acrylic acid, polyacrylate, chitosan, polyalkylene glycols such as polyethylene glycol (PEG) or polypropylene glycol, polyethylene glycol/dextran aldehyde, polyalkylene oxides such as polyethylene oxide and polypropylene oxide, polyvinyl esters such as polyvinyl acetate, polyhydroxyethyl methacrylate, polyvinyl alcohol, polyvinyl ether, and so forth. High molecular weight starches and carbohydrates may also be employed.
[0041] Hydrogel materials are disclosed in commonly assigned U.S. Pat. No. 5,693,034 to Buscemi et al., the entire content of which is incorporated by reference herein.
[0042] Any suitable biodegradable material can be employed herein that does not form an adhesive layer. These biodegradable materials break down and lose their integrity in vivo. Examples of suitable biodegradable polymers include, but are not limited to, poly(amides) such as poly(amino acids) and poly(peptides), poly(esters) such as polylactide including poly(DL-lactide) and polyglycolide, and copolymers thereof such as polylactide-co-glycolide including poly(DL-lactide-co-glycolide), poly(L-lactide-co-glycolide), poly(caprolactone) and polylactide-co-caprolactone including poly(DL-lactide-co-caprolactone and poly(L-lactide-co-caprolactone), poly(anhydrides), poly(orthoesters), poly(carbonates) including tyrosine derived polycarbonates, polyhydroxyvalerate, polyhydroxybutyrate, polyhydroxybutyrate-co-valerate, and chemical derivatives thereof (substitutions, additions of chemical groups, for example, alkyl, alkylene, hydroxylations, oxidations, and other modifications routinely made by those skilled in the art), copolymers and mixtures thereof.
[0043] Therapeutic agents may be incorporated in the tacky polymeric material, the hydrophilic or biodegradable coating layer, or both.
[0044] Various therapeutic agents may be employed herein depending on the condition which is being treated. As used herein, the terms, “therapeutic agent”, “drug”, “pharmaceutically active agent”, “pharmaceutically active material”, “beneficial agent”, “bioactive agent”, and other related terms may be used interchangeably herein and include genetic therapeutic agents, non-genetic therapeutic agents and cells. A drug may be used singly or in combination with other drugs. Drugs include genetic materials, non-genetic materials, and cells.
[0045] A therapeutic agent may be a drug or other pharmaceutical product such as non-genetic agents, genetic agents, cellular material, etc. Some examples of suitable non-genetic therapeutic agents include but are not limited to: antithrombogenic agents such as heparin, heparin derivatives, vascular cell growth promoters, growth factor inhibitors, etc. Where an agent includes a genetic therapeutic agent, such a genetic agent may include but is not limited to: DNA, RNA and their respective derivatives and/or components; hedgehog proteins, etc. Where a therapeutic agent includes cellular material, the cellular material may include but is not limited to: cells of human origin and/or non-human origin as well as their respective components and/or derivatives thereof.
[0046] Other active agents include, but are not limited to, antineoplastic, antiproliferative, antimitotic, antiinflammatory, antiplatelet, anticoagulant, antifibrin, antiproliferative, antibiotic, antioxidant, and antiallergic substances as well as combinations thereof.
[0047] Examples of antineoplastic/antiproliferative/antimitotic agents include, but are not limited to, paclitaxel (e.g., TAXOL® by Bristol-Myers Squibb Co., Stamford, Conn.), the olimus family of drugs including sirolimus (rapamycin), biolimus (derivative of sirolimus), everolimus (derivative of sirolimus), zotarolimus (derivative of sirolimus) and tacrolimus, methotrexate, azathiprine, vincristine, vinblastine, 5-fluorouracil, doxorubicin hydrochloride, mitomycin, cisplatin, vinblastine, vincristine, epothilones, endostatin, angiostatin and thymidine kinase inhibitors. While the preventative and treatment properties of the foregoing therapeutic substances or agents are well-known to those of ordinary skill in the art, the substances or agents are provided by way of example and are not meant to be limiting. Other therapeutic substances are equally applicable for use with the disclosed methods and compositions. See commonly assigned U.S. Patent Application Nos. 2010/0087783, 2010/0069838, 2008/0071358 and 2008/0071350, each of which is incorporated by reference herein. See also commonly assigned U.S. Patent Application Nos. 2004/0215169 and 2009/0098176, and U.S. Pat. No. 6,805,898, each of which is incorporated by reference herein.
[0048] Derivatives of many of the above mentioned compounds also exist which are employed as therapeutic agents and of course mixtures of therapeutic agents may also be employed.
[0049] For application, the therapeutic agent can be dissolved in a solvent or a cosolvent blend along with the bioadhesive or biodegradable polymer material.
[0050] Suitable solvents include, but are not limited to, dimethyl formamide (DMF), butyl acetate, ethyl acetate, tetrahydrofuran (THF), dichloromethane (DCM), acetone, acetonitrile, dimethyl sulfoxide (DMSO), butyl acetate, etc.
[0051] In other embodiments, the tacky polymeric material is delivered to the treatment site prior to delivery and deployment of the stent, for example via injection with a syringe, as in the esophagus, through or along the scope with a catheter, providing the viscosity is not too high for injection.
[0052] In some embodiments, the tacky polymeric material is a moisture cured polydimethylsiloxane which, once delivered to the treatment site, cures in the presence of moisture.
[0053] Once cured, the stent is then delivered and deployed at the treatment site. The tacky silicone material hinders stent migration. The stent can also be delivered before the tacky polymer is fully cured.
[0054] If the stent is a removable stent, the moisture cured polydimethylsiloxane can then be removed similar to removal of a dermal patch, such as with forceps.
[0055] If the viscosity of the tacky polymeric material is too high, it can be delivered as a patch and delivered with a scope. Suitably, the patch is about 1 cm in diameter, or delivery may involve the use of several smaller patches at more than one location to coincide with several locations along the stent, for example, distal, center and proximal locations of the stent.
[0056] If a patch is employed, it may be desirable to dispose a hydrophilic or biodegradable coating on the tacky polymeric material to facilitate delivery through a patient's body lumen.
[0057] If a hydrophilic coating is employed, water can be injected into the body lumen to facilitate dissolution/removal of the hydrophilic coating.
[0058] An alternative delivery technique is to employ a balloon to delivery the tacky polymeric material to the treatment site. Either patches or tubular members of the tacky polymeric material may be delivered in this manner. Multiple tubular members can also be delivered on a single balloon if desired.
[0059] For balloon delivery, it may also be desirable to dispose a hydrophilic polymer material on the tacky polymeric material to facilitate delivery through a patient's body lumen. The hydrophilic polymer may also be applied to the inner surface of the tacky polymeric material to prevent adhesion to the balloon. Dissolution/removal of the hydrophilic material can be facilitated by injecting water into the body lumen.
[0060] These techniques are most suitably employed with stents used in the gastrointestinal tract, but the techniques are not limited as such.
[0061] The description provided herein is not to be limited in scope by the specific embodiments described which are intended as single illustrations of individual aspects of certain embodiments. The methods, compositions and devices described herein can comprise any feature described herein either alone or in combination with any other feature(s) described herein. Indeed, various modifications, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description and accompanying drawings using no more than routine experimentation. Such modifications and equivalents are intended to fall within the scope of the appended claims.
[0062] All publications, patents and patent applications mentioned in this specification are herein incorporated by reference in their entirety into the specification to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. Citation or discussion of a reference herein shall not be construed as an admission that such is prior art.
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A stent having an inner surface and an outer surface, at least a portion of the outer surface of the stent comprising a tacky biocompatible coating comprising a tacky polymer material and to methods of delivering and deploying a stent using a tacky biocompatible coating comprising a tacky polymer material.
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FIELD OF THE INVENTION
The invention relates to large dimension emulsion polymer particles, compositions containing the large dimension emulsion polymer particles and processes of manufacture.
SUMMARY OF THE INVENTION
In one embodiment, the large dimension emulsion polymer particles are high aspect ratio polymers, ranging from particles of 3 to 4 microns in length and 0.3 micron diameter to particles of about 800 microns in length and up to 5-10 microns in diameter. The shapes of these particles range from egg-like to rods to extended strands.
In another embodiment, the large dimension emulsion polymer particles are spherical particles which range in diameter from 2 microns to 40 microns.
In the processes of the invention, large dimension emulsion polymer particles are produced. Both large spherical particles and high aspect ratio emulsion polymer particles can be produced according to the process of the invention. The process involves emulsion polymerization of monomers in an aqueous medium which contains a particle stabilizer system.
In one aspect the invention provides an emulsion polymerization process for preparing large dimension emulsion polymer particles comprising polymerizing at least one ethylenically unsaturated monomer in the presence of
i) stabilizer system containing from about 0.5 to 50 weight percent of primary amphiphilic polymeric stabilizer based on the total monomer reactants, and optional organic additive, in which the polymeric stabilizer is selected from the group consisting of hydrophobic-hydrophilic balanced alkaline soluble resin solubilized with organic or inorganic base and hydrophobic-hydrophilic balanced acid soluble resin solubilized by organic or inorganic acid, and;
ii) a free-radical polymerization initiator;
under conditions which favor the continued solubility of the primary amphiphilic polymeric stabilizer, and adding additional monomer in a controlled manner to cause the spherical particles to grow into stabilized large dimension emulsion particles and, optionally, continuing to add monomer to cause the large dimension emulsion particles to grow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a transmission optical micrograph (magnification 868x) of high aspect ratio polymer particles prepared according to Example 154.
FIG. 2 is a transmission optical micrograph (magnification 868x) of high aspect ratio polymer particles prepared according to Example 6.
FIG. 3 is a transmission optical micrograph (magnification 868x) of large spherical emulsion polymer particles prepared according to Example 186 (approx. 10 micron diameter).
DETAILED DESCRIPTION OF THE INVENTION
Stabilizer System
The process of the invention involves the emulsion polymerization or copolymerization of selected monomers in the presence of a stabilizer system. The stabilizer system contains a primary amphiphilic polymeric stabilizer from one of two classes: alkali-soluble resins and acid-soluble resins, respectively, that contain both hydrophobic and hydrophilic segments. An amphiphilic material is one that contains both hydrophobic and hydrophilic segments covalently bound to the same molecule. Examples of hydrophilic groups include --OH, amido, --O(CH 2 CH 2 --O--) m H [m=2 to 70], --COO--NH4+, --SO 3 --Na + , and --N(--CH 3 ) 3 +Cl--. Examples of hydrophobic groups include alkyl groups (of the general formula C n H 2n+1 --) having greater than about 6 carbons to about 20 carbon atoms, such as octyl, nonyl, decyl, undecyl, dodecyl, etc. as well as cyclic (i.e. cyclohexyl) and aromatic groups such as phenyl, tolyl, and arylalkyl groups such as nonylphenyl and t-octylphenyl.
The polymeric stabilizers used in this invention, whether prepared by means of bulk, suspension, solution or emulsion polymerization techniques are all characterized by a balance of hydrophobic and hydrophilic properties.
These polymeric stabilizers can be prepared by typical free radical addition polymerization processes. Bulk, solution, suspension and emulsion polymerization processes are described in "Polymerization Processes", edited by C. E. Schildknecht, John Wiley and Sons, 1977. Preferred are the resins prepared by emulsion and solution polymerization processes. Many conventional pigment dispersants such as Rohm and Haas Company's Tamol®731, a diisobutylene/maleic acid polymer and the styrene/maleic anhydride resins, such as SMA 1000 (MW-1600; acid number 480) available from ARCO Chemical Company, and the like, are examples of commercially available amphiphilic polymeric stabilizers.
The structure and performance properties of the primary polymeric stabilizers are important elements in producing the unique and unexpected particle shapes of this invention. Suitable polymeric stabilizers can be prepared from conventional ethylenically unsaturated and vinyl monomer mixtures that include a high proportion of acid- or amine-functional monomers and that produce, by emulsion or solution polymerization, a polymer product having a molecular weight greater than 1000. The polymeric stabilizer generally has a molecular weight less than 15,000 weight average molecular weight. The preferred molecular weight is from about 5,000 to about 10,000. Polymeric stabilizers of higher molecular weight generally are not preferred as they develop viscosity upon neutralization and may become too insoluble in water to be useful.
The polymeric stabilizer used in the process can generally be prepared from any known polymerizable monomers which are ordinarily used in emulsion and solution polymerization and include, for example, ethylenically unsaturated monomers, aromatic vinyl monomers, acrylic and methacrylic esters having an alkyl group of from 1 to 20 carbon atoms. The functionalities in the polymeric stabilizer can be incorporated through the use of functional monomers in the polymer preparation or through post-polymer functionalization reactions.
The acidic functional monomers of the polymeric stabilizer used in the process are known monomers and include acrylic acid, methacrylic acid, maleic acid, fumaric, crotonic and itaconic acid, sulfonic acid monomers, phosphoric acid monomers, and the like. The alkali-functional monomers which can be used to make the polymeric stabilizer used in the process are known monomers and include N,N-dimethylaminoethyl methacrylate, N,N-dimethylaminoethyl acrylate, N,N-diethylaminoethyl methacrylate, t-butylaminoethyl methacrylate, N,N-dimethylaminopropyl methacrylamide, N,N-dimethylaminopropyl acrylamide, oxazoladinylethyl methacrylate, and the like.
The preferred amount of acid-functional monomers is from about 5 to about 75 weight percent and the preferred amount of alkali-functional monomers is from about 20 to about 70 weight percent, respectively. However, the level of functional monomers required for the formation of rod-shaped or large spherical particles depends significantly on the total composition of the polymeric stabilizers. For example, if chain transfer agents that contain acid- or alkali-functional groups are employed, the proportion of acid- or alkali-functional monomers to be employed should be altered to account for the effect of the groups contributed by the chain transfer agent. The resulting acid-functional or alkali-functional polymeric stabilizer is then solubilized with alkali or acid, respectively, to produce the soluble polymeric stabilizer.
Applicants shall refer to some of the examples, which appear below, to more directly tie the general discussion of the technical effects to some concrete illustrations.
Chain transfer agents (CTAs) are usually required to obtain the preferred 5,000-10,000 molecular weight for the amphiphilic polymeric stabilizer. In addition, the hydrophobic, hydrophilic, associative and steric spacing effects of the chain transfer agents have a profound effect on the formation of large emulsion polymer particles. Examples 16-43 illustrate these effects. Hydrophobic CTAs (Examples 16 and 17) gave 65 BA/35 MMA rod-shaped polymers. Less hydrophobic CTAs (Example 18) gave large spheres, while hydrophilic CTA (3-MPA, Example 22) gave small spheres. Using hydrophobic CTAs such as n-hexadecyl mercaptan, n-octadecyl mercaptan, and benzyl mercaptan, did not give rods (Examples 19, 20 and 21).
With this specific ASR composition, the very hydrophobic n-hexadecyl and n-octadecyl mercaptan and the benzyl mercaptan, which may lead to hydrophobic groups that pack efficiently because of less steric hindrance, may result in polymeric stabilizers that are too hydrophobic to give large polymer particles.
Hydrophilic CTAs like hydroxyethyl mercaptan, mercapto-1,2- propandiol, and 1-mercapto-2-propanol give rods (Examples 23, 24, 25, and 26). We postulate that the hydrophilic OH-containing CTA groups orient along with the charged segment (i.e., poly carboxylic acid), thus diminishing some of the electrostatic forces, and results in hydrophobic-hydrophilic forces balanced enough for rod formation.
The level of hydrophobic CTA, such as n-DDM, in the ASR has an effect on the particle morphology (Examples 31-35). Example 30, which contained only 1% n-DDM, did not form rod-shaped particles; the poor solubility of ASR in Example 30 is believed to be the reason. When excess hydrophilic CTA, HEM or 3-MMP is present (Examples 39 and 43), the ASR polymer chains have electrostatic repulsion force stronger than the hydrophobic interaction since in the low molecular weight ASR, there are fewer BA units per polymer chain. These changes in the balance of hydrophobic-hydrophilic character are believed to be the reason for rod-shaped particles not forming in these examples.
As mentioned above, the type and amount of hydrophilic monomer used and the nature of the CTA used to make the amphiphilic polymeric stabilizer have a pronounced influence on the large emulsion polymer particle produced. The hydrophobicity of the ASR backbone also affects the production of large particles. There is an appreciable increase in the hydrophobicity of alkali-soluble resins as butyl acrylate replaces the less hydrophobic methyl methacrylate. Small amounts of the very hydrophobic monomers such as dodecyl-, hexadecyl- and octadecyl methacrylate have a strong influence on the formation of rod-shaped polymers.
Neutralization of ASR
The neutralizer for the alkali soluble resin used in the process can be selected from the organic and inorganic alkalis and include, for example, sodium hydroxide, potassium hydroxide, lithium hydroxide, ammonium hydroxide, primary, secondary and tertiary amines such as triethylamine and triethanolamine, and quaternary amines. The neutralizer for the acid soluble resins used in the process can be organic and inorganic acids and include, for example, hydrochloric acid, acetic acid, propionic acid, tartaric acid, and the like. The type and amount of neutralizers used in the process is chosen in each case based on the composition of the polymeric stabilizer (ASR), the final emulsion polymer composition, and on the morphology desired.
Triethanol amine is an especially favored alkaline neutralizer for the formation of rod-shaped particles. This may be due to the adsorption of this organic amphiphilic amine along with the polymeric stabilizer in a manner that decreases the mutual repulsion of the ionic heads in the polymeric stabilizer and in this way decreases the electrical work required to form an assembly of particles. Triethanol amine may be used as the sole neutralizing base or in the admixture with other volatile or non-volatile bases.
The degree of neutralization of ASRs, which usually effects the hydrophobic-hydrophilic balance, also effects the shape and size of polymer particles produced. Polymeric stabilizers that are already appreciably hydrophilic by virtue of a high proportion of acid (or amine) functionality are less influenced by the degree of neutralization than are more hydrophobic, less functionalized resins. We observed that when unsolubilized ASR was used, only regular small spherical latex particles were obtained. Rod-shaped particle latexes were obtained once the ASR was neutralized by the base. Some solubility or swelling of the ASR is required to enable the amphiphilic character of the polymeric stabilizer to function in the aqueous phase.
Thus, the structure of the CTA, the amount of CTA used, the vinyl monomers selected, the acid (or amine) content, the solubilizing base (or acid) and the method of preparation are among the variables that affect the balance of hydrophobic interactions and electrostatic repulsions (the amphiphilic character) of these low molecular weight alkali- or acid-soluble resins.
In designing a process, the decision whether to use an acid-soluble or alkali-soluble polymeric stabilizer in the process is based on the pH limits of the polymerization process, especially as determined by the pH requirements for solubility of the ASR. A polymeric stabilizer which is a carboxylic acid-functional resin solubilized by base, may be rendered insoluble by the addition of acidic materials such as acid-functional monomers. Therefore, an acid-soluble resin stabilizer would be the preferred one for manufacture of an acid-functional polymer, as well as for polymers composed of monomers that are unstable under alkaline conditions, such as vinyl acetate-containing polymers. Alkali-soluble resins are preferred polymeric stabilizers for use in the manufacture of amine-functional polymers as well as alkali-stable polymers.
The stabilizer system can also contain other organic additives which influence the morphology of the particles. The organic additives that affect the morphology of latex particles include hydrophobic alcohols, hydrophobic amines, ionic and nonionic surfactants, polyvinyl alcohols and coalescent agents. The presence of hydrophobic alcohols, nonionic surfactants and/or ionic surfactants especially promotes the formation of long rod-shaped latex particles. Preferred hydrophobic alcohols for use in the process are alcohols in which the alkyl group is from about 6 to 18 carbon atoms.
It is taught in the literature, for example, H. Hoffmann, Angew.-Chemie Int. Ed. Engl. 27 902-912 (1988), that small amounts of organic materials, especially amphiphilic alcohol molecules, adsorb at micellar interfaces and may produce marked changes in the Critical Micelle Concentration (CMC) of surfactants. Shorter chain alcohols are adsorbed mainly in the outer portion of the micelle, close to the micelle-water interface, where they may adsorb and desorb quickly. Intermediate chain length alcohols like decanol are believed to be incorporated into the micellar arrangement mainly in the outer portion of the core, and the polymeric stabilizers in the case discussed here are postulated to be located in this area. Adsorption of additives in this way decreases the electrical work required to form an assembly of particles by decreasing the mutual repulsion of the ionic heads in the polymeric stabilizer.
Surfactants useful as part of the stabilizer system in these processes include ionic surfactants; anionics such as sodium lauryl sulfate, sodium dodecylbenzenesulfonate, and the like, when using acid-functional polymer stabilizers, and cationic surfactants when using amine-functional polymer stabilizers. Nonionic surfactants such as ethoxylated alkylphenols and ethoxylated linear and branched C 10 -C 18 alcohols are also useful. When attempting to make rod-shaped particles composed of polymers of high Tg, it may be desirable to use coalescent or other softening agents to promote the formation of the rod-shaped latex particles. The coalescent agents which can be used in the process include Texanol, xylene, and the like.
The amount of ASR used in this invention generally ranges from 0.5 to 50 weight percent based on the total weight of monomers used to make the polymer particles. Without the use of additives such as ionic and nonionic surfactants, the length of the rod-shaped polymer particles decreases and the diameter of the rods increases as the ASR use level decreases. The polymeric stabilizer can be added to the reaction vessels as a preformed product or can be prepared in situ. The formation of rod-shaped and large spherical latex polymer particles depends on emulsion polymer composition as well as on the polymeric amphiphilic stabilizer and organic additives. We observed that when modifying a process which produces large dimension particles by increasing the Tg of the desired emulsion polymer or increasing the proportion of hydrophobic elements in the emulsion polymer composition, it is advisable to increase the acid content or the proportion of hydrophilic elements in the ASR stabilizer employed in the modified process. Adsorption of a surfactant or stabilizer has been noted to be a function of the hydrophobic part of the stabilizer and the surface of the polymer particles. Usually, the more hydrophobic or non-polar the latex surface, the greater the adsorption of the stabilizer. A more hydrophilic ASR may be needed to counter-balance the strong hydrophobic interactions encountered with hydrophobic polymer compositions.
Emulsion Polymers
The large emulsion polymer particles of this invention are preferably made by conventional emulsion polymerization processes using the appropriate monomers in the proper proportion in an aqueous phase in the presence of the water-soluble stabilizer system, which includes the solubilized amphiphilic polymeric stabilizer, and free-radical generating initiators such as alkali metal persulfates or redox initiator systems such as t-butyl hydroperoxide/sodium metabisulfite. Emulsion polymerization techniques are taught, for example, in U.S. Pat. Nos. 2,754,280, 2,795,564 and 3,732,184 as well as by Gary W. Poehlein in "Encyclopedia of Polymer Science and Engineering", 2nd Ed., Vol. 6, pp. 1-151, John Wiley and Sons, 1986.
Preferably, the process is carried out by adding, under polymerization conditions, the monomer mixture of the composition of the large polymer particle desired which, optionally, may be emulsified in water to an aqueous phase containing the solubilized amphiphilic polymeric stabilizer and, optionally, other suitable anionic, cationic or nonionic emulsifiers or mixtures thereof. Optional organic additives or protective colloids, illustrated by polyvinyl alcohols of various molecular weights and degree of hydrolysis, may also be present.
Suitable monomers which may be polymerized to form the rod-shaped and large spherical particles of this invention include the acrylate and methacrylate monomers such as alkyl acrylates wherein the alkyl group contains from about 1 to about 22 carbon atoms, including methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, etc., and alkyl methacrylates, such as methyl methacrylate, ethyl methacrylate, butyl methacrylate, isodecyl methacrylate, dodecyl methacrylate and similar alkyl methacrylates.
Other suitable monomers include acrylonitrile, methacrylonitrile, methylvinyl ether, vinyl acetate, vinyl formate, vinyl versatate, and the like. Other especially preferred monomers include the monovinylidine aromatic monomers such as, for example, styrene, α-methylstyrene, and other substituted styrenes.
Carboxylic acid monomers such as acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, crotonic acid, and the like, may also be used. Similarly, amine-functional monomers such as N,N-dimethylaminoethyl acrylate and methacrylate, t-butylaminoethyl methacrylate, N,N-dimethylaminopropyl methacrylamides, and the like, are also readily incorporated into large emulsion polymer particles.
Functional monomers such as glycidyl methacrylate, acetoacetoxyethyl methacrylate, hydroxyethyl methacrylate, hydroxyethyl acrylate, acrylamide, methylolated acrylamide and methacrylamide can be incorporated in these large emulsion polymer particles without difficulty. These functional polymers can be post-crosslinked by known methods to give crosslinked, solvent-resistant large particles. Hydroxyl-containing large polymer particles, including highly functional hydrophilic material, can be prepared by preparing polyvinyl acetate-containing polymers and then hydrolyzing the acetate groups to yield hydroxyl groups.
Conventional chain transfer agents can also be employed in the practice of this invention, and indeed, in many examples, especially with hydrophilic, higher Tg polymers, it is preferable to use amphiphilic chain transfer agents such as n-dodecyl mercaptan. Examples of such conventional chain transfer agents include bromoform, carbon tetrachloride, long chain mercaptans (octyl mercaptan, dodecyl mercaptan), mercapto esters such as methyl mercaptopropionate and 2-ethylhexyl mercaptoacetate and other mercaptans such as mercaptopropionic acid, 2-hydroxyethyl mercaptan, and the like.
The polymerization temperature is in the range of about 30° C. to about 100° C., most preferably from about 55° C. to about 90° C. Polymerization temperatures toward the high end of the range appear to favor the formation of rod-shaped polymer particles. These temperatures may favor the aggregation process postulated as the mode of rod formation. Temperature may also effect the solubility and the amphiphilic balance of the stabilizer system.
Other ingredients known in the art to be useful for specific purposes in emulsion polymerization can be employed in the preparation of these large emulsion polymer particles. For example, appreciable amounts (0.1 to 25%) of water-miscible solvents such as tertiary-butanol, ethanol, methyl Carbitol, butyl Cellosolve, and the like, may be present in the aqueous polymerization medium. Chelating agents may be present to remove metal ions.
During processing of the colloidal dispersions of these large emulsion polymer particles, one must bear in mind that they are stabilized by the solubilized primary polymeric stabilizer. In the case of the alkali soluble resins, for example, a reduction in the pH of the colloidal dispersion to a level that neutralizes the stabilizer will flocculate the dispersion. Similarly, a dispersion of large particles stabilized by an acid-soluble resin will not be stable at the higher pHs that reduce the solubility of the acid-soluble resin. Adjustment of the pH provides a way to flocculate these large polymer particles.
If desired, one may improve or alter the chemical resistance or physical properties of these large particles by conventional second stage polymerizations with conventional monomers and/or crosslinking monomers such as 1,3-butyleneglycol dimethacrylate, allyl methacrylate, trimethylolpropane triacrylate and trimethacrylate, divinyl benzene and the like (see, for example, U.S. Pat. No. 4,814,373, issued Mar. 21, 1989 to Frankel, Jones and Winey).
While not intending to be bound by the theoretical explanation, we provide the following discussion as a guide to those interested in practicing the invention.
We theorize that rod-shaped particles are obtained when the primary polymeric stabilizer, the ASR, has its hydrophobic interaction and electrostatic repulsion forces (hydrophilic interactions) in balance, and that the mechanism of rod or large sphere formation is an aggregation process that occurs when small sized spherical emulsion polymer particles, generated in the presence of the primary polymeric stabilizers, rapidly assemble into rods or spheres. We speculate that rods and spheres form by the same mechanistic process, but that the interactive forces in the stabilizer system may not be as well-balanced when large spheres form. The shape of the large particle produced is apparently controlled by the packing parameters of the amphiphilic stabilizer molecules in the assembly of small particles. In describing large micellar aggregates of different shapes, it has been noted that "one of the fascinating aspects of these systems is the fact that slight changes in the system on a microscopic level can lead to dramatic changes in the macroscopic properties of the system" (H. Hoffmann, Angew. Chem. cited above). In a similar manner, exactly why particular conditions should favor or inhibit the formation of rods or large spheres is not always immediately evident. Independent of the mechanistic theory, the technical effect of the invention is reproducible.
Optical and electron micrographs of samples at stages in the process indicated that small spherical particles formed first in the early stages, and then rod-shaped or large spherical particles formed by coalescence of small spherical particles. The time for first appearance of rod-shaped or large spherical particles varied with both ASR and polymer compositions. Transformation of small spherical particles to rods or large spherical particles occurred rapidly after the appearance of the first large dimension particle. The end product often contained about 70 wt % rods or large spherical particles and about 30 wt % fines (<400 nm). The level of fines at each interval was determined by centrifugation methods. It is suspected that the solubilized ASR (a salt) induces agglomeration of fine particles to rod-shaped or large spherical particles. However, post-adding solubilized ASR to a latex containing fine particles (30-100 nm) prepared from excess ionic surfactants but without any ASR did not produce rod-shaped or large spherical particles; only ˜300 nm particles were produced (as shown in Example 173 below). Apparently, incorporation of ASR molecules into the fine particles, i.e., in the early polymerization stage, is necessary for the formation of rod-shaped or large spherical particles.
Not all of the small spherical particles (referred to here as "fines") present at the time of the aggregation process are incorporated into rods or large spheres. Usually, from 10 to 40% fines are present in these preparations in addition to the rods and/or spheres. These fines may be separated from the particles and recycled to the next large particle preparation where they will participate in large particle formation.
The rod-shaped latex particles can be converted to large spherical latex particles by swelling the rod-shaped latex particles with either excess monomers or solvents. High standing monomer levels in the emulsion polymerization process may favor the production of spheres rather than rods.
The solvents which can be used to swell the high aspect ratio particles to form large spherical particles include, for example, hexane, heptane, toluene, xylene, and the like. Nevertheless, the conversion of rods to large spheres by the solvents and excess of monomers depend significantly on the polymer backbone. Highly crosslinked rod-shaped latex particles are unable or unlikely to convert to spheres by either excess solvents or monomers.
Solid Particles
Rod-shaped and large spherical polymer particles in the form of fine powders can be prepared from the rod-shaped and large spherical polymer latexes by removing water and, if necessary, surface active agents (including ASRs), and fine particles from the latexes. The polymer powder can be obtained by various techniques such as filtration, freeze-drying, centrifugal separation, spray-drying, precipitation with organic solvent or by salting-out, and the like.
The diameters and lengths of the large latex particles prepared by this invention include a wide range of dimensions. Preferred diameters of large spherical latex particles are in the ranges of 2 to 40 microns. High aspect ratio particles with diameter from 0.3 to 10 microns, and length up to ˜800 microns were prepared. Long particles with an aspect ratio of 3 or greater have been prepared.
Uses
Potential applications for this invention include the use of large spheres as flatting agents and to provide superior burnish resistance to PVC siding, flat and sheen paints, and as the polymerization seed of suspension polymer processes such as ion-exchange beads. Uses for the high aspect ratio particles to provide resistance to mudcracking in pigmented and unpigmented films (especially coatings near or above critical pigment volume concentration over porous substrates), as reinforcing agents in films and plastics, as rheology modifiers, as precursors of carbon rods, and as the basis for non-woven mats and controlled porosity membranes.
EXAMPLES
Fines Determination
To a plastic centrifuge tube was charged 0.5 gram of a latex and approximately 30 grams of water. The mixture was placed in a high speed centrifuge and then spun at 6,000 r.p.m. for 30 minutes to separate the fine particles from particles greater than one micron. The supernatant layer, the layer containing fine particles, was decanted to a weighing pan, and the total non-volatiles were measured after drying the aqueous solution in an oven at 150° C. for two hours. The % fines were then calculated by dividing the total weight of solids in the supernatant layer with the total solid weight (weight of latex times the solid of latex) charged into the centrifuge tube.
Particle Size Determination
The particle size of latexes was determined by an optical microscopy (Zeiss of West Germany).
__________________________________________________________________________Abbreviationof Materials Full Name of Materials__________________________________________________________________________ASR Alkaline soluble resinAA Acrylic acidMAA Methyl methacrylic acidIA Itaconic acidAMPS 2-acrylamido-2-methyl-1-propanesulfonic acidSMA 1000 Styrene/Maleic anhydride copolymerBA Butyl acrylateMMA Methyl methacrylateEA Ethyl acrylateEHA 2-Ethyl hexyl acrylateSty StyreneDMAEMA N,N-Dimethylaminoethyl methaccrylateTBAEMA N-tert-Butylaminoethyl methacrylateVAc Vinyl acetateIDMA Isodecyl methacrylateMLAM N-Methylol acrylamideGMA Glycidyl methacrylateAAEM 2-Acetoacetoxy ethyl methacrylateHEMA 2-Hydroxyethyl methacrylateALMA Allyl methacrylateTEA Triethanol aminePPA Propionic acidTTA Tartaric acidHMPA 2,2-Bis(hydroxymethyl)-propionic acidVT Vinyl tolueneAN AcrylonitrilePVOH Polyvinyl alcoholAirvol 203 ˜88% hydrolyzed PVOH with 7,000-13,000 Number Average Molecular WeightAirvol 205 ˜88% hydrolyzed PVOH with 15,000-27,000 Number Average Molecular WeightAirvol 523 ˜88% hydrolyzed PVOH with 44,000-65,000 Number Average Molecular WeightConco AAS-60S Triethanolamine salt of dodecylbenzene sulfonateSLS Sodium lauryl sulfateDS-4 Sodium dodecylbenzene sulfonateAlipal CO-436 Ammonium salt of sulfated polyethoxy nonyl phenolTriton X-405 Octylphenoxy ethylene oxide (with ˜40 EO)Triton X-100 Oxtylphenoxy ethylene oxide (with ˜9-10 EO)CTA Chain transfer agentn-DDM n-Dodecanethioltert-DDM tert-DodecanethiolHEM 2-Mercaptoethanol3-MMP Methyl 3-Mercaptopropionaten-C.sub.8 SH n-Octanethiol3-MPA 3-Mercaptopropionic acidTBHP tert-Butyl hydroperoxideNaBS Sodium bisulfiteSSF (Formopon) Sodium formaldehyde sulfoxylate (NaHSO.sub.2.CH.sub.2 O.2H.sub.2 O)IAA Isoascorbic acidAPS Ammonium persulfateVAZO 52 2,2'-Azobis(2,4-dimethylvaleronitrile)Versene Ethylene diamine tetraacetic acid tetrasodium salt__________________________________________________________________________ hydrate
Example 1
This example illustrates the preparation of an alkali-soluble resin (ASR) for use as a primary polymeric stabilizer.
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple, and condenser was charged with 700 gram of water and 1.7 grams of Alipal CO--436. The kettle solution was heated at 80° C. and seed monomers, 12 grams of butyl acrylate, 12 grams of methyl methacrylate, 12 grams of methacrylic acid, and 1.6 gram of n-dodecanethiol were added and mixed well. Five minutes later, an initiator, 10 grams of ammonium persulfate (APS) dissolved in 100 grams of water, was added. Fifteen minutes later, a monomer emulsion, 488 grams of butyl acrylate, 488 grams of methyl methacrylate, 488 grams of methacrylic acid, 66 grams of chain transfer agent, 1-dodecanethiol, and 6 grams of Alipal CO--436 in 488 grams of water, and an initiator, 5 grams APS dissolved in 100 grams of water, were cofed over a period of two hours while the kettle temperature was maintained at 80° C. The kettle temperature was held at 80° C. for fifteen minutes after the end of the feeds and then cooled to 60° C. A chaser system, 2 grams of ferrous sulfate solution (0.1%), 1 gram of tert-butyl hydroperoxide (TBHP) in 10 grams of water and 0.7 gram of Formopon in 15 grams of water were then added. After completion of the polymerization, the copolymer emulsion was cooled to ambient temperature and filtered through a 100 mesh size screen. The resulting emulsion polymer had total solids of 51.7%, 0.35 gram wet gel, and 1.96 milliequivalents of acid per gram.
Example 2
This example shows the preparation of rod-shaped latex particles from a premade ASR.
One hundred and twenty grams of the above emulsion polymer (Example 1 ), diluted with 500 grams of water was charged to a 5 liter four-necked flask and heated at 68° C. To the kettle was then added 28 grams of triethanolamine to solubilize the first stabilizer, and a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active). Subsequently, three feeds: (1) a monomer emulsion comprising 300 grams of water, 6.5 grams of Conco AAS-60S (60% active), 325 grams of butyl acrylate, 175 grams of methyl methacrylate, and 0.4 gram of n-dodecanethiol: (2) an initiator, 1.5 gram of TBHP and 1.5 gram of APS dissolved in 50 grams of water; and (3) a reducing agent, 2 grams of sodium bisulfite dissolved in 50 grams of water, were cofed into the kettle over a period of 1.5 hours while the kettle temperature was maintained at 68° C. The resulting polymer contained rod-shaped particles of 0.8 microns in diameter and 50-70 microns in length.
Example 3
This illustrates the preparation of rod-shaped polymer particles with an ASR made in situ.
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple and condenser was charged with 208 grams of water and 0.01 gram of Alipal CO--436. The kettle solution was heated at 80° C. To the kettle was then added 0.6 gram of butyl acrylate, 0.6 gram of methyl methacrylate, 0.6 gram of methacrylic acid, and 0.08 gram of n-dodecanethiol. Five minutes later, a kettle initiator, 0.4 grams of APS dissolved in 20 grams of water was added. Fifteen minutes later, a monomer emulsion containing 19.4 grams of butyl acrylate, 19.4 grams of methyl methacrylate, 19.4 grams of methacrylic acid, 2.32 grams of chain transfer agent, 1-dodecanethiol, and 0.3 gram of Alipal CO--436 in 242 grams of water, and an initiator solution, 0.6 gram APS dissolved in 30 grams of water, were cofed over a period of one hour while the kettle temperature was maintained at 82° C. The kettle temperature was held at 82° C. for fifteen minutes after the end of the feeds.
To the above emulsion polymer (ASR) was then added 32 grams of triethanolamine and a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active). Subsequently, three feeds, one a monomer emulsion containing 300 grams of water, 6.5 grams of Conco AAS-60S (60% active), 325 grams of butyl acrylate, 175 grams of methyl methacrylate, and 0.4 gram of n-dodecanethiol, the second an initiator, 1.5 grams of TBHP and 1.5 grams of APS dissolved in 50 grams of water, and the third a reducing agent, 2 grams of sodium bisulfite dissolved in 50 grams of water were cofed into the kettle over a period of 1.5 hours while the kettle temperature was maintained at 82° C. Fifteen minutes after the end of the feeds, the kettle was cooled to 63° C. A chaser couple, 1.0 gram of TBHP in 10 grams of water and 1.0 gram of Formopon in 10 gram of water were added thereafter. Fifteen minutes later, the polymer was cooled to ambient temperature. The resulting polymer had 36% of total solids and rod-shaped particles 0.9 microns in diameter, 100-150 microns in length. It also contained fine particles (36 wt % of total latex particles).
Example 4
This example demonstrates an ASR preparation via a one-shot process followed by an in situ preparation of rod-shaped emulsion polymer particles.
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple, and condenser was charged with 300 grams of water and 0.5 gram of Alipal CO--436. The mixture was heated at 80° C., and the monomers, 40 grams of methyl methacrylate, and 20 grams of methacrylic acid, were added along with 2.6 grams of a chain transfer agent 1-dodecanethiol. Subsequently, 0.5 gram of APS initiator dissolved in 10 grams of water was added to the flask. The monomer containing mixture was held at 80° C. for approximately fifteen minutes. After completion of the polymerization, 14 grams of aqueous ammonia (25 wt %) was added to neutralize (solubilize) the stabilizer. Thus, a clear solution polymer was obtained. To the clear solution polymer was then added a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active).
Three feeds: (1) a monomer emulsion comprising 325 grams of butyl acrylate, 175 gram of methyl methacrylate, 0.5 gram of n-dodecanethiol, 4 grams of Conco AAS-60S and 250 grams of water; (2) an initiator, 1.0 grams of APS and 1.5 grams of TBHP dissolved in 100 grams of water; and (3) a reducing agent, 1.8 grams of sodium bisulfite dissolved in 100 grams of water were then slowly cofed to the above neutralized polymer over a period of one hour. Mild heat was applied to the flask so that the kettle temperature was maintained at 70° C. The solution was held at 70° C. for fifteen minutes after the end of the feeds and then cooled to 60° C. A chaser couple, 1.0 gram of TBHP in 10 grams of water and 0.7 gram of Formopon dissolved in 15 grams of water were added thereafter. Fifteen minutes later, the polymer was cooled to ambient temperature. The resulting polymer had negligible amounts of gel, 35.6% of total solids and rod-shaped particles 0.9 microns in diameter, 50-70 microns in length.
Example 5
Here, the ASR stabilizer of Example 1 is used to prepare rod-shaped emulsion polymer particles in a gradual addition thermal process.
One hundred and twenty grams of emulsion polymer prepared as Example 1 diluted with 280 grams of water was charged to a 5 liter four-necked flask and heated at 82° C. To the kettle was then added 32 grams of triethanolamine to solubilize the stabilizer, and a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active). Subsequently, a monomer emulsion containing 250 grams of water, 6.5 grams of Conco AAS-60S (60% active), 325 grams of butyl acrylate, 175 grams of methyl methacrylate, and 0.4 gram of n-dodecanethiol, and an initiator, 2.5 grams of APS dissolved in 50 grams of water, were cofed into the kettle over a period of one hour while the kettle temperature was maintained at 82° C. Fifteen minutes after the end of the feeds, the kettle was cooled to 63° C. A chaser couple, 1.0 gram of TBHP in 5 grams of water and 0.7 gram of Formopon in 10 grams of water were added thereafter. Fifteen minutes later, the polymer was cooled to ambient temperature. The resulting polymer had 45.6% of total solids and rod-shaped particles 1.5 microns in diameter, 20-60 microns in length.
Example 6
This example shows that rod-shaped latex particles can also be prepared from an ASR which was prepared by solution polymerization.
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple, and condenser was charged with 1000 grams of tert-butanol. The kettle was heated at 80° C., and the seed monomers, 16.5 grams of butyl acrylate, 16.5 grams of methyl methacrylate, 17.0 grams of methacrylic acid, and 0.45 gram of chain transfer agent 2-mercaptoethanol were added. Subsequently, 1.0 gram of the free radical initiator VAZO-52 dissolved in 10 grams of tert-butanol was added to the flask. The mixture was held at 80° C. for approximately fifteen minutes. Two mixtures, one containing 313.5 grams of butyl acrylate, 313.5 grams of methyl methacrylate, 317 grams of methacrylic acid and 8.55 grams of 2-mercaptoethanol, and the other containing 10 grams VAZO-52 and 100 grams tert-butanol, were then cofed to the kettle over a period of three hours while the kettle solution was maintained at reflux. Fifteen minutes after feeds were completed, 2 grams of VAZO-52 in 10 grams of tert-butanol as chaser was added. Thirty minutes later, the kettle solution was cooled to 70° C., and then 1 gram of VAZO-52 in 10 grams of tert-butanol was added. Held kettle temperature at 70° C. for one hour and then stripped off tert-butanol using Dean-Stark trap until temperature reached 90° C. To the kettle was then added 530 grams of triethanolamine and two thousand grams of water. Stripping was continued until all tert-butanol was off. The acid content of the resulting solution polymer was 1.277 meq. per gram.
Part of the above solution polymer (7.8 grams), 87 grams of sodium dodecyl benzene sulfonate (23% active) and 200 grams of water were charged to a 5 liter four-necked flask and heated at 80° C. To the kettle was then added a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active). Subsequently, three feeds, a monomer emulsion comprising 300 grams of water, 4.2 grams of Conco AAS-60S (60% active), 250 grams of butyl acrylate, 250 grams of styrene, and 0.5 gram of n-dodecanethiol, an initiator solution containing 1.5 grams of TBHP and 1.5 grams of APS dissolved in 50 grams of water, and a reducing agent containing 2 grams of sodium bisulfite dissolved in 50 grams of water, were cofed into the kettle over a period of 1.5 hours while the kettle temperature was maintained at 80° C. Fifteen minutes after the feeds were completed, a chaser, 1 grams of TBHP dissolved in 5 grams of water and 0.7 gram of Formopon dissolved in 10 grams of water, were added to chase the residual monomers. The resulting latex had total solids of 33.2% and rod-shaped particle sizes of 2-3 microns in diameter and 40-100 microns in length.
The following summarizes the procedures conducted in Examples 1-6.
__________________________________________________________________________ ASRExample ASR Preparation Neutr. Polymer Preparation__________________________________________________________________________1 Grad-add thermal; stock2 Grad-add thermal; stock TEA grad-add redox; 70° C.3 Grad-add thermal; in-situ TEA grad-add redox; 80° C.3 Grad-add thermal; in situ NH.sub.4 OH grad-add redox; 70° C.5 Grad-add thermal; stock TEA grad-add thermal; 80° C.6 By solution polymerization TEA grad-add redox; 80° C.__________________________________________________________________________
Examples 7-13
The procedure was similar to Example 2, except that the ASR neutralizer was altered as shown in Table 1.
TABLE 1__________________________________________________________________________ Type of Neutralizer % Shape & Sizes ofExample for ASR Neutralized Particle (d × l, microns)__________________________________________________________________________ 7 Ammonia 80 rods: 0.8 × 50-70 8 Sodium hydroxide 80 rods: 0.8 × 50-70 9 Triethylamine 80 rods: 0.8-2 × 30-6010 Tripropylamine 80 Spheres: 1-711 N-benzyltrimethyl 80 rods: 3.5 × 50-70 ammonium hydroxide12 Tris (hydroxymethyl) 80 Rods (60%): 2 × 40-60 aminomethane (THAM) Spheres (40%): 3-7__________________________________________________________________________
The result (Table 1) indicated that all bases used to neutralize 33 BA/33 MMA/34 MMA (4,5 n-DDM) ASR led to rods except tripropylamine (produced spheres), Tripropylamine may be too hydrophobic or too bulky to produce rods with this specific polymeric stabilizer, The type of neutralizer does affect the shape and size of rods.
Examples 13-15
The procedure was similar to Example 2, except that the polymerization temperature were altered as shown in Table 2. Higher polymerization temperature favors formation of rod-shaped polymer particles.
TABLE 2______________________________________ASR: 33 BA/33 MMA/34 MAA (4.5 n-DDM)Polymer: 65 BA/35 MMA (0.1 n-DDM) Polymerization Shape and Sizes ofExample Temperature (C) Particles (microns)______________________________________13 40 Spheres: 2-714 60 Rods (60%): 0.8 × 40-60 Spheres (40%): 3-815 80 Rods: 0.8 × 50-70______________________________________
Example 16-28
A set of experiments was conducted using one of two processes, A and B, similar to Examples 2 and 3, except that the chain transfer agent used in preparing the ASR was altered as shown in Table 3.
TABLE 3__________________________________________________________________________ CTA in ASR Particle Particle Size ASR*ExampleWt % Type shape (d × l, microns) Process__________________________________________________________________________16 4.5 tert-Dodecyl mercaptan rod 0.8 × 40-60 A17 3.5 tert-Octyl mercaptan rod 1 × 40 & 3-4 × 40 A18 2.5 n-Octyl mercaptan spheres 15-25 A19 1.7 Benzyl mercaptan clover 5 B20 4.5 Hexadecyl mercaptan spheres 0.3 A21 4.9 Octadecyl mercaptan spheres 0.5 B22 2.3 3-Mercapto propionic acid spheres <1 B23 1.6 Hydroxy ethyl mercaptan rod 0.8 × 40-60 B24 2.4 Mercapto-1,2-propandiol rod 0.7 × 20-40 B25 2.1 1-Mercapto-2-propanol rod 0.7 × 20-40 B26 2.4 3-Mercapto-2-butanol rod 0.7 × 80 & 2 × 20 B27 3.1 3-Mercaptoethyl ether spheres 15-25 B28 2.8 4-Hydroxythiophenol spheres 1 B__________________________________________________________________________ *A: Using stock ASR (ref. Exampls 1 & 2) B: Continuous process (ref. Example 3)
As shown in Table 3, the chain-transfer agent (CTA) in ASR (BA/MMA/MAA) has a pronounced effect on the rod-shaped particles formation. Hydrophobic CTAs (Examples 16 and 17) gave 65 BA/35 MMA rod-shaped polymers. Less hydrophobic CTA (Example 18) gave large spheres, while hydrophilic CTA (3-MPA, Example 22) gave small spheres. Using hydrophobic CTAs such as n-hexadecyl mercaptan, n-octadecyl mercaptan, and benzyl mercaptan, did not give rods (Examples 19, 20 and 21).
With this specific ASR composition, the very hydrophobic n-hexadecyl and n-octadecyl mercaptan and the benzyl mercaptan, which may lead to hydrophobic groups that pack efficiently because of less steric hindrance, may result in polymeric stabilizers that are too hydrophobic to give large polymer particles. Hydrophilic CTAs like hydroxyethyl mercaptan, mercapto-1,2-propandiol, and 1-mercapto-2-propanol give rods (Examples 23, 24, 25, and 26). We suspect that the hydrophilic OH-containing CTA groups orient along with the charged segment (i.e., poly carboxylic acid), thus diminishing some of the electrostatic forces, and results in hydrophobic-hydrophilic forces balanced enough for rod formation.
Examples 29-43
The procedure was similar to Example 3, except that the CTA level in the ASR was altered as shown in Table 4.
TABLE 4__________________________________________________________________________ASR Compositions: 33 BA/33 MMA/34 MAA (CTA) Shape and Size of Particles and Proportion by WeightExample CTA % CTA Rods, Wt % Spheres, Wt %__________________________________________________________________________29 None -- -- <1u, 100%30 n-DDM 1.0 -- <2u, >90%31 n-DDM 2.0 1 × 50 u, 70% 2-4u, 30%32 n-DDM 4.0 1 × 50-90u, 80% 2-4u, 20%33 n-DDM 8.0 1 × 30-90u, 80% 2-4u, 20%34 n-DDM 12.0 2 × 30-70u, 80% 2-4u, 20%35 n-DDM 16.0 2 × 40-100u, 80% 2-4u, 20%36 HEM 0.8 1 × 30u, 30% 3u, 70%37 HEM 1.55 1 × 100u, 80% 4u, 20%38 HEM 3.1 1 × 100u, 70% 5u, 30%39 HEM 4.7 1 × 100u, 10% 10u, 90%40 3-MMP* 1.3 1 × 100u, 60% 10u, 40%41 3-MMP* 2.7 1 × 100u, 80% 10u, 20%42 3-MMP* 5.4 1 × 100u, 40% 25u, 60%43 3-MMP* 8.10 0 <1u, 100%__________________________________________________________________________ *Polymers contained 2% of decanol (based on total monomers).
The data in Table 4 shows that the level of hydrophobic CTA, such as n-DDM, in the ASR has an effect on the particle morphology (Examples 31-35). Example 30, which contained only 1% n-DDM, did not form rod-shaped particles; the poor solubility of ASR in Example 30 is believed to be the reason. When excess hydrophilic CTA, HEM or 3-MMP, is present (Examples 39 and 43), the ASR polymer chains have electrostatic repulsion force stronger than the hydrophobic interaction since in the low molecular weight ASR, there are fewer BA units per polymer chain. These changes in the hydrophobic-hydrophilic balancing character are believed to be the reason for rod-shaped particles not forming in these examples.
Examples 44-52
The procedure was similar to Example 3, except that the ASR compositions were altered as shown in Table 5.
TABLE 5__________________________________________________________________________ Shape & Size ofExampleASR Composition CTA in ASR Particles (microns)__________________________________________________________________________Polymer composition: 65 BA/35 MMA44 33 BA/33 MMA/34 MAA n-octyl mercaptan Spheres: 15-2545 42 BA/25 MMA/33 MAA " Rods: 2 × 4046 55 BA/12 MMA/33 MAA " Spheres: 4-947 33 BA/33 MMA/34 MAA 3-MMP Spheres: 7-2448 50 BA/17 MMA/33 MAA " Rods: 2 × 40Polymer composition: 70 BA/30 MMA49 36.2 BA/26.3 MMA/37.5 MAA 3-MMP Rods (60%): 3 × 60 Spheres (40%): 4-1250 62.5 BA/37.5 MAA " Rods: 1 × 6051 36.2 BA/26.3 MMA/37.5 MAA n-DDM Rods: 2 × 3652 62.5 BA/37.5 MAA " Rods: 0.8 × 80__________________________________________________________________________
Table 5 shows that in addition to the hydrophobic groups (CTAs) at the end of polymer chains, the hydrophobicity of the ASR backbone affects the formation of rod-shaped particles in a similar manner. As the amount of BA in both n-octyl mercaptan and 3-MMP terminated ASRs increased, the hydrophobicity of ASR also increased, and once the forces between the hydrophobic interaction and the electrostatic repulsion were in balance, rod-shaped particles formed (Examples 44, 45, 47, 48, 49, and 50). However, when the ASR became too hydrophobic, the rods disappeared (Example 46). The backbone hydrophobicity in n-DDM terminated ASRs affected the size of the rod-shaped particle more than the particle shape (Examples 51 and 52).
Examples 53-55
The procedure was similar to Example 7, except that the ASR Levels were altered as shown in Table 6.
TABLE 6______________________________________Effect of ASR Level on Size of RodsASR: 65 MMA/35 MAA (4.5 n-DDM)Emulsion Polymer: 65 BA/35 MMAExample Wt % ASR* Rod Size (microns)______________________________________53 12 0.8 × 3554 4 1.5 × 3055 2.4 2.5 × 16______________________________________ *Based on Emulsion Polymer monomers
Table 6 shows the effect of ASR level on the size of rod-shaped particles. The length of rods decreased and the diameter of rods increased progressively as the ASR use level decreased. However, long rods can be prepared in the presence of low levels of ASR and other ionic surfactants (see Examples 100 to 111 below).
Examples 56-62
The procedure was similar to Example 2, except that the degree of ASR neutralization was altered as shown in Table 7.
The degree of neutralization of ASRs also affected the size and shape of the polymer particle produced. However, the more MAA in the ASR, the less the effect of the degree of neutralization. Apparently, solubilization of the ASR affects the hydrophobe-hydrophile balance. It is well known that less base is needed to solubilize the higher acid containing (more hydrophilic) ASRs. Only regular small spherical latex particles were obtained from unsolubilized ASR (see Table 7). Rod-shaped particle latexes were obtained once the ASR was solubilized by the base.
Example 63-83
The procedure was similar to Examples 2 and 3, except that ASRs contained hydrophobic monomers as shown in Table 8.
Incorporating hydrophobic monomer into hydrophilic chain-transfer agent terminated ASRs promoted the formation of rod-shaped particles.
TABLE 7__________________________________________________________________________ASR Degree of Polymer Shape and SizeExampleComposition Neutralization Composition Particles (microns)__________________________________________________________________________56 33 BA/17 MMA/50 MAA/4 n-DDM 0% 30 BA/70 Sty/0.1 n-DDM spheres: 0.2-0.457 " 39% " spheres: 1-2 with few 1 × 100 um rods58 " 58% " rods: 1-2 × 10059 " 90% " rods: 1-2 × 50-10060 33 BA/33 MMA/34 MAA/4.5 n-DDM 60% " spheres: <161 " 90% " rods: 0.8 × 50-7062 " 100% " rods: 0.8 × 50-70__________________________________________________________________________
TABLE 8__________________________________________________________________________Polymer Composition: 65 BA/35 MMA (0.08 n-DDM) Shape and Size ofExampleASR Composition Particles (microns)__________________________________________________________________________63 32 BA/32 MMA/34 MAA/2 Octadecyl acrylate (2.0 nDDM) Mostly rods: 1 × 10-7064 32 BA/32 MMA/34 MAA/2 Octadecyl acrylate (4.0 nDDM) Mostly rods: 1 × 10-9065 32 Ba/32 MMA/34 MAA/2 Lauryl acrylate (2.4 MMP) Large spheres: 7-1266 31 BA/31 MMA/34 MAA/4 Lauryl acrylate (2.4 MMP) Mostly rods: 1 × 60-18067 29 BA/29 MMA/34 MAA/8 Lauryl acrylate (2.4 MMP) Large spheres: 2-668 25 BA/33 MMA/34 MAA/8 Lauryl acrylate (2.4 MMP) Rods: 1 × 55-12069 33 EA/37 MMA/25 MAA/5 Lauryl acrylate (2.4 MMP) Large spheres: 10-2570 23 EA/37 MMA/25 MAA/15 Lauryl acrylate (2.4 MMP) Large spheres: 5-3571 31 BA/31 MMA/34 MAA/4 Lauryl methacrylate (2.4 MMP) Rods: 1 × 30-90 (80%); Spheres: 3-8 (20%)72 28.6 BA/28.6 MMA/32.4 MAA/5.7 IDA/4.7 LA (2.4 MMP) Rods: 1 × 50-12073 32 BA/32 MMA/34 MAA/2 cetyl methacrylate (2.4 MMP) Rods: 1 × ˜60 (30%); Spheres: 6-15 (70%)74 31 BA/31 MMA/34 MAA/4 cetyl methacrylate (2.4 MMP) Rods: 3 × 30 (40%); Spheres: 6-12 (60%)75 29 BA/33 MMA/34 MAA/4 cetyl methacrylate (2.4 MMP) Mostly rods: 1 × 40-120 (60%)76 32.5 BA/32.5 MMA/34 MAA/1 octadecyl acrylate (2.4 MMP) Large spheres: 5-1677 32.0 BA/32.0 MMA/34 MAA/2 octadecyl acrylate (2.4 MMP) Rods: 1 × 40-20078 31.0 BA/31.0 MMA/34 MAA/4 octadecyl acrylate (2.4 MMP) Rods: 1 × 40-200 (80%); Spheres: 3-7 (20%)79 31 BA/31 MMA/34 MAA/4 IDMA (2.4 MMP) Mostly fines & large Spheres: 3-2080 30.5 BA/30.5 MMA/34 MAA/5 IDMA (2.4 MMP) Rods: 1 × 25-145, mostly 1 × ˜12081 30 BA/30 MMA/34 MAA/6 IDMA (2.4 MMP) Rods: 1 × 30-100 (30%); Spheres: ˜6 (70%)82 27 BA/33 MMA/34 MAA/6 IDMA (2.4 MMP) Rods: 1 × 30-80 (85%); Spheres: 3-8 (15%)83 29 BA/29 MMA/34 MAA/8 IDMA (2.4 MMP) Large spheres: 4-10__________________________________________________________________________
TABLE 9__________________________________________________________________________Effect of Additives wt % Second Stage Shape and Size ofExampleASR Composition ASR Polymer Composition Additives* Particles__________________________________________________________________________ (microns)84 33 BA/33 MMA/34 MAA/2.5 C.sub.8 SH 12 65 BA/35 MMA/0.1 n-DDM None spheres: 15-2085 " 12 " 2.0 decanol rods: 1-1.5 × 30-6086 33 BA/33 MMA/34 MAA/2.7 3-MMP 12 65 BA/35 MMA/0.1 n-DDM None spheres: 7-2487 " 12 " 0.6 butanol** spheres: 9-1588 " 12 " 0.8 hexanol** spheres: 20-3089 " 12 " 1.0 octanol** rods: 1 × 60.90 & spheres: 15-2590 " 12 " 1.2 decanol** rods: 2 × 50-7091 " 12 " 1.4 dodecanol** rods: 1 × 70-9092 " 12 " 0.6 decanol spheres: 15-3093 " 12 " 2.4 decanol rods: 1-1.5 × 70-9094 " 12 " 2.4 butanol spheres: 12-2595 65 MMA/35 MAA (4.5 n-DDM) 12 50 BA/50 MMA/0.1 n-DDM None spheres: <196 " 12 " 2.0 decanol mix rods: 3 × 40 & 0.8 × 6097 33 BA/22 MMA/45 MAA/4 n-DDM 12 100 Sty/0.1 n-DDM 2 decanol, rods: 1.5 × 10-40 10 Texanol98 " 12 " 2 decanol, rods: 1.5 × 10-25 10 xylene99 " 12 " 2.0 decanol spheres: <1100 33 BA/33 MMA/34 MAA/4.5 t-DDM 1 65 BA/35 MMA/0.1 n-DDM 1.5 SLS rods: 2 × 200101 " 1 " 4.0 × X-165 spheres: 10-15 & a few short rods102 33 BA/33 MMA/34 MAA (3.5 n-C.sub.8 SH) 1 " 3.0 SLS rods: 2 × 200103 33 BA/33 MMA/34 MAA (4.5-DDM) 2 " 3.0 SLS rods: 2 × 300104 " 1 " 1.0 SLS spheres: 6-15105 " 1 " 0.5 SLS spheres: 6-10106 " 1 " 3.0 SLS rods: 2 × 300107 " 1 " 3.0 DS-4 rods: 2 × 300108 " 1 " 3.0 Alipal CO-436 rods: 2 × 150 & spheres: ˜5109 " 0.5 " 0.75 SLS rods: 4 × 50-100110 " 2 40 BA/60 Sty 3.0 SLS rods: 2 × 200111 " 2 40 BA/60 MMA 3.0 SLS rods: 2 ×__________________________________________________________________________ 200
Examples 112-153
Table 10 shows that monomers such as EA, EHA and styrene also gave rod-shaped or large spherical latex particles. In general, EHA or styrene containing ASRs produce shorter rods. A variety of functional monomer containing rod-shaped latex particles were obtained as shown in Table 10. Crosslinked rod-shaped latex particles also can be prepared. As shown in Table 10, ASRs based on monomers other than MAA, such as AA, AMPS and maleic acid, can also give rod-shaped or large spherical latex particles.
TABLE 10__________________________________________________________________________ PolymerExampleASR Composition Composition Stabilizers Neutralizer Particles__________________________________________________________________________ (microns)112 33 EA/42 MMA/25 MAA (2.4 MMP) A 12 ASR/.8 hexanol ammonia spheres: 25113 33 EA/42 MMA/25 MAA (6.0 DDM) " 12 ASR/1.2 hexanol ammonia rods: 0.8 × 50 (40%); 2-4 × 10-20u (60%)114 33 EA/12 MMA/55 MAA (4.0 nDDM) " 12 ASR/1.3 decanol TEA spheres: <0.6115 33 EA/10 styrene/2 MMA/55 MAA (4.0 nDDM) " 12 ASR/1.3 decanol ammonia rods: 0.3 × 10116 33 BA/27 MMA/40 MAA (3.6 MMP) " 12 ASR/1.3 decanol TEA spheres: 9-12117 33 BA/27 MMA/40 MAA (4.0 nDDM) " 12 ASR/1.9 decanol TEA rods: 1 × 100 (60%); spheres: 6-10 (40%)118 33 EHA/10 styrene/17 MMA/40 MAA (4.0 nDDM) " 12 ASR/1.2 hexanol ammonia rods: 0.25 × 3-4119 33 EHA/10 styrene/32 MMA/25 MAA (4.0 nDDM) " 12 ASR/1.3 decanol ammonia spheres: <1120 33 EA/42 MMA/25 MAA (2.4 MMP) B 12 ASR/1.9 decanol ammonia rods: 0.8-4 × 20-80 (70%); spheres: 10-15 (30%)121 33 EA/12 MMA/55 MAA (4.0 nDDM) " 12 ASR/0.8 hexanol TEA rods: 1 × 80 (85%); spheres: 5-8 (15%)122 33 EA/27 MMA/40 MAA (4.0 n-DDM) " 12 ASR/1.9 decanol ammonia rods: 0.6 × 3-10123 33 EA/10 styrene/32 MMA/25 MAA (2.4 MMP) " 12 ASR/1.3 decanol TEA spheres: 7-20124 33 BA/27 MMA/40 MAA (4.0 nDDM) " 12 ASR TEA rods: 2 × 70125 33 BA/42 MMA/25 MAA (2.4 MMP) " 12 ASR/0.8 hexanol TEA spheres: 2-10126 33 BA/10 styrene/17 MMA/40 MAA (4.0 nDDM) " 12 ASR/1.2 hexanol ammonia rods: 1.5 × 20-50 (70%); spheres, 2-5 (30%)127 33 EHA/12 MMA/55 MAA 92.4 MMP) " 12 ASR/1.9 decanol ammonia spheres: <1128 30 BA/45 MMA/15 HEMA/10 MAA/4.5 n-DDM C 10 ASR TEA/ spheres: ˜1 ammonia129 30 BA/45 MMA/15 HEMA/10 MAA/4.5 n-DDM " 4 ASR/6 SLS Ammonia rods (50%): 2 × 50-100; spheres (50%): 5-12130 30 BA/45 MMA/15 HEMA/10 MAA/4.5 n-DDM " 2 ASR/3 SLS Ammonia spheres: 6-18131 30 BA/40 MMA/25 HEMA/5 MAA/4.5 n-DDM " 2 ASR/3 SLS Ammonia mostly small spheres <1132 30 EA/40 MMA/25 HEMA/5 MAA/4.5 n-DDM " 2 ASR/3 SLS Ammonia spheres:__________________________________________________________________________ 25-50Exam-ple ASR Composition Polymer Composition Stabilizers Particles__________________________________________________________________________ (microns)133 33 BA/33 MMA/34 MAA/4.5 n-DDM 100 BA 12 ASR rods: 0.8 × 10-20134 33 BA/33 MMA/34 MAA/4.5 n-DDM 100 MMA 12 ASR spheres: <1135 33 BA/33 MMA/34 MAA/4.5 n-DDM 86 EA/14 MMA 12 ASR rods: 2 × 20-40136 33 BA/33 MMA/34 MAA/4.5 n-DDM 45 BA/55 EA 12 ASR rods: 2 × 20-30137 33 BA/33 MMA/34 MAA/4.5 n-DDM 93 BA/7 AN 2 ASR/2 DS-4 rods: 2 × 50-100138 33 BA/33 MMA/34 MAA/4.5 n-DDM 20 (65 BA/35 MMA/0.1 n-DDM)// 12 ASR rods: 3 × 80-165 80 (65 BA/27.5 MMA/7.5 TBAEMA)*139 33 BA/33 MMA/34 MAA/3.5 n-C.sub.8 SH 34 BA/60 Sty/4 EA/3 ALMA 12 ASR spheres: 9-15140 33 BA/27 MMA/40 MAA/4 n-DDM 50 BA/40 MMA/10 AAEM/0.1 n-DDM 12 ASR/ rods: 1.5 × 100-150 2 decanol141 33 BA/22 MMA/45 MAA/4 n-DDM 100 VT//3 DVB* 5 ASR/ rods: 2 × 40-100 2 SLS/ 4 Xylene142 25 BA/75 MAA/4.5 n-DDM 65 BA/35 MMA/0.1 n-DDM 10 ASR spheres: 3-5143 73 MMA/27 MAA/4.5 n-DDM 60 BA/38 MMA/2 DMAEMA 5 ASR rods: 4 × 50-100144 65 MMA/35 MAA/4.5 n-DDM 65 BA/35 MMA 12 ASR rods: 0.9 × 50-70145 50 MMA/50 MAA/4 n-DDM 20 BA/80 VOAc 15 ASR rods: 1 × 7-18146 25 BA/50 MLAM/25 MAA (4.0 n-DDM) 46 BA/54 MMA 2 ASR/ rods: 1 × 90 2 SLS/ 4 decanol147 40 BA/35 MLAM/25 MAA 50 BA/50 EA 2.0 ASR/4 SLS rods: 1 × (15-30)148 40 BA/35 MLAM/25 MAA 49.75 BA/49.75 EA//0.5 IA* 0.5 ASR/4 SLS rods: 4 × (20- 40), some small spheres149 40 BA/35 MLAM/25 MAA 48BA/48EA//1 MAA/3 MLAM* 0.5 ASR/4 SLS rods (90%): 1 × 20, spheres (10%): 2-5150 30 BA/70 AMPS/3 n-DDM 65 BA/35 MMA/0.1 n-DDM 8 ASR spheres: 6-8151 33 BA/33 MMA/33 AA/4 n-DDM 50 BA/50 Sty 2.4 ASR/4 SLS rods: 2-3 × 50-90152 SMA 1000 50 BA/50 Sty 2 ASR/3 SLS rods: 2 × 50-100153 SMA 1000 65 BA/35 MMA 2 ASR/3 SLS spheres:__________________________________________________________________________ 10-18 Examples 112-127 are similar to the process of Example 3. Examples 128-132 are similar to the process of Example 2. In Table 10, these three polymers were used: A = 65 BA/35 MMA/0.08 nDDM; = 50 BA/50 MMA/0.08 nDDM and C = 65 BA/35 MMA/0.1 nDDM. *Monomers after double slash (//) were charged to monomer emulsion after rodshaped particles were observed. Neutralizer was TEA in all Examples except 143 where NaOH and Lime were added to TEA, and in 145 where KOH was used. Examples 133-138, 141-145 and 150-152 were run according to the process o Example 2. Examples 139 -140 were run according to the process of Example 3. Examples 146-149 and 151 were run according to the process of Example 6.
Example 154
This example shows that rod-shaped latex particles can also prepared from an acid soluble resin.
Preparation of Acid Soluble Resin (DMAEMA-Containing Resin)
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple and condenser was charged with 360 grams of water and 13 grams of Triton X-405. The mixture was heated at 40° C., and 75 grams of methyl methacrylate as well as 6 grams of n-DDM were added. Twenty minutes later, 75 grams of dimethylaminoethyl methacrylate was added. Subsequently, a mixture of 10 grams of ferrous sulfate solution (0.1%) and 10 grams of versene solution (1%) was added as promoter. To the kettle was then added 1.5 grams of TBHP in 15 grams of water, followed by one gram of isoascorbic acid dissolved in 20 grams of water. A twenty degree temperature increase was observed within ten minutes of reaction. When the kettle temperature reached its maximum (60° C.), a chaser couple, 1 gram of TBHP in 10 grams of water and 0.7 grams of Formopon dissolved in 10 grams of water were added to complete the polymerization. The resulting polymer contained 24.7% total solids and 0.664 meq. amine per gram.
Preparation of Rod-Shaped Polymer Particles
Part of above emulsion polymer (200 g), diluted with 100 grams of water was charged to a 5 liter four-necked flask and heated at 70° C. To the kettle was then added 12 grams of propionic acid to solubilize the stabilizer, and a mixture of 10 grams of ferrous sulfate solution (0.1% active) and 10 grams of versene solution (1% active). Subsequently, three feeds, a monomer emulsion containing 300 grams of water, 20 grams of Triton X-100, 100 grams of butyl acrylate and 400 grams of vinyl acetate, an initiator containing 1.5 grams of TBHP and 1.5 grams of APS dissolved in 60 grams of water, and a reducing agent containing 2 grams of sodium bisulfite dissolved in 60 grams of water, were cofed into the kettle over a period of one hour while the kettle temperature was maintained at 72° C. Thirty minutes after the feeds, a chaser couple, one gram of TBHP in 5 grams of water and 0.7 grams of Formopon dissolved in 10 grams of water, were added to chase the residual monomers. The resulting latex had total solids of 45.9% and rod-shaped particles of 1 micron in diameter and 3-12 microns in length.
Examples 155-164
In the Examples 155 to 164 processes were run in a manner similar to Example 154 except that the acid-soluble resin composition, neutralizer, use level, and co-surfactant were altered as shown in Table 11. As shown in Table 11, various types of acid can be used to neutralize DMAEMA-containing resin which then offered rod- shaped latex particles. The formation of rod-shaped particles in the DMAEMA-containing ASR depended significantly on the stabilizer composition and hydrophobic and hydrophilic balancing, as was seen with the MAA containing ASRs.
TABLE 11__________________________________________________________________________ExamplePolymer Composition Kettle Charge Neut. ME Soap & Additive Shape and Size of Particles (microns)__________________________________________________________________________ASR: 50 MMA/50 DMAEMA (4.0 nDDM)155 20 BA/80 VAc 10 ASR PPA 0.8 Conco AAS rods: 1 × 15-90156 20 BA/80 VAc 10 ASR TTA.sup.2 0.8 Conco AAS rods: 10-15 × 35-140 (40%); Spheres, 10 (60%)157 20 BA/80 VAc 10 ASR HMPA.sup.3 0.8 Conco AAS rods: 2 × 20-140 (30%); Spheres, 10 (70%)158 20 BA/80 VAc 10 ASR HCl 0.8 Conco AAS rods: 1 × 3-15 (50%); Spheres, 3 (50%)159 20 BA/80 VAc 10 ASR PPA none rods: 0.7 × 60-70160 50 BA/50 VAc 10 ASR PPA 4.0 Triton X-100 rods: 1 × 3-6161 60 BA/40 MMA 10 ASR PPA 4.0 Triton X-100 rod: 0.8 × 8-10162 98 BA/2 MAA 6 ASR PPA 4.0 Triton X-100 rod: 1 × 12-40ASR: 40 MMA/60 DMAEMA (4.0 n-DDM)163 20 BA/80 VAc 10 ASR PPA 0.8 Conco AAS mostly spheres, ˜1; some rodsASR: 10 BA/30 MMA/60 DMAEAM (4.0 nDDM)164 20 BA/80 VAc 10 ASR PPA none rods: 1 × 15-50__________________________________________________________________________ .sup.1 PPA: propionic acid .sup.2 TTA: tartaric acid .sup.3 HMPA: 2,2bis(hydroxymethyl)-propionic acid Example 165
The ASR was prepared in the presence of polyvinyl alcohol by one-shot emulsion polymerization. The ASR was solubilized by aqueous ammonia and used as the stabilizer.
______________________________________Stabilizer: 1% PVOH/12% ASRPVOH: Airvol 203ASR: 32 BA/35 MMA/33 MAA (4.3 n-DDM)Polymer: 65 BA/35 MMA (0.5 n-DDM)______________________________________
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple and condenser was charged with 345 grams of water, 5 grams of Airvol 203 (polyvinyl alcohol) and 0.2 grams of Alipal CO-436. The mixture was heated at 80° C., and monomers, 19 grams of butyl acrylate, 21 grams of methyl methacrylate, 20 grams of methacrylic acid, and 2.6 grams of a chain transfer agent, 1-dodecanethiol, were added and mixed well. Subsequently, a free radical initiator, 0.5 gram of APS dissolved in 5 grams of water was added to the flask. The monomer-containing mixture was held at 80° C. for approximately fifteen minutes. After completion of the polymerization, 14 grams of aqueous ammonia (26 weight %) was added to neutralize (solubilize) the stabilizer. Thus, a clear polymer solution was obtained.
Three feeds containing a second monomer emulsion comprising 325 grams of butyl acrylate, 175 grams of methyl methacrylate, 2.5 grams of n-dodecanethiol, 1.8 grams of Conco AAS-60S, 14.5 grams of Triton X-165, and 250 grams of water, an initiator, 1.0 gram of APS and 1.5 grams of TBHP dissolved in 100 grams of water, and a reducing agent, 1.8 grams of sodium bisulfite in 100 grams of water were then slowly cofed to the above neutralized polymer over a period of one hour. Mild heat was applied to the flask so that the kettle temperature was maintained at 70° C. The solution was held at 70° C. for fifteen minutes after end of feeds and then cooled to 60° C. A chaser couple, 1.0 gram of TBHP in 10 grams of water and 0.7 gram of Formopon dissolved in 15 grams of water were added thereafter. Fifteen minutes later, the polymer was cooled to ambient temperature. The resulting polymer had negligible amounts of gel, 39.9% of non-volatiles, 650 cps of Brookfield viscosity and rod-shaped particles, 0.5 microns in diameter, 10 microns in length.
Examples 166-172
Process as Example 165 except that PVOH, ASR and polymer compositions were altered as indicated in Table 12.
Table 12 shows the effect of PVOH on rod-shaped particles. The presence of PVOH does influence the rod size; shorter rods are produced when PVOH is present. Grafting partially hydrolyzed (88%) PVOH to the ASR also aids in stabilizing the resulting polymer to sedimentation and syneresis.
TABLE 12__________________________________________________________________________Exam- Shape and Size ofple % PVOH 1st stage (ASR) Composition ASR 2nd Stage Composition Particles__________________________________________________________________________ (microns)166 1 Airvol 203 32 BA/35 MMA/33 MAA/4.3 n-DDM 12 65 BA/35 MMA/0.5 n-DDM rod: 0.5 × 10167 " 32 BA/35 MMA/33 MAA/4.3 n-DDM 12 65 BA/35 MMA rod: 0.6 × 30-40168 " 66.7 MMA/33.3 MAA/4.3 n-DDM 12 65 BA/35 MMA/0.3 n-DDM rod: 0.7 × 10-15169 - 66.7 MMA/33.3 MAA/4.3 n-DDM 12 65 BA/35 MMA/0.3 n-DDM rod: 0.8 × 15-25170 1 Airvol 205 66.7 MMA/33.3 MAA/4.3 n-DDM 12 65 BA/35 MMA/0.3 n-DDM rod: 0.8 × 35171 1 Airvol 523 66.7 MMA/33.3 MAA/4.3 n-DDM 12 65 BA/35 MMA/0.3 n-DDM rod: 0.5 × 10172 1 Airvol 203 66.7 MMA/33.3 MAA/4.3 n-DDM 12 65 BA/30 MMA/5 GMA rod: 0.3__________________________________________________________________________ × 4
Example 173
This example shows that one can convert fine spherical latex particles (<50 nm) to bigger size particles (˜300 nm) by post treating the fine particles with a salt of an ASR. However, no large spheres (>1 micron) or rod-shaped particles were obtained by this route. Therefore, incorporation of ASR molecule to particles in the beginning stage of polymerization appears to be critical for the rod or large spherical particles formation.
Process
A 5 liter, four-necked flask equipped with a mechanical stirrer, nitrogen sparge, thermocouple and condenser was charged with 200 grams of water, 50 grams of sodium lauryl sulfate (28 percent active), 2.7 grams of triethanolamine and heated at 80° C. To the kettle was added a mixture of 10 grams of ferrous sulfate solution (0.1%) and 10 grams of versene (1%). Subsequently, three feeds, (1) a monomer emulsion comprising 300 grams of water, 6.5 grams of Conco AAS-60S (60% active), 325 grams of butyl acrylate, 175 grams of methyl methacrylate and 1.0 gram of n-dodecanethiol, (2) an initiator, 1.5 grams of TBHP and 1.5 grams of APS dissolved in 50 grams of water and (3) a reducing agent containing 2 grams of sodium bisulfite dissolved in 50 grams of water, were cored into the kettle over a period of one hour while the kettle temperature was maintained at 80° C. The resulting polymer contained fine spherical particles (˜36 nm). To the resulting polymer was then added a triethanolamine (5 grams dissolved in 20 grams of water) neutralized ASR (40 grams of 25.2% total solids of 33.3 BA/33.3 MMA/33.3 MAA/4.5 tert-DDM composition ASR which was prepared by the method described in Example 1). Immediately after the addition of ASR, the kettle polymer became chalky and had 293 nm size of spherical particles.
Example 174
Filtration of high Tg, large spherical latex particles.
To filter a latex, a Buchner funnel was used in conjunction with a suction flask, into which it was fitted by means of a rubber stopper; the flask was attached by means of thick-walled rubber tubing to a water suction pump. A grade 230 filter paper from Whatman Inc., Clifton, N.J., was placed onto the top of Buchner funnel. The latex was then filtered through with the aid of vacuum. The fines and water soluble stabilizers were collected in the flitrate. The high Tg, large spherical latex particles were collected on the top of the filter paper. A latex polymer (34 BA/60 Sty/4 EA/2 ALMA) was prepared by the process described in Example 6. The resulting latex was passed through a Buchner funnel with the aid of vacuum. A non-sticky, flowable, white powder (368 g. ˜73% yield) was collected on the top of filter paper. The redispersed powder had spherical particle sizes of 23-32 microns.
Example 175
This example shows that one can convert rod-shaped particles to large spherical particles by swelling the rod-shaped particles with either excess monomers or solvents.
A 65 BA/35 MMA/0.1 n-DDM composition rod-shaped latex was prepared from an ASR (65 MMA/35 MAA/4.5 n-DDM) as described in Example 4. The resulting latex had 32% of total solids and rod-shaped particles (0.8 microns in diameter and 50-70 microns in length). To 20 grams of this rod-shaped latex was added 20 grams 1,3-butylene glycol dimethacrylate. The mixture was initiated with TBHP/SSF and stirred for 12 hours. The particles obtained were 4 to 6 microns spherical particles.
In another experiment, 17 grams hexane was mixed with 20 grams of rod-shaped latex and stirred for 12 hours. The resulting latex had 3 to 5 microns spherical particles.
Example 176-178
The following samples (Table 13) shows that rod-shaped latex containing hydroxy functional group can be prepared by partial hydrolysis of a vinyl acetate/acrylic copolymer with sodium hydroxide.
TABLE 13__________________________________________________________________________ Vinyl AlcoholExample Base Polymer ASR Composition Content*__________________________________________________________________________176 20 BA/80 VAc 7.5% 50 MMA/50 DMAEMA 36%177 20 EA/80 VAc 7.5% 50 MMA/50 DMAEMA 32%178 20 MA/80 VAc 7.5% 50 MMA/50 DMAEMA 54%__________________________________________________________________________ *Mole % based on polymer composition
The emulsion polymers were prepared in a manner similar to Example 154. The resulting polymers had a total solids of 44%. The rod-shaped latexes were then hydrolyzed with NaOH. To 100 grams of VAc/acrylate copolymer which contains 0.4 mole of vinyl acetate was added 12 grams Triton X-405, 10 grams 28% ammonia and 0.1 to 0.4 moles of 16.5% sodium hydroxide solution. The mixture was heated in an oven at 60° overnight. Sample 178 contained fewer rods than 176 and 177, which may be due to increased solubility of the higher polyvinyl alcohol-content in that sample.
Example 179-181
Another approach to prepare rod-shaped particle latex containing hydroxyl group is to add hydroxyethyl methacrylate (HEMA) as a shell on a BA/MMA rod polymer (Example 181) or to post-add HEMA to monomer emulsion after rod formation (Example 179 and 180).
TABLE 14__________________________________________________________________________Particles Containing --OH GroupEx. Stabilizer Polymer Group Morphology__________________________________________________________________________179 2 (33 BA/27 MMA/40 MAA) 1 SLS 33 (68 BA/32 MMA)/ Rods: 1 × 30 μm 67 (67 BA/30 MMA/3 HEMA)180 3 (33 BA/27 MMA/40 MAA) 1 SLS 25 (50 BA/50 MMA)/ Rods: 5 × (10-30) 75 (50 BA/46.5 MMA/2.0 AM/ 1.5 HEMA)181 11.5 (33 BA/27 MMA/40 MAA) 39.5 BA/59.5 MMA/1 ALMA/ Rods: 1 × (25-50) /5 HEMA and 2 × (10-30)__________________________________________________________________________
The procedure for preparing ASR was similar to Example 1, except that the composition was altered as shown in Table 14. The rod-shaped latex particles were prepared in a manner similar to Example 2 using a premade ASR. In Example 179 and 180, HEMA was added to monomer emulsion after the formation of rod-shaped particles. In Example 181, HEMA was added in a single charge to a premade, rod-shaped polymer to form a shell.
Example 182-183
Table 15 (Examples 182 and 183) shows that polymerization process has an effect on the polymer morphology. Rod-shaped particles were obtained when the polymer was prepared using a gradual addition process. On the other hand, multishot process generated a latex with large spherical particles.
TABLE 15______________________________________Process EffectASR: 33 BA/33 MMA/34 MAA (2.7 MMP)Emulsion Polymer: 65 BA/35 MMAExample Process Morphology______________________________________182 Gradual addition Rod, 2 × 100 μm183 Multi-shot Sphere, 11-14 μm______________________________________
Example 182 was run in a manner similar to Example 3 except for n-dodecanthiol which was replaced by methyl mercaptopropionate in the stabilizer (ASR). The resulting polymer had a total solids of 36.6% and particle size of 2×100 μm.
The ASR of Example 183 was prepared in the same way as Example 182 ASR. The emulsion polymer was prepared by a shot process instead of gradual addition process as in Example 182. The monomer emulsion was divided into four parts (10/20/35/35) and each shots were polymerized at 60° C. with a redox initiator. The resulting polymer had a total solids of 35.8% and particle size of 11-14 μm.
Applications Data
Polymers prepared according to the invention were evaluated in end use applications. The polymers provided improved performance in reducing a phenomenon known as mud-cracking in films and in burnish resistance.
All Formulations list ingredients in order of addition. In Formulations A and C, the grind portion of the formula is all the ingredients up to, but not including, the binder (Formulation A, the binder is UCAR 367 (Union Carbide Chemicals and Plastics), Formulation C the binder is Rhoplex AC-490 (Rohm and Haas Company). Example 2 does not have a pigment grind.
______________________________________Material Composition ASR Level Shape and Size______________________________________184 60 BA/40 MMA 2% 2 × 80μ Rod185 20 BA/80 VAc 10% 1 × 3 to 12μ Rod (DMAEMA ASR)186 30 BA/70 MMA 12% 10μ Sphere187 20 BA/80 VAc 6% 4 to 7μ Sphere188 20 BA/80 Sty 2% 6 to 14μ Sphere______________________________________ Process Notes: Ex 184 was prepared according to a process similar to Ex. 111; Ex. 185 wa prepared according to a process similar to Ex. 155; Ex. 186 was prepared according to a process similar to Ex. 47; Ex. 187 was prepared according to a process similar to Ex. 145; Ex. 188 was prepared according to a process similar to Ex. 116.
______________________________________FORMULATION AMud Cracking - Interior Flat Wall Paint -Acrylic and Vinyl Acetate Rod ParticlesMaterials Control Acrylic Rod) Vinyl Acetate Rod______________________________________Water 176.2 176.2 176.2Ethylene Glycol 27.6 27.6 27.6Tamol 7.7 7.7 7.7AMP-95 2.0 2.0 2.0Colloid 643 2.0 2.0 2.0250 MHR (2.5%) 70.0 70.0 70.0Acrysol RM-825 14.1 14.1 14.1Ti-Pure R-900 153.4 153.4 153.4Optiwhite P 247.5 247.5 247.5Nyad 400 42.9 42.9 42.9Ucar 367 252.9 187.5 190.8Ex. 184 0.0 86.5 0.0Ex. 185 0.0 0.0 74.8Texanol 5.1 5.1 5.1Colloid 643 4.0 4.0 4.0Nuosept 95 1.0 1.0 1.0NH4OH (28%) 0.0 0.0 2.8Water 129.0 105.8 113.7Total 1135.4 1133.3 1135.6PVC 58.1 58.1 58.1Volume Solids 34.2 34.2 34.2______________________________________
______________________________________Example Control 184 185______________________________________Mud Cracking 4.2 7.4 9.8______________________________________
Mud Cracking Test Method
Paints are drawn down over unsealed wallboard at 30 mil wet film using a multiple film caster, dried for 24 hours in a constant temperature/humidity room (77 Degrees/50% Relative Humidity) and visually rated for mud cracking using a scale of 0 (poor) to 10 (excellent).
______________________________________FORMULATION BFlatting of Clear Wood Varnish-Acrylic Large Spherical ParticleMaterials Control Acrylic Sphere______________________________________Rhoplex CL-104 540.0 410.1Sancure 815 148.5 148.5Surfynol 104PG-50 3.0 3.0Tego 800 0.7 0.7Propylene Glycol 30.0 30.0Hexyl Carbitol 20.8 0.0Dowanol PnB 0.0 20.8Michem 39235 22.4 22.4Water 76.3 106.1Aqueous Ammonia 2.5 2.5Ex. 186 Concentrate* 0.0 88.7Acrysol Rm-1020 18.0 24.0Total 862.2 856.8Volume Solids 28.6 28.6______________________________________ *Note that the material referred to as "186 Concentrate" was prepared by allowing the 186 dispersion, described above to settle overnight, then decanting the liquid portion off. The concentrate is the remaining sediment and is easily dispersed into the formulation. This process removes the smaller (<0.7μ) particles ("fines") from the large spherical particles.
______________________________________Example Control 186______________________________________Gloss, 20 Degree 62.9 2.9Gloss, 60 Degree 88.5 13.9Gloss, 85 Degree 102.4 12.8______________________________________
Flat Test Method
Apply three coats by brush on a stained white pine wood board. Dry 24 hours between coats. Light sand between coats. Allow third coat to dry for 24 hours before measuring gloss. Measure gloss at 20, 60 and 85 degrees.
______________________________________FORMULATION CBurnish Resistance Interior Sheet Paint -Acrylic and Vinyl Acetate Spheres Vinyl AcetateMaterials Control Acrylic Sphere Sphere______________________________________Tamol 731 11.0 10.6 10.6Colloid 643 2.0 2.0 2.0Propylene Glycol 43.0 43.0 43.0Water 50.0 50.0 50.0Ti-Pure R-900 234.5 234.5 234.5Atomite 36.2 36.2 36.2Celite 281 69.2 0.0 0.0AC-490 370.8 374.1 374.1Propylene Glycol 34.4 34.4 34.4Texanol 17.0 17.0 17.0Colloid 643 4.0 4.0 4.0Nuosept 95 2.0 2.0 2.0Ex. 188 0.0 71.0 0.0Ex. 187 0.0 0.0 86.22.5% HEC Solution 159.2 159.2 159.2Water 60.0 21.2 8.6Total 1093.3 1059.3 1061.8PVC 40.0 40.0 40.0Volume Solids 30.0 30.0 30.0Celite 281 PVC 12.0Ex. 188 PVC 12.0Ex. 187 PVC 12.0______________________________________
______________________________________Example Control 188 187______________________________________Gloss Change (%) 77 10 5______________________________________
Burnish Resistance reported as % change in 85 degree gloss. The lower the value, the better the burnish resistance.
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A process for preparing large dimension emulsion polymer particles and the polymer products of the process are disclosed. In one embodiment, the invention provides particles having a high aspect ratio, having a shape described by a long axis and an intersecting short axis. These particles range in shape from egg-like, through rod-like, up to extended filaments. In another embodiment, the invention relates to large, nearly spherical emulsion polymer particles.
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BACKGROUND OF THE INVENTION
The present invention generally relates to apparatus operably positionable in the wellbore of a subterranean well and, in a preferred embodiment thereof, more particularly provides specially designed latching apparatus and associated methods for operatively coupling a firing head structure to a perforating gun.
In subterranean wells, such as oil and gas wells, it is common practice to facilitate the flow of production fluid by perforating a fluid bearing subterranean formation using a device commonly referred to as a perforating gun which is lowered into the wellbore to the depth of the formation and then detonated to form perforations in the formation surrounding the gun. A firing head assembly is operatively coupled to the gun and detonated to fire the gun. While the firing head assembly may be coupled to the perforating gun before the gun is lowered into the wellbore, it is often preferred, for safety and other reasons, to couple the firing head to the gun after the gun is positioned downhole in the wellbore.
For the lowered gun to function, it must be properly coupled to the subsequently lowered firing head. This downhole coupling, or “latching”, of the firing head to the associated perforating gun has heretofore been subject to several problems, limitations and disadvantages. For example, one previously proposed firing head/perforating gun latching system utilizes flexible collet fingers on the firing head that are designed to be outwardly deflected over an upper end of an associated stinger portion of the perforating gun, and then snap into a circumferential groove in the stinger to operatively latch the firing head to the perforating gun.
The collet fingers, as they approach the stinger, pass though a centering restriction in the tubing on which the perforating gun has been previously lowered into the wellbore, and through which the firing head passes on its way to the perforating gun. This centering restriction is designed to laterally align the collet fingers with the upper end of the stinger, but can easily be struck by and inwardly bend one or more of the collet fingers, thereby preventing the proper latching between the firing head and the perforating gun. This same undesirable bending of the collet fingers could also result from the collet structure striking some other obstruction or irregularity in the tubing as the collet structure passes through it in a downhole direction toward the previously lowered perforating gun.
A potential solution to this downhole firing head/perforating gun latching problem is simply to attach the firing head to the perforating gun at the surface, and then lower the coupled firing head and perforating head into the wellbore together. However, as previously mentioned, in many instances this is considered undesirable from safety and other standpoints. Additionally, if for some reason the firing head malfunctions, both the firing head and the perforating gun must be pulled from the wellbore, as opposed to simply pulling and replacing the malfunctioning firing head.
As can readily be seen from the foregoing, a need exists for improved apparatus and associated methods for effecting the downhole latching of a firing head to a previously lowered perforating gun. It is to this need that the present invention is directed.
SUMMARY OF THE INVENTION
In carrying out principles of the present invention, in accordance with a preferred embodiment thereof, perforating apparatus is provided which is operatively positionable in a subterranean wellbore and includes a firing head and an associated perforating gun. Cooperatively engageable first and second latching structures are preferably of fixed geometry configurations, are respectively carried by the firing head and the perforating gun, and are operative to couple them, while in the wellbore, in a manner such that subsequent operation of the firing head responsively fires the perforating gun. According to an aspect of the present invention, a portion of one of the first and second latching structures is shearable in a manner permitting the firing head, after being coupled to the perforating gun in the wellbore, to be disengaged from the perforating gun and retrieved from the wellbore.
In an illustrated embodiment of the present invention, the first latching structure is representatively a tubular latch collar portion of the firing head and has a circumferentially spaced plurality of shearable lugs extending radially inwardly into its interior. The second latching structure is representatively a stinger portion of the perforating gun, is telescopingly receivable in the latch collar, and has a circumferentially spaced plurality of J-slot recesses formed on an exterior sidewall portion thereof. As the latch collar is telescoped onto the stinger, the shearable studs enter the stinger J-slots to couple the firing head to the perforating gun.
In accordance with a method of the invention, the perforating gun is lowered into the wellbore to a predetermined depth therein and held at such predetermined depth. The firing head is then lowered, on a suitable lowering structure such as a slickline, into the wellbore until the latching portions of the firing head and perforating gun are interengaged. The slickline is then pulled up to verify, via a sensed increase in its tension, that the lowered firing head has been properly latched to the previously lowered perforating gun. After proper firing head/perforating gun latching has been verified the firing head is appropriately actuated to responsively fire the perforating gun. Subsequent to the firing of the perforating gun, the spent firing head is pulled up with sufficient force to shear the shearable portion of the latching structure, for example the shearable latch collar studs, thereby releasing the firing head from the perforating gun and permitting the unlatched firing head to be pulled out of the wellbore.
According to another aspect of the present invention, cooperative auxiliary connecting structures are provided on the interengageable latching portions of the firing head and perforating gun which permit them to be fixedly secured to one another in a manner permitting the perforating gun and firing head to be simultaneously lowered into the wellbore in an operatively connected state instead of being sequentially lowered into the wellbore and operatively latched together therein. Representatively these cooperative auxiliary connecting structures include a circumferentially spaced plurality of openings formed in the sidewall of the latch collar and alignable with side surface depressions in the stinger, and connecting members extendable through the collar openings into the stinger depressions to longitudinally and rotationally lock the collar onto the stinger.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1F are cross-sectional views of longitudinally successive portions of a representative firing head/perforating gun assembly having incorporated therein a specially designed firing head/perforating gun latching system embodying principles of the present invention;
FIG. 2 is an exploded perspective view of latching collar and stinger portions of the latching assembly;
FIG. 3 is an enlarged scale cross-sectional view through a lower end of the latching collar structure illustrated in FIG. 2 and showing diametrically opposed shearable stud members incorporated therein; and
FIG. 4 is a developed side elevational view of the stinger structure shown in FIG. 2 and illustrating an opposed pair of external J-slots formed thereon for operatively receiving the shearable stud members.
DETAILED DESCRIPTION
The present invention provides specially designed latching apparatus 10 (see FIGS. 1E and 2) useable to releasably latch a firing head 12 (see FIGS. 1C-1E) to a perforating gun 14 (see FIG. 1F) downhole within a subterranean wellbore 16 , portions of which are illustrated in FIGS. 1A and 1F. Representatively, the wellbore 16 is lined in a conventional manner with a cemented-in tubular casing structure 18 , but the principles of the present invention are also applicable to uncased wellbores. As subsequently described herein, the latching apparatus 10 includes a tubular latching collar structure 20 (see FIGS. 1E and 2) that defines a lower end portion of the firing head 12 , and a tubular stinger structure 22 (see FIGS. 1E and 2) having a pair of external J-slots 24 formed on opposite external side portions thereof. The stinger structure 22 defines an upper end portion of the overall perforating gun assembly.
The schematically depicted perforating gun 14 (FIG. 1F) is of a conventional construction and has a reduced diameter threaded upper end portion 26 which is connected to a threaded tubular crossover member 28 which, in turn, is threadingly coupled to the lower end of an outer tubular structure 30 used to lower the perforating gun 14 through the casing 18 to a predetermined depth therein adjacent a subterranean formation (not shown) to be penetrated as a result of firing the perforating gun 14 . The upper end of the tubular structure 30 (see FIG. 1A) is threadingly coupled to the lower end of a tubing structure 32 extending to the surface.
Extending upwardly from the perforating gun 14 is an extension tube 34 (see FIGS. 1E and 1F) which is threaded at its upper end into the lower end of the stinger 22 . A detonator cord 36 extends through the interior of the extension tube 34 , and into the interior of the stinger 22 . As illustrated in FIG. 1E, the upper end of the detonator cord 36 is communicated with an initiator 38 within an upper end portion of the stinger 22 , and as illustrated in FIG. 1F the lower end of the detonator cord 36 is communicated with a booster 40 in an upper end portion of the perforating gun 14 .
The firing head 12 is representatively of a conventional mechanically actuated type, but could be of another known type such as, for example, a pressure-actuated firing head. As previously mentioned, the latch collar 20 (see FIGS. 1D and 1E) defines a lower end portion of the firing head 12 . The threaded upper end portion 26 of the latch collar 20 , as shown in FIG. 1D, is threaded into the lower end of a tubular crossover member 42 having an upper end 44 that is threaded into the lower end of an inner tubular structure 46 (see FIGS. 1 A-A- 1 D) coaxially received within the outer tubular structure 30 and axially movable relative thereto. For purposes later described herein, an open upper end portion 48 of the inner tubular structure 46 (see FIG. 1A) has an annular latching profile 50 formed on its inner side surface.
Turning now to FIG. 1D, an extension tube 52 is coaxially received in the inner tubular structure 46 and has a lower end portion threaded into the upper end portion 44 of the crossover member 42 . At its upper end, the extension tube 52 is coupled to a somewhat larger diameter tubular member 54 (see FIG. 1 C). Operatively secured to the upper end of the tubular member 54 , and defining an upper end portion of the firing head 12 , is an upper releasing pin 56 which is disposed above a firing piston 58 slidably carried within the tubular member 54 . As illustrated in FIG. 1C, the firing piston 58 is disposed in an upwardly spaced relationship with an initiator 60 carried within the tubular member 54 . Initiator 60 is operatively coupled to a detonator cord 62 (see FIGS. 1C-1E) that extends downwardly from the initiator 60 , through the extension tube 52 and the crossover member 42 , to a shape charge assembly 64 secured within an upper interior end portion of the latch collar portion 20 of the firing head 12 .
With reference now to FIGS. 2 and 3, the latch collar 20 has a tubular body 66 with an open lower end 68 . Four internally threaded circular holes 70 , 70 a are equally spaced, in diametrically opposite pairs, around the circumference of a lower end portion of the collar body 66 . For purposes later described, shearable metal studs 72 are threaded into a diametrically opposite pair of holes 70 so that inner end portions of the studs 72 extend into the interior of the collar body 66 as illustrated in FIGS. 1E and 3.
Turning now to FIGS. 2 and 4, each of the previously mentioned opposite J-slots 24 externally formed on the outer side surface of the stinger 22 has a longitudinally extending upper entry portion 74 positioned between a pair of deflector portions 76 of the stinger having generally inverted V-shaped apex sections 78 . Each J-slot entry portion 74 is communicated with a circumferentially offset, longitudinally extending receiving portion 80 by a downwardly sloping transfer portion 82 . Each receiving portion 80 has an upper portion 80 a, and a lower portion 80 b. The entry portions 74 of the J-slots 74 are diametrically opposite from one another, as are the receiving portions 80 of the J-slots 74 .
To operatively attach the collar 20 to the stinger 22 , as later described herein, the collar 20 is simply dropped onto the upper end of the stinger 22 . The inwardly projecting end portions of the shearable studs 72 either drop directly into the J-slot entry portions 74 or are rotationally deflected by the apexed deflectors 76 into the entry portions 74 (thus causing the collar 22 to rotate relative to the stinger 22 ). The lugs 72 are then directed into the J-slot receiving portions 80 via the J-slot transfer portions 82 (thereby further rotating the collar 20 relative to the stinger 22 ) whereupon the lugs drop into the lower receiving slot portions 80 b . When the collar 20 is subsequently lifted, the lugs 72 enter the upper receiving slot portions 80 a , thereby locking the collar 20 the stinger 22 .
For purposes later described herein, the in-place collar 20 may be fixedly secured to the stinger 22 which it coaxially overlaps using threaded studs 84 (see FIG. 2) These studs 84 are threaded into the diametrically opposite pair of collar holes 70 a (see FIGS. 2 and 3) until the studs 84 enter a diametrically opposite pair of circular recesses 86 formed in the outer side surface of the stinger 22 . This translationally and rotationally locks the collar 20 to the stinger 22 .
The use of the perforating gun 14 , utilizing the specially designed firing head/perforating gun latching apparatus 10 of the present invention, will now be described with reference to FIGS. 1A-1E. To position the perforating gun 14 for subsequent firing, the gun 14 (see FIG. 1F) is lowered to a preselected depth in the wellbore 16 on the outer tubular structure 30 secured to the lower end of the upper tubing structure 32 (see FIG. 1 A). The firing head 12 is prepared for lowering into the outer tubular structure 30 by latching a schematically depicted pulling tool 88 (see FIG. 1A) into the internal profile 50 , and interconnecting the latched-in pulling tool 88 to a lowering structure, such as the illustrated slickline 90 , via a conventional telescoped weight and jar assembly 92 , 94 which is schematically depicted in FIG. 1 A. Lowering structures other than the representatively illustrated slickline 90 , such as coiled or jointed tubing, or wireline, could be alternatively utilized if desired.
The slickline-supported firing head structure 12 , whose lower end is defined by the specially designed latch collar 20 , is lowered into the outer tubular structure 30 toward the upper stinger end portion 22 of the in-place perforating gun 14 until the latch collar 20 telescopes over the stinger 22 and the shearable collar studs 72 (see FIGS. 1E and 3) enter the lower end portions 80 b of the stinger J-slot receiving portions 80 (see FIG. 4 ). As previously described, during the downward movement of the collar 20 over the stinger 22 , the shearable studs 72 sequentially pass downwardly through the J-slot portions 74 , circumferentially and downwardly through the transfer portions 82 , and then downwardly into the lower end portions 80 b of the J-slot receiving portions.
To verify that the lowered collar 20 is latched to the stinger 22 , thereby operatively coupling the firing head 12 to the perforating gun 14 , the slickline 90 is pulled upwardly in a manner causing the inner end portions of the collar studs 72 to move upwardly in the J-slot receiving portions 80 until they enter the upper portions 80 a thereof and bottom out against their upper ends. A resulting sensed substantial increase in the slickline tension verifies that the collar 20 has been operatively latched to the stinger 22 .
After the operative collar/stinger latching has been verified in this manner, slack is appropriately introduced into the slickline 90 in a manner causing the weight 92 to strike and “shear down” the slickline pulling tool 88 out of its associated tubing profile 50 . The slickline 90 is then pulled upwardly to remove the now unlatched pulling tool 88 from the wellbore 16 leaving the firing head 12 operatively latched to the perforating gun 14 . As will be appreciated, as alternatives to the weight and jar structure 92 , 94 , other types of jarring mechanisms or other types of unlatching mechanisms may be utilized to decouple the pulling tool 88 from the inner tubular structure 46 Subsequent to the removal of the pulling tool 88 in this manner, a suitable drop bar 96 (see FIG. 1B) is dropped through the inner tubular structure 46 and permitted to fall on the upper releasing pin portion 56 of the firing head structure 12 . In response to the impact of the drop bar 96 on the releasing pin 56 , the firing piston 58 is driven downwardly against the underlying initiator 60 to thereby cause a depending firing pin 98 on the piston 58 to penetrate the initiator 60 and ignite the explosive material therein. This ignites the detonator. cord 62 (see FIGS. 1C-1E) which, in turn, operates the booster 64 to thereby drive a shape charge 100 therein downwardly through the upper end wall of the stinger 22 . The shape charge penetration of the upper stinger end wall operates the stinger initiator 38 in a manner igniting the perforating gun detonating cord 34 (see FIGS. 1E and 1F) and, in turn, operating the perforating gun booster 40 (see FIG. 1 F). Operation of the booster 40 fires the perforating gun 14 and, in a conventional manner, drives its shape charges (not shown) outwardly through the cased wellbore 16 into the surrounding subterranean formation (also not shown).
After the perforating gun 14 has been fired, the spent firing head 12 may be retrieved by lowering the pulling tool 88 on the slickline 90 (see FIG. 1A) into latched receipt with the inner tubular structure profile 50 , and then pulling upwardly on the slickline 90 with sufficient force to shear the collar lugs 72 , thereby freeing the collar 20 from the stinger 22 and correspondingly freeing the firing head structure 12 from the perforating gun 14 . Once freed in this manner from the perforating gun 14 , the firing head 12 may be simply pulled out of the wellbore 16 on the slickline 90 . This also permits the drop bar 96 to be brought to the surface without the necessity of a separate trip.
As an alternative to first lowering the perforating gun 14 into the wellbore 16 and then separately lowering the firing head 12 into the wellbore 16 and latching the separately lowered firing head 12 to the perforating gun 14 , the same collar 20 may be used to operatively secure the firing head 12 to the perforating gun 14 in a manner permitting the firing head and perforating gun to be simultaneously lowered into the wellbore 16 . This alternate connection of the firing head 12 and the perforating gun 14 may be achieved simply by latching the collar 20 to the stinger 22 , using the studs 72 threaded into the collar holes 70 a until inner ends of the studs 72 enter the stinger side recesses 86 . This longitudinally and circumferentially locks the collar 20 to the stinger 22 , thereby locking the firing head 12 to the perforating gun 14 for simultaneous lowering into the wellbore 16 .
As can be seen, in contrast to the use of resilient collet fingers to operatively couple a firing head to an associated perforating gun, the present invention representatively utilizes latching structures (i.e., the latching structures 20 and 22 ) which preferably have fixed geometry configurations. As used herein, the term “fixed geometry” with respect to these latching structures means that their configurations are not appreciably altered during the latching operation. The latching operation is thus not dependent on the resilient deflection of any portion of the structures 20 and 22 , and neither structure is appreciably susceptible to deformation or other damage while being lowered through the wellbore. Additionally, because of the rigid yet intentionally shearable nature of the firing head/perforating gun latching interconnection, both the verification of proper latching and the subsequent separation of the latched firing head and perforating gun are substantially facilitated.
The unique latching apparatus of the present invention thus provides for more reliable downhole latching of a firing head to a perforating gun and, via the shearable interconnection between the firing head and the perforating gun, permits the easy retrieval of the spent firing head from the perforating gun. The same firing head, however, may be alternatively attached directly to the perforating gun, as described above, to facilitate the joint lowering of the firing gun and attached perforating gun into the wellbore. Additionally, by using a drop-away attachment instead of the threaded crossover member 28 illustrated in FIG. 1F, the perforating gun 14 and attached firing head 12 may be simply dropped into the wellbore 16 after the perforating gun 14 is actuated by the firing head 12 . Moreover, if well parameters change such that a different firing head is required, the firing head in place can be retrieved and a new firing head redeployed without having to trip the perforating gun.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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A latching system permits a firing head to be lowered into a wellbore and reliably coupled to a perforating gun previously lowered into the wellbore. In a disclosed embodiment thereof, the latching system includes a tubular collar associated with the firing head, and a stinger associated with the perforating gun. As the firing head approaches the previously lowered perforating gun, shearable studs projecting into the interior of the collar are received in external side surface J-slots formed on the stinger. The latching of the collar studs in the stinger J-slots permits the firing head/perforating gun connection to be verified simply by pulling up on and creating increased tension in the structure, such as a slick line, used to lower the firing head to the perforating gun. After the firing head is used to detonate the perforating gun, the spent firing head may be retrieved by pulling it uphole with sufficient force to shear its collar studs. Cooperating auxiliary attachment structures are formed on the firing head and perforating gun to facilitate their interconnection and simultaneous lowering into the wellbore if desired.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Korean Patent Application No. 10-2012-0125072 filed on Nov. 6, 2012, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND
[0002] The present invention relates to an integrated apparatus for detecting a gear shift, and more particularly, to an integrated apparatus for detecting a gear shift in which a switch and a gear shifting detection controller that detects a sports mode of a vehicle are integrally implemented.
[0003] A gear shifting controller is an apparatus that is installed between a clutch and a propeller shaft and appropriately changes power of an engine based on a variation of a vehicle driving state, and is provided with a gear shifting manipulation mechanism that allows the gear shifting controller to be operated by a manipulation of a driver.
[0004] In a manual transmission, a gear shifting detection controller is mounted to provide a gear shift feel of an automatic transmission, and the gear shifting detection controller refers to a technology that provides both improved fuel efficiency and a sport mode driving performance of the manual transmission, and driving convenience and smoother gear shifting performance of the automatic transmission.
[0005] The gear shifting detection controller may be divided into a wet type and a dry type. First, in the wet type, a clutch drum is disposed, which has a structure similar to a structure of a wet type multiple plate switch used in the automatic transmission, at an input end side of the gear shifting controller, and is configured to transmit or block power to allow power of an engine to be used as an input of the gear shifting controller.
[0006] However, in the dry type, an outer clutch that has a substantially large effective radius and two inner clutches having a small radius are disposed to be parallel to each other in a structure similar to a clutch of the gear shifting controller, and when first, third, and fifth speed stages (odd number stages) are driven, the outer clutch is directly connected, and when second, fourth, and sixth speed stages (even number stages) are driven, the inner clutch is directly connected, to transmit or block power to allow power of the engine to be used as an input of the gear shifting controller.
[0007] Meanwhile, the automatic transmission transmits power using the oil in the transmission, and thus generally has lower fuel efficiency due to higher energy loss than the manual transmission that has direct power transmission mechanism between gears.
[0008] To supplement the drawbacks of the automatic transmission, a sports mode gear shifting stage (e.g., M gear shifting stage) in which a shift lever is manipulated in a sports mode in a vertical manner is separately provided in addition to a main gear shifting stage that includes a parking stage (P), a reversing stage (R), a neutral stage (N), and a driving stage (D).
[0009] When the gear shifting stage is converted into the sports mode gear shifting stage by a shift lever manipulation of the driver, a method of detecting that the gear shifting stage is converted into the sports mode gear shifting stage is implemented using a switch that is operated together with one side of a lower end of the shift lever. In addition, a gear shifting detection controller and a switch, among configurations for detecting gear shifting in the related art, share inherent component characteristics in that the gear shifting detection controller and the switch are operated in the sports mode, but the gear shifting detection controller and the switch are separately provided. Accordingly, bracket bases that accommodate, respectively, the gear shifting detection controller and the switch may be more complex, connectors and wires may be required to transmit signals in relation to the gear shifting detection controller and the switch, and insert injection molded components for coupling the gear shifting detection controller and the switch may be required.
[0010] Therefore, in the related art, production cost may increase due to production and assembly processes for providing the gear shifting detection controller and the switch to the configuration for detecting a gear shifting may be complex. Furthermore, since the switch of the related art for detecting whether the mode is converted into the sports mode selectively accommodates a protrusion positioned at one side of the shift lever based on movement of the position of the shift lever, a guide structure inside a coupling aperture for accommodating the protrusion and the accommodated protrusion come into contact with each other, and contact noise may occur between the guide structure and the protrusion.
SUMMARY
[0011] The present invention provides an integrated apparatus for detecting a gear shift in which a switch and a gear shifting detection controller that detects a sports mode of a vehicle may be integrally implemented.
[0012] In addition, the present invention provides an integrated apparatus for detecting a gear shift that detects whether a mode is converted into the sports mode based on a non-contact recognition manner.
[0013] The objects of the present invention are not limited to the aforementioned object, and other objects, which are not mentioned above, will be apparently understood by the person skilled in the art from the following description.
[0014] An exemplary embodiment of the present invention provides an integrated apparatus for detecting a gear shift, including: a switch configured to output whether intensity of a magnetic field is detected, wherein the magnetic field may be generated from a shift lever based on movement of the position of the shift lever, and configured to determine whether to select a gear shifting stage of a sports mode; and a gear shifting detection controller configured to output a result for specifying the gear shifting stage based on a position movement direction and a position movement width by a lower end linkage shaft protrusion of the shift lever.
[0015] The intensity of the magnetic field generated from the shift lever may be generated from a first magnet positioned at an end portion of an upper end linkage shaft protrusion positioned at an upper end of the shift lever. The switch may include a first hall sensor configured to detect the intensity of the magnetic field generated from the first magnet. In addition, the upper end linkage shaft protrusion may protrude to be oriented toward a position of the first hall sensor.
[0016] When the gear shifting stage of the sports mode is selected, the intensity of the magnetic field generated from the first magnet may be set to an intensity at which the magnetic field is able to be transmitted in a spaced distance between the end of the upper end linkage shaft protrusion and the first hall sensor.
[0017] The integrated apparatus for detecting a gear shifting may further include an electronic controller configured to determine a gear shift based on the output result provided from one or more of the switch and the gear shifting detection controller, in which the electronic controller may be configured to determine that the gear shifting stage of the sports mode is selected when the output result from the switch is converted from a state in which the intensity of the magnetic field is not detected into a state in which the intensity of the magnetic field is detected. Further, the electronic control unit may be configured to determine that the gear shifting stage of the sports mode is released when the output result from the switch is converted from a state in which the intensity of the magnetic field is detected into a state in which the intensity of the magnetic field is not detected.
[0018] The gear shifting detection controller may include a rotating member configured to be operated with respect to a position movement direction and a position movement width by the lower end linkage shaft protrusion of the shift lever, a second magnet disposed at one side of the rotating member, and a second hall sensor configured to detect the intensity of the magnetic field generated by the second magnet. The second hall sensor may be disposed in a region where the detection for the intensity of the magnetic field generated by a rotation direction and a rotation amount of the second magnet is maintained at a predetermined ratio or greater. At least one second hall sensor may be disposed in the region.
[0019] Another exemplary embodiment of the present invention provides an integrated apparatus for detecting a gear shifting, including a gear shifting detection controller which may include: a rotating member configured to be operated with respect to a position movement direction and a position movement width by a lower end linkage shaft protrusion of a shift lever, a magnet disposed at one side of the rotating member; and a hall sensor configured to detect intensity of the magnetic field generated by the magnet, wherein when a gear shifting stage, which is specified by a position movement of the shift lever, is divided into a sports mode or an auto-mode, the position movement direction and the position movement width of the gear shifting detection controller by the lower end linkage shaft protrusion of the shift lever may be changed to correspond to the divided sports mode or auto-mode.
[0020] The integrated apparatus for detecting a gear shifting may further include a switch configured to output whether intensity of a magnetic field is detected, wherein the magnetic field may be generated from the shift lever based on movement of the position of the shift lever, and configured to determine whether to select a gear shifting stage of a sports mode. The intensity of the magnetic field generated from the shift lever may be generated from a first magnet positioned at an end portion of an upper end linkage shaft protrusion positioned at an upper end of the shift lever. The switch may include a first hall sensor configured to detect the intensity of the magnetic field generated from the first magnet. The upper end linkage shaft protrusion may protrude to be oriented toward a position of the first hall sensor.
[0021] When the gear shifting stage of the sports mode is selected, the intensity of the magnetic field generated from the first magnet may be set to an intensity at which the magnetic field is able to be transmitted in a spaced distance between the end of the upper end linkage shaft protrusion and the first hall sensor.
[0022] Therefore, in the present invention, a switch and a gear shifting detection controller for detecting a sports mode of a vehicle may be integrally implemented, and whether the mode is converted into the sports mode may be detected based on a non-contact recognition manner, and thus it may be possible to simplify production and assembly processes for providing the gear shifting detection controller and the switch to a gear shifting detection configuration, thereby reducing production costs, minimizing noise generated when a general gear shifting mode is converted into the sports mode, or the sports mode is converted into the general gear shifting mode, and increasing a lifespan of the switch configured to detect whether the mode is converted into the sports mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0024] FIG. 1 is an exemplary view illustrating a front state in which an integrated apparatus for detecting a gear shifting according to an exemplary embodiment of the present invention is mounted;
[0025] FIG. 2 is an exemplary view illustrating a rear structure in which the integrated apparatus for detecting a gear shifting, which is illustrated in FIG. 1 , is mounted according to an exemplary embodiment of the present invention;
[0026] FIG. 3 is an exemplary view illustrating an interior structure of the integrated apparatus for detecting a gear shifting which is illustrated in FIG. 1 according to an exemplary embodiment of the present invention; and
[0027] FIG. 4 is an exemplary view illustrating an interior structure of the integrated apparatus for detecting a gear shifting which is illustrated in FIG. 1 according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0028] Advantages and features of the present invention and methods of accomplishing the same may be understood more readily by reference to the following detailed description of exemplary embodiments and the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art, and the present invention will only be defined by the accompanying claims. Like reference numerals refer to like elements throughout the specification.
[0029] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0030] It will be understood that when an element or layer is referred to as being “on”, “connected to” or “coupled to” another element or layer, it can be directly on, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on”, “directly connected to” or “directly coupled to” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0031] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
[0032] Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0033] It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, combustion, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum).
[0034] Although exemplary embodiment is described as using a plurality of units to perform the exemplary process, it is understood that the exemplary processes may also be performed by one or plurality of modules. Additionally, it is understood that the term controller/control unit refers to a hardware device that includes a memory and a processor. The memory is configured to store the modules and the processor is specifically configured to execute said modules to perform one or more processes which are described further below.
[0035] Furthermore, control logic of the present invention may be embodied as non-transitory computer readable media on a computer readable medium containing executable program instructions executed by a processor, controller/control unit or the like. Examples of the computer readable mediums include, but are not limited to, ROM, RAM, compact disc (CD)-ROMs, magnetic tapes, floppy disks, flash drives, smart cards and optical data storage devices. The computer readable recording medium can also be distributed in network coupled computer systems so that the computer readable media is stored and executed in a distributed fashion, e.g., by a telematics server or a Controller Area Network (CAN).
[0036] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term “about.”
[0037] Embodiments are described herein with reference to cross-section illustrations that are schematic illustrations of exemplary embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, these exemplary embodiments should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle will, typically, have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the present invention.
[0038] 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 the present 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 this specification and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0039] Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0040] FIG. 1 is an exemplary view illustrating a front state in which an integrated apparatus 100 for detecting a gear shifting according to an exemplary embodiment of the present invention is mounted, FIG. 2 is an exemplary view illustrating a rear structure in which the integrated apparatus 100 for detecting a gear shifting, which is illustrated in FIG. 1 is mounted, and FIGS. 3 and 4 are exemplary views illustrating exemplary embodiments of an interior structure of the integrated apparatus 100 for detecting a gear shifting which is illustrated in FIG. 1 . As illustrated, the integrated apparatus 100 for detecting a gear shifting may include a switch 110 and a gear shifting detection controller 120 integrated in a single controller.
[0041] When a position of a shift lever 200 is moved to a gear shifting stage of a sports mode that manually shifts gears vertically in addition to a main gear shifting stage including a parking stage (P), a reversing stage (R), a neutral stage (N), and a driving stage (D), the switch 110 may be configured to detect that the gear shifting stage is changed to the gear shifting stage of the sports mode while being operated together with motion of the shift lever 200 .
[0042] Thereafter, the switch 110 may be configured to transmit to an electronic controller gear shifting stage detection information based on the detection of the change of the gear shifting stage to the gear shifting stage of the sports mode. Specifically, the switch 110 may be fixed to one side of a lower portion of the shift lever 200 , which may be manipulated by a user to shift gears, and may be provided in a shape that stands in a vertical direction of the shift lever 200 . In particular, the switch 110 may be fixed and positioned within a region where the switch 110 may detect the relative movement of the position of the shift lever 200 , and specifically, the position of the shift lever 200 may not be moved forward/rearward (e.g., horizontally) to specify the main gear shifting stage including the parking stage (P), the reversing stage (R), the neutral stage (N), and the driving stage (D), but may be fixed and positioned in the region where the switch 110 may detect whether a gear shifting position is changed to the side, to specify the gear shifting stage of the sports mode instead of the main gear shifting stage.
[0043] In other words, when the position of the shift lever 200 is changed to the gear shifting position for specifying the gear shifting stage of the sports mode, the position of the shift lever 200 may be moved to the gear shifting position for specifying the gear shifting stage of the sports mode to cause a position of an upper end linkage shaft protrusion 210 , which is formed at one side of the lower portion of the shift lever 200 , to be moved in the same direction.
[0044] The upper end linkage shaft protrusion 210 may include a first magnet 211 to allow the switch 110 to detect that the shift lever 200 is positioned at the gear shifting position for specifying the gear shifting stage of the sports mode in a non-contact recognition manner. A position of the first magnet 211 may be disposed at an end side of the upper end linkage shaft protrusion 210 .
[0045] When the upper end linkage shaft protrusion 210 , which may be moved together with the movement of the position of the shift lever 200 for specifying the gear shifting stage of the sports mode, is positioned in a predetermined detection possible region, the switch 110 may be configured to respond to intensity of a magnetic field of the first magnet 211 included in the upper end linkage shaft protrusion 210 . In other words, the switch 110 may include a first hall sensor 111 to detect the intensity of the magnetic field of the first magnet 211 . The first hall sensor 111 in the switch 110 may be disposed at a position where magnetic field may be detected with respect to the detection possible region, and for example, the first hall sensor 111 may be disposed at a region in the switch 110 in which the first hall sensor 111 may be equipped at a minimum distance from the first magnet 211 that is positioned in the detection possible region.
[0046] The detection of the intensity of the magnetic field of the first magnet 211 using the first hall sensor 111 may mean the detection of the change of the position of the shift lever 200 to the gear shifting stage of the sports mode. When the intensity of the magnetic field of the first magnet 211 is detected, the first hall sensor 111 may be configured to transmit the detected sensor signal to the electronic controller. In addition, the upper end linkage shaft protrusion 210 may not be formed at one side of the lower portion of the shift lever 200 . In other words, the aforementioned example is possible by attaching the first magnet 211 to one side of the lower portion of the shift lever 200 , forming a protrusion, which corresponds to the shape of the upper end linkage shaft protrusion 210 , from the switch 110 , and then providing the first hall sensor 111 at an end of the formed protrusion.
[0047] When the position of the shift lever 200 is changed to the gear shifting position for specifying the gear shifting stage of the sports mode, the position of the shift lever 200 may be moved to the gear shifting position for specifying the gear shifting stage of the sports mode to cause a position of the first magnet 211 , which is formed at one side of the lower portion of the shift lever 200 , to be moved in the same direction.
[0048] When the first magnet 211 , which is moved together with the movement of the position of the shift lever 200 for specifying the gear shifting stage of the sports mode, is positioned in a predetermined detection possible region, the first hall sensor 111 of the switch 110 may be configured to respond to the intensity of the magnetic field of the first magnet 211 . The detection possible region may be a peripheral region based on the protrusion of the switch 110 .
[0049] In addition, when selecting the gear shifting stage of the sports mode, to provide a grip feeling to a driver when the shift lever 200 is moved to a neutral control position in the gear shifting stage of the sports mode after performing a ‘+’ gear shift or a ‘−’ gear shift with respect to the gear shifting stage of the sports mode, the switch 110 may have a coupling aperture which selectively accommodates a predetermined shaft of the shift lever 200 in relation to the ‘+’ gear shifting or the ‘−’ gear shifting with respect to the gear shifting stage of the sports mode. In other words, when the ‘+’ gear shift or the ‘−’ gear shift with respect to the gear shifting stage of the sports mode is performed after selecting the gear shifting stage of the sports mode and when the predetermined shaft of the shift lever 200 is inserted into the coupling aperture to provide the predetermined grip feeling to the driver, restraining forces may occurs against the predetermined shaft of the shift lever 200 , which is inserted into the coupling aperture, by elastic repulsive force of an elastic member in the coupling aperture.
[0050] The gear shifting detection controller 120 may be configured to more accurately provide information regarding a type of gear shifting selected by the driver in a manipulation state of the shift lever 200 , to the electronic controller. For example, the gear shifting detection controller 120 may include a DCT (double clutch transmission).
[0051] In addition, the gear shifting detection controller 120 may be implemented as a structure implemented in the form of a single controller together with the aforementioned switch 110 . First, a configuration will be described in which the gear shifting detection controller 120 may obtain information regarding a type of gear shift from a manipulation state of the shift lever 200 .
[0052] When the shift lever 200 is operated to the main gear shifting stage including the parking stage (P), the reversing stage (R), the neutral stage (N), and the driving stage (D), or when the shift lever 200 is operated to perform a vertical gear shift at the gear shifting stage of the sports mode capable of manually shifting gears, a position of a lower end linkage shaft protrusion 220 , which is formed at another side of the lower portion of the shift lever 200 , may also be moved. The movement of the position of the lower end linkage shaft protrusion 220 may be caused by the movement of the position of the shift lever 200 , and therefore the position of the lower end linkage shaft protrusion 220 may be moved forward/rearward (e.g., horizontally) based on the forward/rearward movement of the position of the shift lever 200 .
[0053] Referring to the illustrated configuration, the movement of the position of the lower end linkage shaft protrusion 220 means the movement of the position of the shift lever 200 in a forward/rearward direction, but in particular, observing the movement of the position of the lower end linkage shaft protrusion 220 in view of the side thereof, the position of the lower end linkage shaft protrusion 220 may be moved along a rotation trajectory, which forms an are within an angle in a predetermined range, in consideration with a linkage structure with the gear shifting detection controller 120 . In other words, the gear shifting detection controller 120 may have a rotating member 121 to cause the position of the gear shifting detection controller 120 to be moved together with (e.g., correspond to) the movement of the position of the lower end linkage shaft protrusion 220 .
[0054] The rotating member 121 may be formed in a shape that includes a substantially straight slot of which one side may be open, and by fitting the lower end linkage shaft protrusion 220 into the open one side of the straight-line-shaped slot, the rotating member 121 and the lower end linkage shaft protrusion 220 may be coupled to each other. In other words, the lower end linkage shaft protrusion 220 may remain coupled to the rotating member 121 .
[0055] Thereafter, the position of the lower end linkage shaft protrusion 220 may also be moved along the aforementioned rotation trajectory that corresponds to the gear shifting stage designated by the shift lever 200 , to cause the position of the rotating member 121 to also be moved in the same direction and along the same rotation trajectory as the rotation trajectory along which the position of the lower end linkage shaft protrusion 220 is moved.
[0056] In addition, a second magnet 122 may be formed at any one side of the rotating member 121 , and the rotation trajectory with respect to a specific direction of the rotating member 121 may directly lead to the movement of the position of the second magnet 122 .
[0057] Furthermore, a second hall sensor 123 may be disposed within a region in which the rotation trajectory of the rotating member 121 is formed, such that when the position of the second magnet 122 is moved in the detection possible region of the second hall sensor 123 , the second hall sensor 123 may be configured to detect the intensity of the magnetic field of the second magnet 122 . In particular, the second hall sensor 123 may have a structure configured to detect the intensity of the magnetic field generated by the rotation of the second magnet 122 . The above structure may be a method of allowing a size of the gear shifting detection controller 120 to be compact. In other words, it may be efficient to detect the magnetic field when the second hall sensor 123 is positioned in a region where the intensity of the magnetic field generated by the rotation of the second magnet 122 becomes a maximum, and thus, the second hall sensor 123 may be disposed at an upper side or a lower side of the second magnet 122 based on a plane on which the second magnet 122 is disposed.
[0058] For example, when the second hall sensor 123 is disposed at the upper side of the second magnet 122 , the second hall sensor 123 may be configured to detect the intensity of the magnetic field provided from the second magnet 122 when the rotating member 121 is rotated in a clockwise direction. In addition, the second hall sensor 123 may be configured to detect the intensity of the magnetic field, which is provided from the second magnet 122 when the rotating member 121 is rotated in the clockwise direction, by setting the direction to be a different direction of the magnetic field.
[0059] As another example, when the second hall sensor 123 is disposed at the lower side of the second magnet 122 , the second hall sensor 123 may be configured to detect the intensity of the magnetic field provided from the second magnet 122 when the rotating member 121 is rotated in a counterclockwise direction. In addition, the second hall sensor 123 may be configured to detect the intensity of the magnetic field, which is provided from the second magnet 122 when the rotating member 121 is rotated in the counterclockwise direction, by setting the direction to be a different direction of the magnetic field.
[0060] Furthermore, the second hall sensor 123 may be disposed at both the upper side and the lower side of the second magnet 122 to include a configuration for more precisely determining the intensity and the direction of the magnetic field of the second magnet 122 . The detection of the intensity of the magnetic field of the second magnet 122 by using the second hall sensor 123 means that a type of main gear shifting stage that is manipulated, or a vertical gear shifting performed by the gear shifting stage of the sports mode may be detected, and when the intensity of the magnetic field of the second magnet 122 is detected, the second hall sensor 123 may be configured to transmit the detected sensor signal to the electronic controller.
[0061] For example, when the rotating member 121 is rotated in the clockwise direction by about 5°, the first gear shifting stage may be set, when the rotating member 121 is rotated in the clockwise direction by about 10°, the second gear shifting stage may be set, and when the rotating member 121 is rotated in the clockwise direction by about 15°, the third gear shifting stage may be set.
[0062] As another example, when the rotating member 121 is rotated in the counterclockwise direction by about 15°, the third gear shifting stage may be set, when the rotating member 121 is rotated in the counterclockwise direction by about 10°, the second gear shifting stage may be set, and when the rotating member 121 is rotated in the counterclockwise direction by about 5°, the first gear shifting stage may be set.
[0063] In yet another example, when a reference position of the rotating member 121 is about 10°, the second gear shifting stage may be set when the rotating member 121 is positioned at about 10°, the first gear shifting stage may be set when the rotating member 121 is rotated in the clockwise direction by about 5°, and the third gear shifting stage may be set when the rotating member 121 is rotated in the counterclockwise direction by about 5°.
[0064] In addition, since the present invention provides the integrated apparatus for detecting a gear shifting, in which the switch and the gear shifting detection controller for detecting the sports mode of the vehicle may be integrally implemented, the present invention may be apparently and practically implemented, and therefore the present invention may be industrially applicable.
[0065] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of the present invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the embodiments without materially departing from the novel teachings and advantages of the present invention. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the exemplary embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the accompanying claims. The present invention is defined by the following claims, with equivalents of the claims to be included therein.
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An integrated apparatus for detecting a gear shifting is provide that has a switch and a gear shifting detection controller for detecting a sports mode of a vehicle that are integrally implemented. The apparatus is configured to detect whether the mode is converted in to the sports mode based on a non-contact recognition manner. Therefore, production and assembly processes are simplified for providing the gear shifting detection controller and the switch to a gear shifting detection configuration, thereby reducing production costs, minimizing noise generated when a general gear shifting mode is converted into the sports mode, or the sports mode is converted into the general gear shifting mode. In addition, a lifespan of the switch configured to detect whether the mode is converted into the sports mode is increased.
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INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This disclosure is concerned with drain fittings and drain systems, which may be configured to optimize drain flow, particularly from baths and showers.
Description of the Related Art
[0003] A typical drain from a bath is 1½ inches in diameter, with the connection to waste, such as a sewer pipe, being the same diameter. This standard drain size limits the flow of water and therefore the draining of a bath. The rate of flow is further compromised by restrictions in the drain fitting, such as stopper systems and the like. Attempts to increase the drain size are limited by resistance to deviate from industry standards. More particularly, the reduction in diameter from a larger drain to a tail piece component that is 1½ inches in diameter poses various problems. This leads to connection designs that violate code requirements and provide less than optimal outflow, in view of the initial, larger size in the drain shoe that encourages a particular flow rate that then gets slowed by the reduction in size in the connection between the drain and the waste or sewer pipe. This problem has particular inconvenience for users of walk-in-baths, where the user has to wait for the bath to drain before the door in the walk-in-bath can be opened for exit.
[0004] Therefore, objects of this disclosure include connectors from a drain inlet to a waste or sewer pipe, which pipe has a diameter smaller than that of the drain inlet that, in use, meet local code requirements; and/or have improved flow characteristics over comparable such diameter reduction drains; and/or provide faster drain times for showers and baths than comparable such diameter reduction drains.
SUMMARY OF THE INVENTION
[0005] This disclosure provides a drain fitting having a discharge potion comprising a chamber formed by walls extending between and around an inlet and an outlet, the inlet being wider than the outlet or having a greater cross-sectional area than the outlet and the walls having interior surfaces sloping inwardly between the inlet and outlet.
[0006] The drain fitting can further comprise a connector portion having an outlet opening configured to be connected to a pipe for carrying water flowing through the drain fitting to a sewer system or elsewhere and walls forming a hollow body portion, which is in fluid communication with the outlet opening and the outlet of the chamber of the drain fitting. Conveniently, the walls of the chamber can merge with a wall or the walls of the body of the connector portion, for example around a hole in a wall of the body or by joining the walls of the body in a generally elbow shaped manner.
[0007] The chamber can have a shape that is generally that of a truncated cone.
[0008] The walls of the body portion of the connector portion can form a generally cylindrical shape.
[0009] This disclosure also provides a drain fitting or drain shoe comprising an inlet section having an opening and an outlet section having an opening, the inlet opening being larger than the outlet opening, walls extending around the inlet section and extending towards the outlet section, the walls having inner surfaces forming a generally conical section between the inlet section and the outlet section.
[0010] This drain fitting or drain shoe may further comprise a downstream section comprising an inlet in fluid communication with the outlet section and an outlet for connection to a sewer pipe or the like.
[0011] The drain fittings herein may have a central axis extending between the inlet/inlet section and the outlet/outlet section. The walls between the inlet/inlet section and the outlet/outlet section may be formed symmetrically around that axis.
[0012] The drain fitting herein may have a cable drain operating mechanism. For example, the drain inlet may have a fitting for receiving a pop-up drain filter and/or closure. The drain fitting may contain an actuator for opening and closing such a pop-up. Connected to the actuator may be a cable system for remote operation of a linkage mechanism for moving the actuator up and down. The mechanism may be located in the drain fitting or in a housing attached to of formed integrally with the drain fitting.
[0013] This disclosure also provides low profile drain fittings and drain shoes. These may be particularly suitable for use under showers or baths where space is limited. One way of achieving this where a pipe connector portion extends generally perpendicularly to the axis of the drain inlet is to minimize the length of the walls between that inlet and the walls that form the pipe connector portion.
[0014] Such fittings or drain shoes, as with others disclosed herein, can have interior walls and, optionally, exterior walls that converge or taper towards each other between the fitting or drain shoe inlet and outlet, more particularly about a central axis that extends through the drain inlet.
[0015] This disclosure also provides baths and showers incorporating the drain fittings and drain shoes disclosed herein. For example, this disclosure provides walk-in baths having the drain fittings and drain shoes disclosed herein to drain water from such baths.
[0016] This disclosure also provides a method of enhancing flow through a drain, particularly between a bath or shower and sewer pipe or the like, wherein the drain diameter in the shower or bath is larger than the diameter of the sewer pipe or the like, and in which the flow rate of water from the shower or bath is maximized, despite said reduction in size, by using a drain fitting or shoe described herein.
[0017] This disclosure provides drain fittings or drain shoes and systems containing them, such as drain kits and bath or shower installations that get as much water flowing into the drain tail piece as possible using an enlarged inlet to the drain fitting or drain shoe. The denominal diameter of the inlet to the drain fitting or drain shoe and therefore from the bath or shower is more than 1½ inches, for example, 2 inches, 2¾ inches, 2½ or 3 inches. The drain fittings and drain shoes of this disclosure are designed to satisfy the Universal Plumbing Code.
[0018] Getting as much water flowing into the drain tail piece as possible may be achieved by maximizing the size of the water inlet opening, which tends to negate the effect of structures causing flow restrictions, such as the support and mechanism for the pop up valve, and keeping the tailpiece unobstructed.
[0019] In connection with baths, the high flow characteristics of the drain fittings and drain shoes fill the overflow pipe as much as possible, which minimizes or eliminates air from becoming entrained in the water outflow, thereby providing a head or “tower” of water in the overflow pipe, which contributes to an increased static pressure the drives water into the sewer pipe or the like. With optimal enhanced drain flow, as per this disclosure, the height of the water tower in the overflow pipe may be almost to the level of the water in the bath.
[0020] This head of water, together with the water in the bath provides a gravity driven encouragement for water to flow efficiently out of the tailpiece, and into the sewer pipe or the like.
[0021] These systems may “flood” the drain tail pipe with full capacity gravity pressurized water. These systems typically minimize or substantially eliminate flow restrictions in the drain shoe or drain fitting.
[0022] This may be done in combination with opening up the bath water inlet channel in the drain shoes and drain fittings of this disclosure so that any physical restrictions such as support and the like are located in much larger opening for the bath water inlet into the drain shoe or drain fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Some preferred embodiments will now be more particularly described by reference to the accompanying drawings in which:
[0024] FIG. 1 is a schematic illustration of a drain fitting according to the invention.
[0025] FIG. 2 is a top view of a drain fitting according to the invention.
[0026] FIG. 3 is a top view of another drain fitting according to the invention.
[0027] FIG. 4 is cross-sectional view of the drain fitting of FIG. 3 taken along the line 4 - 4 in the direction shown in FIG. 3 .
[0028] FIG. 5 is a schematic illustration of a bath draining through a drain shoe or drain fitting of this disclosure into a waste pipe and connected to a typical over flow pipe system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Referring to FIG. 1 , there is shown a drain fitting ( 100 ) comprising an inlet ( 101 ) and an outlet ( 102 ) having walls ( 103 ) there between. Inlet ( 101 ) typically has a circular periphery ( 104 ) and may have seated therein a waste plug assembly ( 105 ) with a strainer ( 106 ). Walls ( 103 ) slope gradually inwards from inlet ( 101 ) to outlet ( 102 ), preferably forming a generally truncated conical shape. Walls ( 103 ) merge into the walls ( 107 ) of a generally cylindrical short tube ( 108 ), typically having one end closed at ( 109 ) and the other end open at ( 101 ) having an outlet ( 111 ) to form a drain tail piece having a connector element ( 112 ) for attachment to a sewer or waste pipe (not shown).
[0030] Walls ( 103 ) function to gather water exiting a bath or shower or the like through a relatively large inlet ( 101 ) and, despite the reduction in flow area caused by the smaller cross-sectional area of tube ( 108 ), achieve full capacity flow from that tube.
[0031] Referring to FIG. 2 , there is shown a drain fitting ( 200 ), according to this disclosure. Drain fitting ( 200 ) comprises an inlet ( 201 ) which is generally circular in cross section. Extending across the inlet ( 201 ) is a fitting ( 202 ) for receiving a drain closure (not shown).
[0032] Inlet ( 201 ) communicates with an internal chamber ( 203 ) formed by walls ( 204 ). As shown in FIG. 1 , walls ( 204 ) converge or taper generally downwards towards outlet ( 205 ) to communicate with a tail piece fitting ( 206 ) comprising a cylindrical tube having an outlet ( 207 ) with an enlarged fitting ( 208 ) for connection to a sewer pipe.
[0033] A cable drain mechanism may be provided comprising a cable assembly ( 300 ) and an actuator ( 301 ) located at the bottom of chamber ( 203 ). In a conventional manner, cable assembly ( 210 ) operates actuator ( 211 ) to drive the closure upward and downward so as to open and close the water inlet.
[0034] In FIG. 3 there is shown a low profile drain fitting or drain shoe ( 300 ) comprising a plug assembly ( 301 ) that is intended to fit in the outlet of a shower or bath.
[0035] Plug assembly ( 301 ) comprises a fitting ( 302 ) having a central hole ( 303 ) for receiving a pop-up drain plug (not shown).
[0036] Fitting ( 301 ) provides a circular inlet ( 304 ) for water to flow into when in use draining a shower or bath. Inlet ( 304 ) is in fluid communication with a tail piece ( 305 ) extending generally perpendicularly to the central axis of inlet ( 304 ). Tail piece ( 305 ) comprises a generally cylindrical body ( 306 ) terminating in an outlet ( 307 ) formed by a connector portion ( 308 ), used for connecting to a waste or sewer pipe in a conventional manner.
[0037] The drain shoe in FIG. 3 further comprises a housing ( 309 ) for a cable mechanism (not shown) which can be used to open and close a pop-up closure (not shown). As can be seen in more detail in FIG. 4 , fitting ( 301 ) comprises walls ( 310 ) that taper towards each other forming a generally frusto-conical shape that merges into the cylindrical body of the outflow connector ( 305 ). In order to make this embodiment a low profile drain shoe, wall ( 311 ) adjacent the outlet from the connector ( 305 ) is made relatively short and is substantially shorter than the opposing wall ( 312 ). Walls ( 311 ) and ( 312 ) form a chamber ( 313 ) which houses an assembly ( 314 ) for a pop-up valve (not shown). Adjacent the bottom wall ( 314 ) a connector portion there is provided a passageway ( 315 ) for receiving an actuator mechanism for the pop-up valve (not shown).
[0038] Referring now to FIG. 5 , there is shown a bath ( 500 ) containing water ( 501 ). The bath has an outlet ( 502 ) of which is connected to a drain fitting or drain shoe according to this disclosure ( 503 ).
[0039] A tail pipe ( 504 ) is connected to an overflow pipe ( 505 ) as well a pipe connection ( 506 ) to waste. Bath ( 500 ) has a wall ( 507 ) with a hole ( 508 ) receiving a conventional drain plug pop-up actuator ( 509 ).
[0040] When the Bath ( 500 ) is draining, the water in the bath produces a force on outgoing water. Similarly, water height in the overflow pipe ( 505 ) acts like a “water tower” and applies direct gravity force to the outgoing water in the drain pipe so that ultimately, for example at ( 510 ), the pipe system drains at full flow and gravity force and with preferably little or no trapped air and provide gravity pressure to accelerate the flow of the water into waste, such as a sewer pipe.
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This disclosure provides a drain fitting having a discharge potion comprising a chamber formed by walls extending between and around an inlet and an outlet, the inlet being wider than the outlet or having a greater cross-sectional area than the outlet and the walls having interior surfaces sloping inwardly between the inlet and outlet.
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RELATED CASES
Priority for this application is hereby claimed under 35 U.S.C. § 119(e) to commonly owned and co-pending U.S. Provisional Patent Application No. 60/834,581 which was filed on Aug. 1, 2006 and which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
The present invention relates in general to a gutter shield that is used on a standard gutter for preventing leaves and other debris from entering the gutter. More particularly, the invention pertains to an improved gutter guard or gutter shield that can be easily installed and the gutter easily cleaned.
BACKGROUND DISCUSSION
There are numerous existing patents that show various types of gutter protectors such as illustrated in U.S. Pat. Nos. 2,072,415; 4,032,456 and 4,351,134. One of the drawbacks with existing gutter shield constructions is that they still allow too much debris to enter the gutter. Moreover, with existing gutter protectors there is no effective and easy way of cleaning the gutter without removing the gutter protector. Another drawback to existing gutter shields is that they need to be attached to the roofing and thus possibly create an additional problem of leaks at the attachment points.
Accordingly, it is an object of the present invention to provide an improved gutter shield that blocks most debris preventing it from entering the gutter and yet also provides a convenient means for cleaning out the gutter.
A further object of the present invention is to provide an improved gutter shield that blocks most debris preventing it from entering the gutter and includes means to clean out the gutter without having to dismantle the gutter shield.
Still another object of the present invention is to provide an improved gutter shield that does not require that the shield be fastened to the roofing.
BRIEF SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects, features and advantages of the invention, there is provided a gutter shield that is easily installed at the edge of the roof over the gutter and that blocks the majority of leaves and debris that might otherwise accumulate in the gutter. At the same time, the gutter shield of the present invention allows water to flow to a row of perforations thus allowing the water to flow into the gutter.
In accordance with another aspect of the present invention the gutter shield is provided with a hinged cover or lid to allow easy cleaning of the gutter such as with a garden hose. In accordance with a further aspect of the present invention the gutter shield preferably includes a staggered ridge arrangement that provides some limited diversion of the water as it flows from the roof toward the perforations. In accordance with another aspect of the present invention the gutter shield is provided in predetermined lengths that can be interlocked one to the other. Each length may or may not include a hinged lid for clean-out purposes.
In one embodiment of the present invention there is provided a gutter shield that is for inhibiting debris from entering a gutter while allowing water flow to the gutter, said gutter shield comprising, a plate member having a top edge for engagement with a roof shingle and having a lower edge for engagement with an outer side of the gutter; the plate member having a series of holes therethrough that enable water to flow through the holes to the gutter therebelow; a cover on the plate member that has open and closed positions; the cover being in the open position to enable access to the gutter for cleaning purposes and being in the closed position to enable water to flow over the cover and a hinge to enable the cover to be moved between open and closed positions thereof.
In accordance with other features of the present invention the plate member may include at least a top section that is meant to be disposed under the shingles and a base section that has the holes therein; the plate member may also include an intermediate section that interconnects the top and base sections forming a step therebetween; the intermediate section may extend at an angle of less than 45 degrees to the normal of the top section or at an angle less than 30 degrees; the plate member may include a reversed section including a portion that overlies the base section; the plate member may have diverters that re-direct water flow; the plate member may have end ridges for interlocking between separate sections of the gutter shield; fasteners may be provided for securing the base section to an edge of the gutter and the fasteners may be the only means of securing the gutter shield to the gutter or roof shingles.
Also in accordance with the invention there is provided a gutter shield that is for inhibiting debris from entering a gutter while allowing water flow to the gutter, said gutter shield comprising: a plate member having a top edge for engagement with a roof shingle and having a lower edge for engagement with an outer side of the gutter; the plate member having a series of holes therethrough that enable water to flow through the holes to the gutter therebelow; wherein the plate member includes at least a top section that is meant to be disposed under the shingles and a base section that has the holes therein; and including fasteners for securing the base section to an edge of the gutter.
In accordance with still other features of the present invention the plate member the fasteners may be the only means of securing the gutter shield to the gutter or roof shingles; the gutter shield may further include a cover on the plate member that has open and closed positions, the cover being in the open position to enable access to the gutter for cleaning purposes and being in the closed position to enable water to flow over the cover, and a hinge to enable the cover to be moved between open and closed positions thereof; wherein the plate member may also include an intermediate section that interconnects the top and base sections forming a step therebetween; wherein the intermediate section may extend at an angle of less than 45 degrees to the normal of the top section; wherein the plate member may include a reversed section including a portion that overlies the base section; wherein the plate member may have diverters that re-direct water flow; and wherein the plate member may have end ridges for interlocking between separate sections of the gutter shield.
Also in accordance with the invention there is provided a gutter shield that is for inhibiting debris from entering a gutter while allowing water flow to the gutter, said gutter shield comprising: a plate member having a top edge for engagement with a roof shingle and having a lower edge for engagement with an outer side of the gutter; the plate member having a series of holes therethrough that enable water to flow through the holes to the gutter therebelow; wherein the plate member includes at least a top section that is meant to be disposed under the shingles and a base section that has the holes therein; and wherein the plate member includes a reversed section including a portion that overlies the base section
BRIEF DESCRIPTION OF THE DRAWINGS
It should be understood that the drawings are provided for the purpose of illustration only and are not intended to define the limits of the disclosure. The foregoing and other objects and advantages of the embodiments described herein will become apparent with reference to the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of the present invention incorporating a lid or cover for clean-out purposes;
FIG. 2 is a perspective view of the gutter shield of FIG. 1 showing the lid or cover in an open position;
FIG. 3 is a perspective view of the gutter shield in a section that does not include the lid or cover;
FIG. 4 is a perspective view of the gutter shield alone depicted in FIG. 1 ;
FIG. 5 is a perspective view of the gutter shield of FIG. 4 with the lid or cover opened;
FIG. 6 is a cross-sectional view taken transversely through the gutter shield illustrated in FIG. 1 ;
FIG. 7 is an enlarged cross-sectional fragmentary view showing the hinge arrangement for the cover or lid;
FIG. 8 is a cross-sectional view similar to that shown in FIG. 6 but with the lid or cover in an open position for the purpose of providing access to the gutter;
FIG. 9 is a fragmentary perspective view illustrating the end interlocking of the gutter shield;
FIG. 10 is a cross-sectional view through the gutter shield illustrating the diverters;
FIG. 11 is an enlarged fragmentary cross-sectional view of one of the diverters of FIG. 10 ;
FIG. 12 is a fragmentary perspective view of an alternate embodiment of the gutter shield of the present invention; and
FIG. 13 is a cross-sectional view taken transversely through the gutter shield illustrated in FIG. 12 .
DETAILED DESCRIPTION
A first embodiment of the present invention is illustrated in FIGS. 1-11 . An alternate embodiment is shown in FIGS. 12 and 13 .
In the first embodiment of the present invention there is shown a gutter shield 10 that is illustrated as disposed over the gutter 12 . FIGS. 1 and 2 also illustrate a down spout 14 extending from the gutter 12 . In the perspective view of FIG. 1 , associated with the gutter shield 10 , is a lid or cover 20 that is hinged to the gutter shield by means of a conventional hinge 22 (see FIG. 5 ). The gutter shield and cover may both be constructed of a light weight metal such as aluminum, or could be constructed of a plastic material.
The gutter shield 10 is illustrated in FIG. 1 as provided in separate lengths of, for example, four feet and each may or may not be provided with a clean out cover or lid 20 . The embodiment illustrated in FIGS. 1 and 2 may be considered as illustrating a four foot section with the clean out cover 20 . The embodiment illustrated in FIG. 3 includes a four foot section without any clean out cover. For a long length of gutter, one may use the sections with the clean out cover at either end of the gutter shield arrangement and provide intermediate gutter sections that do not use the cover therein. A normal length gutter can be cleaned with a hose from either or both ends.
In either of the embodiments, the gutter shield 10 is comprised of preferably three separate sections, or as illustrated in the cross-sectional view of FIG. 10 four separate sections. These include a top edge section 40 that is adapted to be disposed under at least one course of shingles 50 . The gutter shield 10 also includes a main top section 42 that the water rolls over as illustrated by the arrows 45 in FIGS. 6 and 8 . As noted in FIG. 10 the sections 40 and 42 are disposed at a slightly different angle one to the other. The flat section 42 is also preferably provided with diverters 43 that are shown in a cross-section in FIG. 10 . These diverters run in the same direction as illustrated in FIG. 1 but are staggered from one row to the next. Each diverter may be in the form of a raised ridge. The cover or lid 20 is also preferably provided with flow diverters 23 of a similar configuration to that described in FIG. 10 . This provides some limited interruption to the water flow so as to reduce splashing as the water flows over the gutter shield surface.
The gutter shield 10 also includes a contiguous intermediate section 44 and a lower terminating section 46 . It is the lower flat section 46 that is provided with a series of holes or perforations 47 through which the water flows into the gutter. Refer to the cross-sectional view of FIG. 6 shown by means of arrows 45 the water flow into the gutter 12 through the perforations 47 . Preferably, a series of perforations as illustrated in FIG. 1 extend along the entire lower section 46 . The perforations or holes 47 are shown disposed in two side-by-side rows. The section 42 , as illustrated in FIG. 10 , is disposed at a rather sharp angle “A” relative to the normal line to the section 42 . This is preferred so that, while the water flows downwardly, the leaves or other debris tends to be expelled away from the gutter shield falling toward the ground. The angle “A” is less than 45 degree and preferably is less than 30 degrees.
The gutter shield, as indicated previously, extends at its top end under a course of shingles. Because the gutter shield is preferably secured at its lower edge, it is noted that the top edge that is inserted under the shingles does not require any securing means such as screws or the like. This is helpful in preventing water leaks that might occur if securing means are used. At its lower end, such as illustrated in FIGS. 1 , 2 and 6 there are provided a series of spacedly disposed machine screws 52 that are used to secure the lower section 46 with the edge 54 of the gutter. FIG. 6 shows the screw 52 attaching the section 46 at its edge to the edge 54 of the gutter with the edge of section 46 under the gutter edge. In an alternate arrangement the edge of the section 46 may be attached by the screw 52 over the gutter edge 54 . The gutter typically is an aluminum or other lightweight metal material and the machine screw 52 is readily drilled through the edge of the gutter and into the gutter shield to secure the gutter shield in place. With this as the primary securing location it is noted that there is no requirement that the gutter shield be attached at the top of the section 40 . The shingles are sufficient to hold the top end of the gutter shield in place.
Another feature of the gutter shield of the present invention is the provision of ribs 60 at opposite ends of each section of the shield. The ribs 60 extend orthogonal to the diverters 43 and enable an interlocking between each of the four foot sections of gutter shield. FIG. 1 illustrates two sections being interlocked at 62 . For this purpose, each section of the gutter shield may slightly overlap the adjacent section with the end ridges interlocking with each other.
In the embodiment illustrated in FIGS. 1 and 2 where there is a cover 20 provided, it is noted that the gutter shield, at sections 42 and 44 is provided with an opening 65 that the cover 20 covers. In this regard also refer to the cross-sectional view of FIG. 8 that shows the opening 65 with the cover 20 in its open position. The cross-sectional view of FIG. 6 illustrates the cover 20 closed over the opening 65 . In the closed position water can run over the cover and toward the perforations 47 . The cover 20 is normally moved to its open position as illustrated in FIG. 8 for the purpose of cleaning out the gutter such as by inserting a hose into the gutter to clean out any remaining debris that might accumulate in the gutter. The cover 20 is useful in enabling the gutter to be easily cleaned so that accumulated debris, mold and/or mildew can be removed without requiring that the structure be dismanted.
A further embodiment of the present invention, similar to that illustrated in FIGS. 1-11 may also include an arrangement in which the entire shield is hinged such as at the location 69 indicated in FIG. 10 . In that instance, then the door 20 illustrated in FIG. 9 is not necessary but instead the entire four foot section is hinged so that it can be lifted and the gutter can be cleaned out. Preferably the end four foot sections are provided with such a hinge while the middle sections may be provided with no hinge. This enables one to have access at the opposite ends of the gutter by way of this hinge arrangement. Refer also to FIGS. 12 and 13 which illustrate the use of a hinge 74 for hinging the entire gutter shield or gutter shield section.
Reference is now made to FIGS. 12 and 13 for a further embodiment of the present invention. This illustrates a gutter shield 70 that has a reversed section as shown in the cross-sectional view of FIG. 13 . This arrangement is particularly advantageous in providing a means for accommodating water flow while at the same time extending the shield so that the leaves or other debris tend to be expelled away from the gutter shield falling toward the ground. Refer to the cross-sectional view of FIG. 13 that shows the overhang of the reversed section relative to the base section of the gutter shield.
In the embodiment of the present invention shown in FIGS. 12 and 13 there is provided a top section 72 that may be disposed under at least one course of shingles without having to be fastened at the shingle end. This embodiment is also provided with a hinge 74 that enables the entire remainder of the gutter shield to be pivoted upwardly to an open position for cleaning or to a closed position for normal use. The hinge 74 connects to the reversed section 76 and downwardly to the base or lower section 78 . Section 78 may be substantially horizontally disposed in use and is provided with a plurality of holes or perforations 79 . The perforations may be provided in a pattern similar to that shown in the first embodiment herein. However, in this embodiment the number of perforations are disposed in three rows rather than the two rows shown in the first embodiment.
In the embodiment shown in FIGS. 12 and 13 the gutter shield is illustrated as hinged at 74 . To avoid screws being placed through the roofing, temporary screws may be used to secure the lower edge of the gutter shield to the edge of the gutter as in the first embodiment described herein. If fasteners are used through the roofing then the lower edge of the gutter shield need only rest on the top of the gutter edge. In this second embodiment the gutter shield may also be provided with diverters and interlock ribs as previously described in connection with the first embodiment. Moreover, in place of the hinge 74 this embodiment may use a separate cover or lid as in the first embodiment for cleaning out the gutter.
Having now described a limited number of embodiments of the present invention, it should now be apparent to those skilled in the art that numerous other embodiments and modifications thereof are contemplated as falling within the scope of the present invention as defined by the appended claims.
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A gutter shield is disclosed that is for inhibiting debris from entering a gutter while allowing water flow to the gutter. The gutter shield includes a plate member having a top edge for engagement with a roof shingle and having a lower edge for engagement with an outer side of the gutter. The plate member has a series of holes therethrough that enable water to flow through the holes to the gutter therebelow. The gutter shield also includes a cover on the plate member that has open and closed positions, the cover being in the open position to enable access to the gutter for cleaning purposes and being in the closed position to enable water to flow over the cover and a hinge to enable the cover to be moved between open and closed positions thereof.
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The present invention relates to image compression, and in particular to image compression techniques utilising vector quantization of image data.
BACKGROUND OF THE INVENTION
A two-dimensional image, which may for example be an individual image or may be a frame of a video sequence, can conveniently be represented in a computer system as a two-dimensional array of numbers where the numbers encode the brightness of a particular pixel to be displayed on a CRT or other display device. For data compression purposes it is often convenient to represent the array of image data in a more coarsely quantized form. After compression the data is stored in less memory space, but this occurs at the cost of a loss of accuracy. Vector quantization is a well-known enhancement which can be applied to image compression so as to obtain significant reductions in the number of bits required to represent a given image in a computer system.
In vector quantization of a two-dimensional image a codebook of reference patches (e.g. relatively small portions of an image taken from one or more “library” images) is constructed. An image to be compressed is partitioned into a number of image patches and a matching (i.e. similar) reference patch is selected for each patch of the original image, from the codebook. The codebook index for each chosen reference patch in the codebook is stored, together with addressing information (giving the positions of the image patches in the original image) to provide a compressed representation of the image. The chosen codebook index for a patch is often referred to as the “compressed encoding” of the patch. Providing that a copy of the codebook is available, an approximation of the original image can be constructed by using the stored codebook indices to recover the required set of reference patches and inserting these into an image frame using the respective stored image patch position vectors.
WO97/16026 describes an improved vector quantization technique which increases the compression ratio which can be achieved in the compressed image. This technique effectively decides what subdivision will be carried out for individual patches of the original image, when selecting matching reference patches i.e. the size and position of the reference patches from the codebook which will be used to replicate a given patch of the original image. This involves selecting from a plurality of compressed encodings that one of the compressed encodings which, when uncompressed and added to a reference data array, gives the biggest improvement therein relative to the original image data array. The method progressively adds to the reference data array the compressed encodings providing the greatest improvements to the reference array, until a predetermined maximum number of bits are present in the compressed representation, or a desired quality level is achieved in the reference image data array.
One disadvantage of the technique described in WO97/16026 is that there can be interaction between the improvements or “gains” of different patches at different scales, with the result that the image compressor has to repeatedly re-evaluate the gains to be had from different patches. A combinatorial explosion of calculation times would be required to try to calculate the best possible combinations of patches, and this is not practical to implement in the compression apparatus. The technique can therefore result in non-optimal selections of patches. Moreover, the compressed image often has a “blocky” appearance due to discontinuities at the edges of adjacent patches.
It is an object of the present invention to avoid or minimise one of more of the foregoing disadvantages.
SUMMARY OF THE INVENTION
According to one aspect of the present invention we provide a method of compressing an array of data entries in the form of digital electrical signals, the array representing a two-dimensional image, the method comprising the steps of:
(a) forming an image data pyramid from the array of data entries, said pyramid having a plurality of layers, a first and lowermost said layer comprising said array of data entries, and each subsequent higher layer comprising a data array representing the image using less data, and having smaller dimensions, than the previous layer; (b) processing each layer of the image data pyramid so as to obtain: a set of compressed encodings for each layer, wherein each said compressed encoding can be uncompressed to provide an approximation of a block of image data derived from a respective layer of the image data pyramid; and a respective quality gain factor associated with each said compressed encoding; (c) creating an ordered list of the compressed encodings, ordered sequentially according to the quality gain factors associated therewith; (d) selecting the compressed encoding associated with the largest quality gain factor and adding this compressed encoding to a compressed representation of the data array; (e) selecting the compressed encoding associated with the next largest quality gain factor and adding this compressed encoding to the compressed representation of the original image data array; and (f) recursively repeating step (e) for the remaining compressed encodings until the number of bits in the compressed representation reaches a predetermined maximum.
The compressed representation to which the compressed encoding with the largest quality gain is added the first time step (d) is carried out is an empty data file. As more and more compressed encodings are added to this (initially empty) data file, the number of bits in the data file (and thus in the compressed representation) increases, until finally the predetermined maximum number of bits is reached (this may, for example, be when an area of memory allocated for the data file is full).
Preferably, step (a) comprises forming a non-differential image data pyramid, having layers 0 to n, from the original image data array, and step (b) comprises:
1) define a “current layer number” i and set i=n−1 where n is the topmost (i.e. smallest) layer of the non-differential pyramid; 2) divide layer n of the non-differential pyramid into a grid of blocks which are, preferably, uniformly sized; determine a compressed encoding for each said block in layer n of the non-differential pyramid, wherein the compressed encoding can be uncompressed to provide an approximation of the block; and determine a quality gain factor associated with each said block in layer n of the non-differential pyramid and its respective compressed encoding; 4) replace each block in layer n of the non-differential pyramid with its respective compressed encoding, in uncompressed form, so as to form a current decompressed image at layer n; 5) form an expanded version of the current decompressed image at layer i+1 such that the expanded version has the same dimensions as the pyramid layer i, and subtract this expanded version from the pyramid layer i so as to form a differential pyramid layer i; 6) divide the differential pyramid layer i into a grid of, preferably uniformly sized, blocks; determine a compressed encoding for each said block in the differential pyramid layer i, wherein the compressed encoding can be uncompressed to provide an approximation of the block; and determine a quality gain factor associated with each said block in the differential pyramid layer i and its respective compressed encoding; 7) replace each block in the differential pyramid layer i with its compressed encoding, so as to form a decompressed differential pyramid layer i; 8) add the decompressed differential pyramid layer i to the expanded version of the current decompressed image at layer i+1, to form a current decompressed image at layer i; 9) subtract one from i (i.e. set i to i−1); 10) recursively repeat steps (5) to (9) until the quality gain factors for the lowermost layer (layer 0 ) of the differential pyramid have been determined.
Alternatively, though not so preferred, step (a) may comprise forming a non-differential image data pyramid from the original image data array, and step (b) may comprise:
1) forming a differential image data pyramid from the non-differential image data pyramid; 2) dividing each layer of the differential image data pyramid into a grid of blocks which are, preferably, uniformly sized, said blocks preferably being the same size on each level of the pyramid; 3) determining a compressed encoding for each block on each layer of the differential pyramid, wherein the compressed encoding can be uncompressed to provide an approximation of the block; and 4) determining a quality gain factor associated with each block on each layer of the differential pyramid and its respective compressed encoding.
The compressed encoding for each said block preferably comprises a codebook index of an entry from a vector quantization codebook, which entry most closely matches the said block. The compressed encoding may additionally include addressing information for the said block specifying the layer of the image data pyramid in which the block is located, and the position vectors defining the position within the layer at which the block is located. Alternatively, and preferably, the compressed encodings are listed in a predetermined order in the compressed representation, such that the position in the original data array (i.e. the address) corresponding to a given encoding determines the position of that encoding in this list. The address for any given encoding can thereby be determined by its position in the list of compressed encodings which makes up the compressed representation.
One advantage of the invention is that because the information at each layer of the image data pyramid corresponds to different frequency bands, the vector quantizations of these layers will only minimally interfere with one another. This allows a simple ordering of all possible gain contributions made by the compressed encodings, to the compressed representation. This in turn allows a straightforward selection of the compressed encodings having the largest quality gain factors, for compiling the compressed representation of the image.
A further advantage of the invention will be appreciated from the following. In some prior art vector quantization techniques for image compression, each block of the original image data array is represented in the computer system as two components: a brightness shift and a codebook entry (i.e. compressed encoding). The brightness shift is added to the codebook entry when reconstructing the image. The advantage of this is that the codebook can be made smaller if it does not have to include the same pattern at a whole range of brightnesses. This speeds up encoding and reduces the memory requirements of the decoder (i.e. decompressor) The disadvantage is that additional information (brightness shift) has to be sent to update each block of the image. In the method of the present invention, at all pyramid levels with the exception of the topmost and thus smallest layer, each block will inherit a background brightness level from the layer above it in the pyramid. The amount of information which must be used to represent each block is thus smaller than in the latter described prior art methods. This, in turn, allows higher compression ratios to be achieved with the present invention, as compared with such prior art methods.
A further benefit of the above-described first and preferred embodiment in which step (b) comprises the above-described steps (1) to (10), is that in that embodiment each lower layer (i) of the pyramid is effectively used to partially compensate for any artifacts introduced by mismatches between the codebook entries and the original blocks of data from the layer above (i+1). There are inevitably artifacts in any codebook based compression scheme where the range of possible variety of the entries in the codebook is less than the range of possible variety of the original data. One artifact that will occur when comparing an enlarged version of a decompressed image as compared to what one would get with simply shrinking and then re-expanding an image is that there will be errors in mean brightness over groups of pixels. Suppose that each layer is half the linear dimensions of the layer below, then a pixel in layer corresponds to 4 pixels in layer i−1. Now if we simply shrunk an image and re-expanded it, this would be equivalent, if we used a naive expansion algorithm, with simply replacing each block of 4 pixels with their average. If the layer above has been vector quantized or otherwise compressed, then the pixel that is expanded to 4 pixels may no longer correspond exactly with the average of the 4 original pixels. Instead, it will have a ‘quantization’ error. Such quantization errors are artifacts that, subject to availability of bits in the compressed data channel, can be corrected in the vector quantized layer below.
Preferably, the invention also provides a method of decompressing the compressed representation of the image data array obtained in the method according to the above first aspect of the invention, so as to obtain a reconstructed image data array, the decompression method comprising the steps of:
(a) forming a reference image data pyramid, having the same number of layers, 0 to n, and each layer having the same dimensions, as the image data pyramid formed in step (a) of the above-described method, in which reference pyramid each data entry is preferably set to mid-grey; (b) using the information in the compressed representation to replace at least some portions of each layer of the reference data pyramid; (c) defining the topmost (smallest) layer n of the reference data pyramid to be the “current” layer (d) expanding the current layer of the reference data pyramid to match (in dimensions) the layer immediately below the current layer in the reference data pyramid, so as to form an expanded version of said current layer, and adding said expanded version of the current layer to said immediately below layer to form an updated version of said immediately below layer; (e) defining the updated version of said immediately below layer to be the current layer; (f) recursively repeating steps (d) and (e) until the updated version of the lowermost layer in the reference data pyramid has been obtained, which updated version of the lowermost layer is the reconstructed image.
An additional advantage of the invention, which will be particularly apparent from the above description relating to the decompression process, is that in the decompressed version of the compressed representation the block boundary artifacts (i.e. blocky appearance) that are often visible when using prior art compression/decompression techniques based solely on block encoding schemes (i.e. without using the image data pyramids according to the present invention) can be avoided as long as suitable interpolation, such as for example linear interpolation, is used during the expansion of the pyramid layers.
According to another aspect of the invention we provide apparatus for compressing an array of data entries in the form of digital electrical signals, the apparatus comprising digital data processing apparatus, conveniently in the form of a computer system set up to run a program embodying the method according to the above-described first aspect of the invention.
According to a third aspect of the invention we provide a computer program product comprising a computer usable medium having computer readable code means embodied in said medium for compressing an array of data entries in the form of digital electrical signals, said computer program product having computer readable code means for carrying out the described steps of the method according to the first aspect of the invention.
BRIEF DESCRIPTION THE DRAWINGS
Preferred embodiments of the invention will now be described, by way of example only and with reference to the accompanying drawings in which:
FIG. 1 illustrates the process of forming a differential image pyramid from a non-differential image pyramid;
FIG. 2 illustrates a linear interpolation technique;
FIG. 3 illustrates a differential image divided into a grid of square blocks;
FIG. 4 illustrates an ordered list stored in a memory;
FIG. 5 illustrates schematically two adjacent layers of an image pyramid; and
FIG. 6 is a schematic diagram illustrating an image compression system according to one embodiment of the invention.
DETAILED DESCRIPTION
It will be understood that the images shown in FIG. 1 are digital images which are each represented, in digital image processing, by a two-dimensional array of data entries, each data entry representing the digital electrical signal at one pixel in a two-dimensional pixel array which displays the image. It will further be generally understood that in the below-described image processing methods it is the arrays of data entries representing each image which are operated on as described.
Uppermost in FIG. 1 is a non-differential image pyramid having three layers 1 , 2 , 3 . The lowermost layer 1 is an original image obtained, for example, as a still frame from a video camera. This original image is used to form the two smaller image layers 2 , 3 , by first effectively shrinking the original image to form a half-scale image at the next layer 2 up in the pyramid, which next layer up is then itself shrunk to produce an image at the uppermost (topmost) layer 3 of the pyramid. The topmost layer of the pyramid is quarter-scale in size, relative to the original image (the lowermost layer 1 ). The larger images in the pyramid contain information that is not present in the smaller ones. The formation of such image pyramids is well known in the arts of computer vision and image processing, and one technique is described, for example, in “Structured Computer Vision, S Tanimoto & A Klinger, Academic Press 1980. Various techniques are nevertheless known for forming a non-differential image pyramid and any of these may be used to form the pyramid of FIG. 1 .
Lowermost in FIG. 1 are three image layers 6 , 7 , 8 in a differential image pyramid formed from the non-differential image pyramid layers 1 , 2 , 3 . The full and half scale images in the differential pyramid are formed by subtracting enlarged versions 4 , 5 of the half and quarter scale images (i.e. the two uppermost layers 2 , 3 are enlarged to full and half scale size respectively) from the full and half scale images (the two lowermost layers 1 , 2 ) respectively in the non-differential image pyramid, as illustrated in FIG. 1 . When enlarging the image from one layer to another, some appropriate smoothing interpolation is performed, for example a bi-linear or bi-cubic interpolation. Bi-linear interpolation, where interstitial pixels are formed as the average of the pixels which surround them, is illustrated in FIG. 2 in which the large circles with labelled co-ordinates represent pixels in an image of size N and the small circles represent the pixels in an image of size (2N)−1 that are derived from them by bilinear interpolation when the image in layer of size N is expanded to twice its size. Thus small circle a is the average of pixels (0,0) and (1,0), b is the average of pixels (1,0) and (1,1) whilst e is the average of all of the larger pixels.
The topmost layer 8 in the differential pyramid is the same image as the topmost layer of the non-differential pyramid. Again, the processes for forming differential pyramids are well known in the computer vision arts, and are described for example in the above-mentioned reference “Structured Computer Vision”. It should be noted that the difference images (i.e. the two lowermost layers 6 , 7 ) in the differential pyramid contain information up to a certain frequency. This is the same frequency for the two difference images and will in general be in the range between the Nyquist limit to just above half the Nyquist limit for the scale at which they are represented. Since each image is half the size of the previous one, this means that each contains information corresponding to roughly half the frequency of the previous one. (The information will not be at exactly half the frequency since the process of expanding the smaller image before subtracting it from a larger one may introduce artifacts in frequency space.)
FIRST EMBODIMENT OF THE COMPRESSION METHOD
We now propose an improved process for the vector quantization of video data using the above-described pyramids. The method steps are as follows:
1. Form a non-differential image pyramid from an original video image (as described above); 2. Convert this to a differential image pyramid (as described above); 3. Divide each layer of the differential pyramid into a grid of uniform sized rectangular “patches” as shown in FIG. 3 . The patches are the same size on each layer of the pyramid. In the embodiment illustrated in FIG. 3 , a differential pyramid image layer is shown divided into a grid of 7×7 square patches. 4. For each patch in each layer determine the codebook entry, from a vector quantization codebook, that best matches it; 5. For each patch and its corresponding vector quantization codebook entry determine the quality gain G as follows:
G = ∑ i = 0 n ∑ j = 0 n ( P ij ) 2 - ∑ i = 0 n ∑ j = 0 n ( P ij - C ij ) 2
Where Pij stands for the pixels in the patch and Cij the corresponding pixels in the codebook entry. This can also be represented as: G=S−R where
S = ∑ i = 0 n ∑ j = 0 n ( P ij ) 2
represents the total energy of the image within the patch, and
R = ∑ i = 0 n ∑ j = 0 n ( P ij - C ij ) 2
represents the energy of the residual error within the patch after it has been subjected to the compression and decompression process. Thus, the total gain G is G=S−R i.e. gain G is the source energy S minus residual error. It will be appreciated that this gain measure G is based upon the squared error values since we are assuming that pixels are represented as signed real numbers with 0 representing mid gray. The codebook indices for each patch and the associated gains G are stored in memory locations reserved therefore in a single general purpose memory bank used for all the data which needs to be stored permanently or temporarily.
6. Form an ordered list of the patches based upon their associated gains, as illustrated in FIG. 4 , the list being ordered such that the patches are sequentially ordered according to ever decreasing gain, with the patch having highest gain G being first in the list. Techniques for forming such lists are well known. See, for example, “Fundamental Algorithms”, D. Knuth, Addison Wesley publishing 1975. 7. Add the codebook index for the patch having the highest gain G, along with appropriate addressing information of the patch, into an empty data file, thereby forming an initial compressed representation of the original image. The addressing information specifies the layer of the pyramid and the co-ordinates (i.e. position co-ordinates) within the layer at which the patch occurs. We refer to the chosen codebook index for the patch as the “compressed encoding” of the patch; 8. Continue to add the compressed encodings for the patches successively lower in the ordered list (i.e. according to decreasing gains G) to the compressed representation data file until the number of bits in the compressed representation reaches some pre-determined limit set by the compression ratio.
Methods for creating codebooks and searching them are well known in the art. The technique used in the present invention in this regard are the same as those used and described in WO97/16026.
The Decompression Method
To decode the compressed representation we proceed as follows.
1. Form an image pyramid of the appropriate size (i.e. same number of layers and size of layers as used in the compression method) all of whose pixels on all of whose layers are set to mid grey (0 in the present embodiment) 2. Using the information in the compressed representation replace each patch in the pyramid for which there is a compressed encoding in the compressed representation with the corresponding code book entry. 3. Take the topmost layer of the pyramid, expand the image in size until it is the same size as the layer below. 4. Arithmetically add each pixel in the newly expanded topmost layer to the corresponding pixel in the second from top layer, placing the result of the addition in the corresponding pixel in the second from top layer. 5. Delete the topmost layer of the pyramid, so that the formerly second from top layer becomes the top layer. 6. Repeat steps 3 to 5 until there is only a single layer left in the pyramid. This is then the reconstructed image.
SECOND AND PREFERRED EMBODIMENT OF COMPRESSION METHOD
In a second and preferred embodiment of the invention, the method for compressing an original video image has the following steps:
1. Form a non-differential image pyramid with layers 0 to n, where n is the topmost, and therefore smallest, layer of the pyramid. 2. Allocate a buffer to hold the current representation of the decompressed image, call this buffer B. 3. Allocate a buffer to hold the current differential pyramid layer, in uncompressed form (i.e. not ever compressed and then decompressed), and call this buffer C. 4. Allocate a buffer to hold the current decompressed “differential” pyramid layer, call this buffer D. 5. Allocate a register to hold the current layer number, i, call this register i, and initialise this to i=n−1 6. Copy into C layer n of the pyramid. 7. Divide layer n in C into a grid of uniformly sized rectangular “patches” and for each patch in C find the best matching codebook entry and calculate the gain G associated therewith, using the same formula for the gain G as in step (5) of the first compression method, described above Then place the co-ordinates of this patch, the codebook index for the best matching codebook entry, and the associated gain G calculated therefor, in an empty data file the contents of which will become an ordered list as in step (6) of the first compression method as described above. 8. Place into buffer D a decompressed image formed by replacing each patch in C with the corresponding code book entry (i.e. the best matching codebook entry found therefor in step 7). 9. Copy contents of buffer D into buffer B. 10. If the current layer number i in register i is less than zero go to step 17. 11. Expand the image in B until it is the same size as the image in layer(i), using an appropriate interpolation technique as before, and placing the expanded result back in buffer B. 12. Subtract image B from layer(i) and store the result in buffer C. 13. Divide the image in buffer C into a grid of uniformly sized rectangular patches of the same size as in step 7 above; for each patch in C find the best matching codebook entry, and calculate the gain G associated therewith using the same formula as before; and place the coordinates of this patch, the codebook index of the best matching codebook entry therefor, and the associated gain G therefor, in the ordered list started in step 7 above. 14. Place into buffer D an image formed by replacing each patch in C with the corresponding codebook entry. 15. Add buffer D to buffer B. 16. Subtract 1 from register i and go to step 10. 17. Traverse the ordered list of codebook indices (ordered according to decreasing gain G), placing the codebook indices having the highest gains G into an empty data file, sequentially in order of decreasing gain G (thereby creating a compressed representation of the original image, of increasing bit size) until the data file (and hence the compressed representation) is of a predetermined size (i.e. number of bits).
In either of the above-described compression methods, the codebook indices for the selected patches of high gain G are placed in the compressed representation data file in a predetermined order according to the respective addressing co-ordinates associated therewith. In this manner it is not necessary to also store the addressing co-ordinates in the compressed representation itself: the order of the codebook indices (these are the “compressed encodings” for the related patches) gives the required addressing information for each compressed encoding.
The compressed representation of the original image is thus made up of a series of “codewords”, each codeword consisting of a compressed encoding of a patch. This predetermined order in which the compressed encodings are listed can be chosen from a number of possible orders. For example, the compressed encodings can be stored in “layers” i.e. all the encodings for one layer, followed by all the encodings for the next layer etc. Alternatively, the encodings may be stored recursively, as follows:
Assume that we are considering a local region x on layer i of the image pyramid such that region x can be compressed with a single vector quantization codeword. We denote the vector quantization codeword for x as CodeWord(x). Suppose further that for all i≧1 on layer (i−1), that is to say, the layer immediately below layer i on the image pyramid, the region of the image that corresponds to the region x on layer i, is composed of a rectangle of subregions A, B, C, D as shown in FIG. 5 .
The codeword sequence generated for region x and all regions below it in the pyramid we denote by CodeSeq(x). We define it as follows:
if x is on the lowest layer of the pyramid then codeseq (x)=CodeWord (x), otherwise
CodeSeq (x)=CodeWord (x) CodeSeq (A) CodeSeq (B) CodeSeq (C) Codeseq (D)
A recursive order of this type is likely to be preferred where runlength encoding is to be employed in the data handling. However, other suitable orders could alternatively be used, with or without runlength encoding methods.
To decompress the compressed representation in order to obtain the reconstructed image, the same decompression method (steps 1 to 6) is used as already described above.
It will be appreciated that the advantage of the second and preferred compression method is that each lower layer of the pyramid is able to partially compensate for artifacts (i.e. errors) introduced by mismatches between the chosen codebook entries and the associated original rectangles (patches) in the layer above, by performing the encode/decode process at the layer above and taking the result into account when obtaining the compressed encodings for the layer below.
When the bandwidth for the compressed representation is restricted, then vector quantization data for only a subset of all the possible patches in the pyramid will be stored in the compressed representation e.g. a subset consisting of the chosen encodings having highest gain, as described above. In this case it is still possible to use the position of a codeword in the compressed representation to provide implicit addressing information for that codeword. However, in this case the above-described method for recursively storing the compressed encoding is modified so that CodeSeq(x) is now defined as:
if the compressed representation contains no codebook index for position x and there are no codebook indices for positions below x in the pyramid then output bit 0 ;
if the compressed representation contains no codebook index for position x but it does contain information for one or more of the positions in the pyramid below position x then output bits 10 followed by CodeSeq(A) CodeSeq(B) Codeseq(C) CodeSeq(D);
if the compressed representation contains a codebook index for position x in the pyramid then output bits 11 followed by
CodeWord(x) CodeSeq(A) CodeSeq(B) Codeseq(C) CodeSeq(D).
Apparatus for carrying out the above-described first embodiment of the compression method is illustrated schematically in FIG. 6 which shows the original image I stored in a first buffer RAM 10 . A microprocessor 20 programmed to carry out all the image data processing operations has read access to the first buffer RAM 10 and has read and write access to a series of image buffer RAMS 12 a , 12 b , 12 c , 12 d for storing the differential image pyramid layers respectively ( FIG. 6 illustrates the case where there are four layers in the differential image pyramid, the top-most layer consisting of the original image I). The microprocessor 20 also has write access to an output buffer 30 into which the compressed representation of the original image is stored. In the second and preferred embodiment of the compression method described above, the image buffer RAMs 12 a , 12 b , 12 c , 12 d are used for storing the layers of the non-differential image pyramid and the microprocessor 20 also has read and write access to three temporary working buffers B, C, D (shown in broken line) which are the buffers allocated to hold the current representation of the decompressed image, the current differential pyramid layer, and the current decompressed differential pyramid layer, respectively (see steps 2, 3 and 4 of the second and preferred method).
It will be appreciated that various modifications to the above-described embodiments are possible without departing from the scope of the invention. For example, pyramids having more than three layers could be used. In practice we envisage that approximately ten pyramid layers will be provided.
It will also be appreciated that the feature of storing the compressed encodings in the compressed representation in a predetermined order which is used to indicate the addressing information for each encoding is best suited for compression applications where full image frames are continually being compressed, sent, received and decompressed e.g. in high bandwidth video. However, where only a portion of a full frame is changing/being updated (e.g. in low bandwidth video) it is likely to be preferable to send particular addressing information for the compressed encodings relating to the changing/updated image portion. In this case, therefore, the compressed representation may also contain the addressing co-ordinates for some or all of the compressed encodings therein.
Furthermore, while in general the use of patches of uniform size and shape throughout the image pyramids is preferred in order to keep the size (i.e. no. of entries) of the codebook to a minimum, patches of different size and/or shape could be used at different layers, or even within a layer, of the pyramid (this would necessarily require a larger codebook). Moreover, it may be desirable to choose the shape of the patches to match the shape of the original image e.g. rectangular patches for a rectangular image. However, one could alternatively first change the shape of the original image (e.g. from rectangular to square) and then use a desired shape of patches (e.g. square).
Where the images are colour images it will be preferable to send all the colour data (e.g. red, green and blue components) adjacently (i.e. in immediate succession) for each pixel, rather than sending e.g. all red components for all pixels, all green components for all pixels, all blue components for all pixels. Thus, for colour images we assume that each image layer within the pyramid is made up of three planes holding the three respective colour components of the image. These can be either red, green, blue or some other suitable tristimulus encoding of colour data. We define CodeWord(X) to be given by the sequence CodeWord(Xr) CodeWord(Xg) CodeWord(Xb)
Where Xc with c ranging over the set {r, g, b} stands for one of the different colour planes that corresponds to region X of the layer.
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A method of compressing an image is described in which digital data signals in a 2-dimensional images are formed into an image data pyramid with a number of layers and each layer is processed to give a compressed encoding in an ordered list. The encoding with the largest quality gain factor is selected first and added to a compressed representation of the data array. This is repeated for the next largest gain factor and so on until a predetermined maximum is reached. Each layer of the image data pyramid corresponds to different frequency bands, the vector quantizations of these layers will only minimally interfere with one another. This allows a simple ordering of all possible gain contributions made by the compressed encodings, to the compressed representation. This in turn allows a straightforward selection of the compressed encodings having the largest quality gain factors, for compiling the compressed representation of the image.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates generally to one or more methods, compositions of matter, and or apparatuses useful in suppressing dust releases such as those from mineral supplement material.
[0004] Mineral supplements, like many hard crystalline materials tend to contain fines or to be friable and form fines, and these fines can be a dust releasing nuisance and therefore require dust control. These dust nuisances can create significant health, environmental, and safety problems.
[0005] Dust control methods are practiced in many industries handling such solids. For example, during the production of dry granular fertilizer certain mechanical conveyance steps may generate small particles of fertilizer that can be transported to undesirable locations by stray air currents. Worse, if the particle size is small enough the dust can remain suspended in the air for extended periods of time exacerbating these problems. As a result, a number of dust control technologies have been developed.
[0006] In addition, the properties and end uses of mineral supplement further complicate this situation. Because mineral supplements are directly applied in open environments to plant life and those plants in turn may be consumed by animals or humans, many effective dust control agents must also be non-toxic. Therefore, it is important that the environmental and dietary safety of additives should be considered, In addition dust control agents may not interact with the mineral supplement in any manner which would impair the benefit of the mineral supplement to the plant such as detrimentally changing pH or any other chemical property. Another category of chemicals used in dust control are asphaltenes or heavy petroleum based materials; unfortunately because they contain aromatics and because of other purity issues additives including them often pose health and environmental problems. Also many of these compositions can require cumbersome and dangerous heating systems just prior to their application.
[0007] As a result there is ongoing need and clear utility in a novel improved method and/or composition and/or apparatus for reducing dust release from mineral supplement. The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “Prior Art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 CFR. § 1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
[0008] At least one embodiment of the invention is directed towards a method of reducing the release of dust from a mass prone to release dust. The method comprises the step of: contacting the mass with a composition comprising a polymerized organic acid.
[0009] The polymerized organic acid may be constructed from monomers selected form the list consisting of hydroxy fatty acids such as: ricinoleic acid, 12-hydroxystearic acid, and any combination thereof. The polymerized organic acid may be a copolymer which also comprises glycerol repeating units, the glycerol. repeating units being one of monoglycerol, diglycerol, triglycerol, and any combination thereof. The polymerized organic acid may be a block copolymer comprising a first chain consisting essentially of repeating polymerized organic acid repeating units and a second chain consisting essentially of repeating glycerol units, the first chain and the second chain being linked by an ester bond. The first chain may have an n value of more than 2. The polymerized organic acid may be a block copolymer comprising a first chain consisting essentially of repeating ricinoleic acid repeating units and a second chain consisting essentially of repeating glycerol units, the first chain and the second chain being linked by an ester bond. This block copolymer may have a first chain with an n value of more than 100.
[0010] The polymerized organic acid may also comprise alkoxy groups (such as ethoxy or propoxy) or repeating units thereof. The composition may be applied as a liquid, foam, dispersion, or an emulsion. The mass may be prone to release dust is an aggregation of mineral supplement, mined materials, synthesized dry materials, fertilizer, coal, wood chips, agricultural products, fruit, aggregates, fine materials, potash, phosphate, road dust, and any combination thereof. After the mass has been treated, the mass may be prone to release dust but will have a reduction in released dust that will persist indefinitely (possibly essentially permanently).
DETAILED DESCRIPTION OF THE INVENTION
[0011] The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
[0012] “Mineral Supplement” means a composition of matter characterized as being predominantly made up of materials which function as a form of animal feed and/or dietary supplement and/or nutritional supplement for consumption by an animal and/or which functions as a fertilizer for plants. Fertilizers are predominantly made up of inorganic substances, primarily salts and are in a form which increases the nutrients absorbed by plants. Fertilizers greatly affect the soil (its physical, chemical, and biologic properties) and plants. In soil, fertilizers undergo various changes that influence the solubility of their nutrients, their permeability, and their availability to plants. Fertilizers include direct plant nutrients (N, P, K, Mg, B, Cu, Mn) such as nitrogen fertilizers (ammonium, sodium, and calcium nitrates; ammonium sulfate; urea), phosphorus-supplying fertilizers (superphosphate, ground rock phosphate, ammonium and calcium phosphates), potassium fertilizers (potassium chloride, 30 and 40 percent potassium salt, potassium sulfates, potassium nitrate), and micronutrient fertilizers. Indirect fertilizers improve the agrochemical and physiochemical properties of soil and activate nutrients (for example, lime fertilizers and gypsum).
[0013] “Ricinoleic Acid” means a composition of matter which is an organic acid and may be according to the formula (as well as any steroechemical isomers thereof) of:
[0000]
[0014] “Polyricinoleic Acid ” means a composition of matter which is characterized as being a polymer comprising a number of ricinoleic acid repeating units linked by ester bonds between the hydroxyl group along the fatty chain and the proton donating acid oxygen, the repeating units may be according to the formula (as well as any steroechemical isomers thereof) of:
[0000]
[0000] wherein n is the n value which is a number greater than 1.
[0015] “Polymerized Organic Acid” means a composition of matter characterized as being a polymer comprising ester linked repeating units in which the repeating units have a C4-C100 fatty chain along which are both at least one hydroxyl group and at least one end of at least one of the carboxylic acid group.
[0016] “Fatty Chain” means a portion of a repeating unit characterized as being a series of bonded carbon atoms in one or more arrangements selected from: alkyl, straight chain alkyl, branched alkyl, aryl, cyclo, phenyl, benzyl, cyclic, dendritic, and any combination thereof.
[0017] In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk - Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
[0018] In at least one embodiment of the invention a composition of matter is added to a mineral supplement material and/or a material prone to release dust. The composition comprises a polymerized organic acid. The application of the composition reduces the tendency of the mineral supplement material to release dust. In at least one embodiment the composition is applied to the material as a liquid. In at least one embodiment the composition is applied to the material as foam, In at least one embodiment the composition is applied to the material as dispersion. In at least one embodiment the composition is applied to the material as an emulsion.
[0019] Mineral supplement granules produce large amounts of fugitive dust. This is because ultra-fine mineral supplement particles are so light that they can be suspended and travel aloft when contacted by moving air, Mineral supplement commonly becomes ultra-fine due to excessive grinding or due to attrition of the delicate mineral supplement masses during processing or handling.
[0020] The effectiveness of the invention was quite surprising and in light of the teachings of the prior art the invention displays unexpected results.
[0021] In at least one embodiment the polymerized organic acid comprises repeating units of organic acids containing one or more hydroxyl. functional groups selected from the list consisting of:, ricinoleic acid, 12-hydroxystearic acid, and any combination thereof.
[0022] Fatty acids able to form polymerized fatty acids as defined above have to have at least one hydroxyl group in the carbon chain. A representative list of suitable hydroxy group bearing fatty acids can be found are listed on the website: http://www.lipidmaps.org/data/structure/LMSDSearch.php?Mode=ProcessClassSearch&LMID=LMFA0105&s=hydroxy fatty acids. (As accessed on Nov. 8, 2013)
[0023] In at least one embodiment the polymerized organic acid also comprises glycerol repeating units and can therefore also be considered a species of polyglycerol.
[0024] In at least one embodiment the polymerized organic acid also comprises alkoxy groups (such as ethoxy or propoxy) or repeating units thereof.
[0025] Without being limited by a particular theory or design of the invention or of the scope afforded in construing the claims, it is believed that the particular structure of the polymer is what affords the composition it unexpectedly high effectiveness as a dust control agent. Polymerized organic acids have large numbers of moderately polar ester bonds embedded within largely non-polar fatty region of the polymer. This allows for the formation of unique surface-surface interactions between the polymerized organic acid and the particulate matter. In addition they have just the right molecular weight to induce the formation of agglomerations that are massive and therefore resistant to airborne dispersal.
[0026] Polymerized organic acids may be produced from oleochemicals. Oleochemicals are chemicals derived from plant and animal fats. Most plant and animal oils are glycerides of mixtures of fatty acids. A glyceride is the reaction product of a carboxylic acid and glycerol. Often oleochemicals are formed by taking natural substances like fatty acids, fatty acid methyl esters (FAME), fatty alcohols, fatty amines and glycerols and performing various chemical and enzymatic reactions such as hydrolysis, and/or transesterification.
[0027] As described in the Trade Sheet “Production and Uses of Key Castor Oil Oleochemicals”, Oleochemicals have been used for quite some time in various industries as lubricants, caulks, sealants, paint binders, adhesives, anti-static agents, and varnishes, As described in International Patent Application WO 2006068627 they have been used as an anti-caking agent in rubber manufacturing. They however have not been polymerized and then used as dust control agents for mineral supplements.
[0028] Japanese Patents Publication JP 2011094007 discloses a dust control agent containing water-swellable particles which includes a poly(ricinoleic acid)-polyoxyethylene block copolymer. In at least one embodiment the polymerized organic acid excludes the presence of oxyethylene monomers. In at least one embodiment the polymerized organic acid is a homopolymer and excludes the presence of copolymers and/or heteropolymers.
[0029] U.S. Pat. No. 5,443,846 describes the use of poly(ricinoleic acid) as a binder in a delayed release drug. This however is the opposite of the use in the invention because it is not used to delay release but to bind the mineral supplements indefinitely. In at least one embodiment the polymerized organic acid is so dosed as to not allow for the timed release of the treated material.
[0030] In at least one embodiment the polymerized organic acid has an n value of between 1 and 1000 (or higher). In at least one embodiment the polymerized organic acid has a molecular weight of between 1000 (or lower) and 1,000,000 Dalton (or higher).
[0031] Materials prone to release dust to which the polymerized organic acid may be applied include but are not limited to mined materials, synthesized dry materials, fertilizer, coal, wood chips, agricultural products, fruit, aggregates, fine materials, potash, phosphate, road dust, and any combination thereof.
[0032] In at least one embodiment the polymerized organic acid is used according to the methods and/or alongside the compositions for dust control described in U.S. patent application Ser. Nos. 12/356,352 and 13/826,385.
EXAMPLES
[0033] The foregoing may be better understood by reference to the following examples, which is presented for purposes of illustration and is not intended to limit the scope of the invention.
[0034] Laboratory analyses were conducted on samples of monoammonium phosphate which is a material prone to releasing fugitive dust. The monoammonium phosphate was treated with various polymerized organic acids as well as other materials for comparison. Table illustrates the results.
[0000] TABLE 1 Fugitive % Dust TEST Dust (ppm) Reduction Test #1 Untreated 5830 0% Polyricinoleic acid 4 lb/ton 889 85% Polyricinoleic acid polyglycerol copolymer 810 86% 4 lb/ton Test #2 Untreated 3785 0% Polyricinoleic acid 4 lb/ton 342 91% Polyricinoleic acid polyglycerol copolymer 382 90% 4 lb/ton Heavy Petroleum 4 lb/ton 374 90% Test #3 Untreated 6144 0% Polyricinoleic acid 4 lb/ton 1117 81% Polymerized linseed oil resin 4 lb/ton 3797 38% Test #4 Untreated 4711 0% Poly(12-hydroxystearic acid) 4 lb/ton 856 82%
The reduction in fugitive dust levels demonstrated the efficacy of various additives. Compared to a heavy petroleum based coating, the materials disclosed herein provided equal or better dust control performance while eliminating the use of petroleum derived materials. Compared to a polymerized linseed oil resin, polyricinoleic acid provided significantly improved fugitive dust control.
[0035] While this invention may be embodied in many different forms, there described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein and/or incorporated herein. In addition the invention encompasses any possible combination that also specifically excludes any one or more of the various embodiments described herein and/or incorporated herein.
[0036] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. The compositions and methods disclosed herein may comprise, consist of or consist essentially of the listed components, or steps. As used herein the term “comprising” means “including, but not limited to”. As used herein the term “consisting essentially of” refers to a composition or method that includes the disclosed components or steps, and any other components or steps that do not materially affect the novel and basic characteristics of the compositions or methods. For example, compositions that consist essentially of listed ingredients do not contain additional ingredients that would affect the properties of those compositions. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0037] All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of“1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.
[0038] All numeric values are herein assumed to be modified by the term “about,” whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure. Weight percent, percent by weight, % by weight, wt %, and the like are synonyms that refer to the concentration of a substance as the weight of that substance divided by the weight of the composition and multiplied by 100. Percentages and ratios are by weight unless otherwise so stated.
[0039] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. All chemical structures provided in this application contemplate and include every possible stereo isomers, conformational isomers, rotational isomers, and chiral alternative of the specific illustrated structure.
[0040] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to he encompassed by the claims attached hereto.
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The invention is directed towards methods and compositions for preventing dusting problems in mineral supplement. The method involves treating the mineral supplement or a dust releasing material with a composition comprising polymerized organic acid.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a trailing device in trailing art, more especially, to a trailer system for inspecting a vehicle and an inspection system having the same which are widely used in radiation imaging inspection.
[0003] 2. Description of the Related Art
[0004] Trailers are always used in radiation imaging inspection. The radiation imaging inspection is indispensable for customs, civil airport and railway station. A system used in radiation imaging inspection is normally operated as follows: a radiation source and detector arrays capable of receiving detecting rays penetrating through a vehicle to be inspected are provided in a detecting passage that can shield rays; the vehicle to be inspected is trailed through radiating beams for inspection by a special trailing device. And the system generally comprises subsystems such as an accelerator, a detector, a image acquiring and scanning device, and a running and inspecting device. During inspection, the vehicle to be inspected rapidly passes through the scanning passage, which is essential to the radiation imaging inspection. In prior art, the special trailing device includes a flat car and various trailing bogies etc.
[0005] Chinese Patent No.CN00107480.6 discloses an automatic flatcar for a fixed container inspection system. During inspection, the vehicle to be inspected is driven onto the automatic flatcar. Longitudinal and horizontal travel mechanisms are installed at the bottom of the automatic flatcar, and the travel mechanisms circulate or reciprocate on rectangular rails so that the vehicle to be inspected is smoothly transmitted through the scanning passage. However, the automatic flatcar has following disadvantages: it has to bear total weight of the vehicle to be inspected including the cargo. In addition, the automatic flatcar has a large vehicle body with complex structure, which leads to high cost and maintenance fees.
[0006] On the other hand, Chinese Patent No.CN200310100184.0 discloses a trailer for a radiation imaging trailer system. The trailer comprises a vehicle frame, vehicle wheels and turning plate mechanism etc. During working, the trailer only drags front wheels of the vehicle to be inspected, and the rear wheels follow accordingly. There is climbing slope and a declining slope at both ends of the vehicle frame, and a turning plate mechanism on the vehicle frame. During inspection, the turning plate abuts against the front wheels of the vehicle to be inspected, and the vehicle to be inspected is dragged through the scanning passage by the trailer. According to the solution disclosed therein, when the vehicle to be inspected runs away from the trailer, since, on one hand, the turning plate is opened, it may scrap the chassis, oil tank etc. at the bottom of the vehicle to be inspected. On the other hand, since the climbing and declining slopes are provided on the trailer, the length of the trailer is not enough for structural restraints, for the vehicle to be inspected having longer wheelbase, the front wheels has left the trailers whereas the rear wheels thereof has not left the trailers yet during unloading of the vehicle to be inspected, which may arouse phenomena as vehicle riding over the trailer. In addition, this may also leads to the chassis to be inspected and the bottom attachments being scrapped by the trailer easily, thus the vehicle to be inspected is damaged, which may further influence the normal working of the radiation imaging system. Therefore, the invention thereof reduces the reliability of the system when used for the radiation imaging system. Especially, the invention is not adapted for trailing heavily loaded vehicle with low chassis and long wheelbase.
SUMMARY OF INVENTION
[0007] In view of the above disadvantages in the conventional art, it is an object of the present invention to provide a trailer system for inspection system trailing vehicle to be inspected with various loads safely through a scanning passage etc. The trailer system can bear heavy load while maintaining strength and rigidity thereof.
[0008] Another object of the invention is to provide a radiation imaging inspection system using the trailer system for inspecting a vehicle, the inspection system thereof can harmlessly undertake radiation imaging inspection for the vehicle to be inspected using said trailer system.
[0009] Additional aspects and/or advantages of the invention will be thoroughly understood with reference to the description hereafter in combination with accompanying figures, or learned by practice of the invention.
[0010] The object of the invention is achieved by providing a trailer system for inspecting a vehicle, comprising:
[0011] a trailer having a vehicle body, the trailer bearing a vehicle to be inspected;
[0012] a turning plate mechanism rotatably provided on an upper surface of the trailer for abutting against wheels of the vehicle to be inspected halting on the trailer; and
[0013] a turning plate rotation driving mechanism provided on the trailer for driving the turning plate to turn toward the upper surface of the trailer.
[0014] According to an aspect of the invention, the vehicle body has a vehicle frame.
[0015] According to an aspect of the invention, the trailer system further comprises a floor auxiliary device provided opposing to the trailer in a running direction of the vehicle to be inspected.
[0016] According to an aspect of the invention, the turning plate rotation driving mechanism comprises a linkage device with an end thereof connected to the turning plate mechanism; an actuating device with an end thereof attached to the other end of the linkage device to drive the linkage device when the actuating device is applied with external force so that the turning plate mechanism is rotated.
[0017] According to an aspect of the invention, the linkage device comprises a chain connected to the turning plate mechanism.
[0018] According to an aspect of the invention, the actuating device comprises: a guiding rod, with an end thereof connected to the chain; a spring fitting over the guiding rod at a side near the floor auxiliary device, and elastic force from the spring straining the guiding rod before the guiding rod is pressed; and a bumping shaft coupled with the guiding rod so that the force applied on the guiding rod is counteracted when the bumping shaft is applied with external force, which leads to the turning plate mechanism rotating toward the upper surface of the trailer.
[0019] According to an aspect of the invention, the floor auxiliary device comprises a bumping block provided at a position on the floor auxiliary device which is opposed to the guiding rod.
[0020] According to an aspect of the invention, the turning plate rotation driving mechanism comprises a turning plate brake position adjusting device for adjusting height and angle of the turning plate abutting against the front wheels halting on the trailer.
[0021] According to an aspect of the invention, the turning plate brake position adjusting device is an adjusting bush fitted over the guiding rod, with an end thereof abutting against the spring to adjust the brake height and angle of the turning plate mechanism by the adjustment of the tension degree of the spring.
[0022] According to an aspect of the invention, the vehicle frame comprises a positioning recess provided in a running direction of the vehicle to be inspected facing away the turning plate mechanism, to be coupled with the turning plate mechanism for positioning the front wheels of the vehicle to be inspected.
[0023] According to an aspect of the invention, the turning plate mechanism comprises a turning plate pivotably attached to the vehicle body.
[0024] According to an aspect of the invention, the height at both ends of the vehicle frame are higher than that at the middle portion to form a concave structure, so that the vehicle to be inspected is not scrapped by the middle portion.
[0025] Thus, when the vehicle to be inspected is trailed by the trailer for inspection, the lower middle portion is the main bearing portion of the trailer.
[0026] According to an aspect of the invention, the floor auxiliary device comprises a declining slope device provided at a side toward exit direction of the trailer by a certain distance.
[0027] According to an aspect of the invention, the vehicle body further comprises wheel set units provided at both sides of the vehicle frame.
[0028] According to an aspect of the invention, the vehicle body has four wheel set units.
[0029] According to an aspect of the invention, each wheel set unit comprises: a structural member to be engaged to the vehicle frame; and the wheel is provided on the structural member. Thus, according to the above description, the wheel set unit can be separately assembled, then the wheel set unit is integrally formed with the vehicle frame, the other units can be positioned integrally by the mechanical machining surface of the vehicle frame. And a structure with separate units whereas integrally positioned is achieved, which further reduces the height of the vehicle body and easiness of disassembly and maintenance.
[0030] According to an aspect of the invention, there is wheel flange formed at the inner side of the wheel in the wheel set unit for guiding during the running of the trailer.
[0031] According to an aspect of the invention, the wheel set unit can be independently installed. Thus, the strength and rigidity of the trailer is ensured and the assembly is convenient.
[0032] According to an aspect of the invention, the floor auxiliary device further comprises an auxiliary supporting member provided at lower part of the vehicle frame corresponding to the abutting position of the trailer, when the rear axis of the vehicle to be inspected passes by the trailer, the height of the auxiliary supporting member can provide support when the vehicle frame deforms.
[0033] According to an aspect of the invention, the supporting height of the auxiliary supporting member is adjustable.
[0034] According to another aspect of the invention, a radiation imaging inspection system is provided, comprising an accelerator, a detector, an image acquisition device, a scanning device, an operation and inspection subsystem, and a trailer system for inspecting a vehicle according to an aspect of the invention, the trailer system comprising: a trailer having a vehicle body, the trailer bearing a vehicle to be inspected; a turning plate mechanism rotatably provided on an upper surface of the trailer, for abutting against wheels of the vehicle to be inspected halting on the trailer; and a turning plate rotate driving mechanism provided on the trailer for driving the turning plate to turn toward the upper surface of the trailer.
[0035] Meanwhile, according to above solution, additional features as follows can be provided: since the declining slope fixed at the exit position has a certain length, vehicle striding over the trailer can be avoided otherwise the bottom chassis may be damaged accordingly.
[0036] Compared with conventional art, it can be found that the present invention has simple design and configuration, which not only reduces the height of the trailer but also ensures the strength and rigidity of the trailer, and thus the vehicle to be inspected can pass special detecting facilities, such as a scanning passage, safely without being scrapped or damaging the chassis of the vehicle to be inspected and the attachments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Further disclosure, objects, advantages and aspects of the present invention may be better understood by those skilled in the relevant art by reference to the following description of embodiments taken in conjunction with the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the present invention, and in which:
[0038] FIG. 1 shows a plan view of a trailer system for inspecting a vehicle according to an embodiment of the invention;
[0039] FIG. 2 shows an end view of a trailer system for inspecting the vehicle according to an embodiment of the invention; and
[0040] FIG. 3 shows a schematic view of a wheel set unit in the trailer of the trailer system for inspecting the vehicle according to an embodiment of the invention; and
[0041] FIG. 4 shows a schematic view of a turning plate mechanism of a trailer in the trailer system for inspecting the vehicle according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Above and other aspects of features of the present invention will be become readily apparent with preferred embodiment and referenced to accompany drawing by a detail description hereinafter, wherein the same reference numerals refer to the same elements throughout the specification.
[0043] Meanwhile, in the following embodiment, although a case in which the trailer system for inspecting a vehicle is used in vehicle radiation imaging inspection is described in detail, it is appreciated for a person skilled in the art that the present invention can be applied to other related vehicle inspection without deviating from the scope and the spirit of the present invention.
[0044] With reference to FIG. 1 showing a plan view of a trailer system for inspecting the vehicle according to an embodiment of the invention, the system thereof comprise a vehicle body and a floor auxiliary device. The trailer bears the vehicle to be inspected for different inspection purpose, and the floor auxiliary device prevents the vehicle to be inspected from riding over the trailer to overcome the shortcoming of the art.
[0045] The vehicle body comprises a vehicle frame 1 , a turning plate mechanism 2 , a positioning recess 3 and a wheel set unit 7 (not shown in FIG. 1 ) etc. The detailed structures of the turning plate mechanism 2 and the wheel set unit 7 will be described in detail in the follows. The turning plate mechanism in the present invention is implemented in the form of the turning plate 2 . However, it is obvious for a person skilled in the art to substitute the turning plate 2 by a halting plate, a rotatable positioning plate or a rotatable rail etc.
[0046] The floor auxiliary device comprises a declining slope 5 , an auxiliary supporting member 6 (as shown in FIG. 2 ) etc., the detailed structure of the auxiliary supporting member 6 will be described in the follows. A bumping block 4 is provided at a side of the declining slope 5 toward the trailer.
[0047] The declining slope 5 is fixed at an exit position, i.e., the declining slope 5 is provided at a side of the trailer toward the exit position by a certain distance. Of course, the distance can be appropriately adjusted as required by circumstances. Since the declining slope has a certain length, the vehicle riding over the trailer that may lead to bottom scrapping is avoided.
[0048] The height at both ends of the vehicle frame 1 are higher than that at the middle portion to form a concave structure, so that the vehicle to be inspected is not scrapped by the middle portion. Meanwhile, the vehicle frame 1 supports the vehicle to be inspected on its upper surface.
[0049] The wheel set unit 7 , the auxiliary supporting member 6 in the trailer system for vehicle inspection according to an embodiment of the invention will be further described in detail with reference to FIGS. 2-3 .
[0050] FIG. 2 shows an end view of a trailer system for inspecting the vehicle according to an embodiment of the invention. FIG. 3 shows a schematic view of a wheel set unit 7 in the trailer of the trailer system for inspecting the vehicle according to an embodiment of the invention.
[0051] As shown in FIG. 2 , the wheel set unit 7 is installed under the vehicle frame 1 . In an embodiment of the invention, the vehicle frame is provided with 4 wheel set units 7 at both side thereof. However, it will be appreciated for a person skilled in the art to install more than 4 wheel set units 7 in the trailer system as conditions may require. Meanwhile, the auxiliary supporting member 6 is provided at the exit position of the inspection passage, and is located just under a halting position of the trailer at the exit.
[0052] As shown in FIG. 3 , the wheel set unit 7 comprises a bearing 8 , a wheel 9 , a supporting frame 10 , a shaft 11 and an associated structural member. The wheel 9 has a center opening for the shaft 11 to be penetrated through, the wheel 9 is engaged in the structural member. The shaft 11 is rotatable due to the bearing 8 . And the structural member is used for engaging to the vehicle frame 1 . The supporting frame 10 supports the wheel 9 , the shaft 11 and the bearing 8 . The shaft 11 is positioned by penetrating through the center opening of the wheel 9 . The wheel set unit 7 can be assembled independently, and the wheel set unit 7 is assembled with the vehicle frame 1 integrally. A number of the units are uniformly positioned by a mechanically machined face of the vehicle frame 1 . And such structure with separate units whereas integrally positioned reduces the height of the vehicle frame 1 and makes the assembly, disassembly and maintenance easier.
[0053] Further from FIG. 2 , the auxiliary supporting member 6 does not contact with the bottom of the trailer, however, there is a small gap between the auxiliary supporting member 6 and the bottom of the trailer. After scanning of the vehicle to be inspected (not shown), the trailer dragging the vehicle to be inspected halts just above the auxiliary supporting member 6 . When the rear shaft of the vehicle to be inspected passes the trailer, since the weight of the rear shaft is normally heavier with larger deflection of the vehicle frame, so that the bottom of the trailer contacts with the auxiliary supporting member 6 , which may reduce the deformation of the vehicle frame and enhance the bearing capability of the trailer. It should be noted that although 2 auxiliary supporting members 6 are schematically shown in FIG. 2 , there is no specific requirement on the number and shape of the auxiliary supporting member 6 , since the auxiliary supporting member 6 only supports the bottom of the trailer, and the shape of the auxiliary supporting member 6 can be rectangular, trapezoid, tape-shaped or plate-shaped etc. with the number of two or more as required by circumstances. Still further, it is advantageous that the supporting height of the auxiliary supporting member 6 is adjustable.
[0054] The turning plate mechanism 2 of the present invention will be described with reference to FIG. 4 . FIG. 4 shows a schematic view of a turning plate mechanism of a trailer in the trailer system for inspecting the vehicle according to an embodiment of the invention.
[0055] The turning plate mechanism 2 comprises a turning plate 12 , a chain 13 , a guiding rod 14 , an adjusting bush 15 , a spring 16 , a bumping shaft 17 and a hinge 18 etc. The turning plate mechanism 2 is configured to adjust the height and angle of the raised turning plate 12 for abutting against the front wheels of the vehicle to be inspected. The adjusting bush 15 is configured to adjust the height and angle of the turning plate 12 abutting against the front wheels of the vehicle to be inspected. It is obvious for those skilled in the art that the adjusting bush 15 , used as a turning plate brake position adjusting device, can be substituted by other adjusting means for the adjustment of the angle and height of the turning plate 12 . For example, the adjusting bush 15 can be an angle actuating mechanism provided neighboring the turning plate 12 or a pivot connecting member having a predetermined rotating angle. The above example of the adjusting bush 15 is only for illustration purpose rather than for limitation. The adjusting bush 15 is fitted over the guiding rod 14 , with an end thereof abutting against the spring 16 so that the brake height and angle of the turning plate 12 can be adjusted by the tension degree of the spring 16 .
[0056] The turning plate 12 can be connected with the vehicle body 1 with the hinge 18 . However, the connection thereof is not limited to the hinge 18 , and the rotatable connection thereof can be implemented in other connecting manner. The chain 13 is connected to the turning plate 12 in a manner such as pin connecting, sliding connection, rolling connection etc, but not limited thereto.
[0057] When there is no external force, the spring 16 is compressed, the guiding rod 14 tenses the chain 13 and the turning plate 12 raises. It should be noted that the guiding rod 14 is only an exemplary structure for linking with the turning plate 12 . The present invention is not limited thereto. Any connecting member that may implement the falling down of the turning plate 12 when the vehicle to be inspected passes can substitute the guiding rod 14 .
[0058] When the vehicle to be inspected is loaded, the front wheels of the vehicle to be inspected are driven onto the trailer. The wheels press the turning plates 12 to a horizontal level against the elastic force. After the wheels reaches the positioning recess 3 of the vehicle frame 1 , the turning plate 12 raises under the function of the spring 16 . When the trailer reaches the unloading position, the bumping shaft 17 is acted upon by the bumping block 4 on the floor for further compressing the spring 16 , the chain 13 relaxes, and the turning plate 12 is substantially in a free state. When the front wheels of the vehicle to be inspected exit the positioning recess 3 , the turning plate 12 falls naturally without bumping against the chassis of the vehicle to be inspected and the attachment thereof. When the vehicle to be inspected is driven away, no external force is applied on the guiding rod 14 , and the spring 16 tries to recover the elastic deformation. When the guiding rod 14 strains the chain 13 by a pulling force, the turning plate 12 raises, that is, when the trailer left the exit position moving toward the inlet direction, the turning plate 12 automatically turns under the elastic force of the spring 16 .
[0059] In an embodiment of the invention, the auxiliary supporting member 6 is provided at the exit side of the inspection passage, i.e., the position where the trailer halts, for better description of the structure, function and effect of the present invention. Preferably, the gap between the upper working surface of the auxiliary supporting member 6 and the lower surface of the vehicle frame 1 can be further calculated in a precise manner. After the inspection of the vehicle to be inspected, such as scanning, the trailer drags the vehicle to be inspected halt just above the auxiliary supporting member 6 . When the rear shaft of the vehicle to be inspected passes through the trailer, since the rear shaft is relatively heavier, the vehicle frame 1 is deflected to an extent that the bottom of the vehicle frame 1 contacts with the auxiliary supporting member 6 , and the weight of the rear shaft is transmitted to the floor by the auxiliary supporting member 6 . Thus, the deformation of the vehicle frame 1 is reduced and the bearing capability of the trailer is enhanced.
[0060] The concrete operation of the invention will be described with reference to the above concrete structure of the trailer system for inspecting the vehicle according to an embodiment of the invention, and the appended figures.
[0061] Normally, the trailer is anchored at the loading side, and the turning plate 12 is opened at this time. Then, the vehicle to be inspected runs onto the trailer and is positioned in the positioning recess 3 , and the whole system is prepared to be ready. Then the driving system of the trailer starts to work, the turning plate 12 abuts against the front wheels of the vehicle to be inspected preventing the vehicle to be inspected from moving. Under this state, the trailer passes through inspection device or apparatus such as the scanning passage. After the predetermined inspection such as scanning, the trailer runs to unloading position. At this time, the auxiliary supporting member 6 is placed under the trailer, the bumping block 4 on the declining slope 5 abuts against the bumping shaft 17 of the turning plate mechanism 2 on the trailer, so that the spring 16 is further compressed, and the tension force of the turning plate 12 is released to be in a free state. At this time, the vehicle to be inspected can be driven away from the inspection device or apparatus. When the rear shaft of the vehicle to be inspected passes the trailer, the auxiliary supporting member 6 can prevent the vehicle from generating larger deflection to ensure the passing of the heavily loaded vehicle whilst the turning plate 12 falls naturally when the front wheels left. When the trailer exits from the exit anchoring position, the turning plate 12 opens again under the function of the spring 16 , then the trailer returns to the original loading position for next inspection.
[0062] It can be found from the description of the embodiment of the invention that the turning plate rotate driving mechanism is implemented by the chain 13 , the guiding rod 14 , the spring 16 , the bumping shaft 17 and the bumping block 4 . However, the present invention is not limited thereto since it is only an illustrative embodiment of the invention. And it can be substituted by other linkage device and actuating device implementing the turning plate mechanism. For example, the linkage mechanism can be a hydraulic actuating circuit, a gas actuating circuit or a rotating motor. The actuating device can be the combination of the bumping shaft and the bumping block, or a proximity switch or any other device that can sense signal indicating that the trailer reaches the unloading position, and the device thereof transmit the signals to the linkage device which further change the state of the turning plate.
[0063] In all, the trailer system for inspecting the vehicle according to the invention can be applied to every system for inspection and measurement etc. especially to radiation imaging inspection system widely used customers, civil airport, and the railway station system. The radiation imaging inspection system comprises an accelerator, a detector, an image acquisition device, a scanning device and an operation and inspection subsystem. Since the components in the radiation imaging inspection system are widely used in the conventional art, the detailed description thereof is omitted for clarity purpose.
[0064] In addition, the present invention can also be applied to conditions such as cargo transporting, cargo vehicle weighting etc rather than only limited to inspection, which is also fallen into the protection scope of the invention.
[0065] While the embodiments of the present invention have been described by way of examples taken in conjunction with the accompanying drawings, it should be appreciated that modifications, additions and variations to and from the above described embodiments may be made without deviating from the scope of the present invention which is defined by the accompanying claims.
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The present invention discloses a trailer system for inspecting a vehicle inspection, comprising: a trailer having a vehicle body, the trailer bearing a vehicle to be inspected; a turning plate mechanism rotatably provided on an upper surface of the trailer for abutting against wheels of the vehicle to be inspected halting on the trailer; and a turning plate rotation driving mechanism provided on the trailer for driving the turning plate to turn toward the upper surface of the trailer. The trailer system can trail vehicle with various loads passing through an inspection system such as a scanning passage, while bearing heavy load, maintaining the strength and rigidity thereof without damaging the vehicle to be inspected. In addition, the present invention further discloses a radiation imaging inspection system having the same.
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BACKGROUND OF THE INVENTION
In the construction of a radar detector of the type which is adapted to be carried on the dashboard of a motor vehicle for detecting radar signals being transmitted from a police radar traffic control unit, it is common for most manufacturers to use a horn type antenna. A typical horn antenna includes a tapering wall portion in the form of a frusto-pyramid. The wall portion defines a converging cavity which extends to a rectangular waveguide cavity in which a pair of diodes are mounted for detecting and modulating a microwave signal.
In such radar detectors, it is desirable to minimize the size of the housing which has an aperture aligned with the horn cavity to minimize the depth of the detector. Thus the length of the horn antenna is substantially reduced from the optimum design for the horn antenna with the result that a sacrifice is made in the sensitivity or gain of the antenna, and weak signals are not detected. For example, the radar detectors marketed under the names "FUZZBUSTER", "WHISTLER", "BEARFINDER" and "RADAR RANGER" each include a horn antenna which has been substantially shortened from an optimum design in order to fit within a relatively compact housing which may be mounted on the dashboard of a motor vehicle.
The lost gain or sensitivity in the relatively short horn antenna is due to phase errors at the entrance or mouth of the antenna and in the use of improper angles for the tapering walls of the antenna in addition to matching errors at the junction of the tapered cavity with the rectangular wave-guide cavity of the antenna. These errors result in higher sidelobe levels and/or less energy available for detection by the detector diode.
SUMMARY OF THE INVENTION
The present invention is directed to an improved compact radar detector of the type described above and which significantly increases the gain of the shortened horn antenna, thereby significantly increasing the sensitivity of the radar detector so that it will detect radar signals of lower levels. This primary advantage or feature of the invention is provided by incorporating a dielectric lens which is mounted on the detector housing adjacent the mount of the horn antenna cavity and which introduces a phase relationship across the mount of the cavity. The lens is constructed in order to make the phase of the microwave front at the horn antenna walls lag the phase of the wave front at the center of the horn cavity. Thus the lens introduces a phase delay which is maximum at the center of the cavity and decreases towards the tapered walls of the horn antenna, thereby producing a more planar wave in the horn cavity. As a result, a radar detector and lens assembly in accordance with the invention substantially increases the efficiency or performance of a compact radar detector unit by correcting the deficiencies in the comprised design of the horn antenna.
In accordance with one embodiment of the invention, the dielectric lens is adapted to be quickly and conveniently mounted on a radar detector housing with the aid of pressure sensitive adhesive. In accordance with another embodiment of the invention, the lens includes a flange portion which is sandwiched between the horn antenna and the housing and serves also to cover the cavity within the housing. The lens of the invention includes a portion having a convex or generally part-spherical surface and may project either inwardly into the horn antenna cavity or outwardly from the aligned aperture within the housing.
Other features and advantages of the invention will be apparent from the following description, the accompanying drawing and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a radar detector incorporating a lens member constructed and assembled in accordance with the invention;
FIG. 2 is a plan view of the radar detector and lens assembly shown in FIG. 1 and with the top cover removed;
FIG. 3 is a perspective view of the radar detector lens shown in FIGS. 1 and 2 and illustrating its attachment to the radar detector housing;
FIG. 4 is an exploded fragmentary perspective view illustrating the assembly of a horn antenna and lens constructed in accordance with a modification of the invention;
FIG. 5 is a fragmentary plan view, in part section, of the assembled components shown in FIG. 4; and
FIG. 6 is a fragmentary view similar to FIG. 5 and illustrating the assembly of a horn antenna and lens member in accordance with another modification of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a radar detector 10 which has been marketed by Electrolert Corporation in Troy, Ohio and which is referred to as the "Fuzzbuster". The detector 10 includes a sheet metal housing 12 formed by an inverted U-shaped top section 14 which covers a U-shaped bottom section 16 having a front wall 17 integrally connected to a rear wall 18 by a bottom wall 19. The top and bottom sections are secured together by a set of rivets 21 which extend through holes formed within flanges 22 on the front and rear walls of the bottom section 16.
A horn antenna 25 in the form of a hollow aluminum casting, is cantileverly supported by the front wall 17 and is secured to the front wall 17 by a set of screws 27. The screws 27 extend through holes located on opposite sides of a square aperture 28 (FIG. 1) in the front wall 17 and are threaded into corresponding flanges or ears 29 (FIG. 2) cast as integral parts of the horn antenna 25. The rear wall 18 of the housing 12 supports an alarm in the form of a light indicating unit 32 and also supports a sensitivity selection unit 34 having an adjustable control knob 36.
The horn antenna 25 includes a tapering wall portion 42 in the form of a frusto-pyramid section which extends from a rectangular waveguide portion 44. Thus the portion 42 defines a converging cavity which extends from a rectangular waveguide cavity formed by the portion 44. A pair of diodes 46 extend into the waveguide cavity and are secured to the antenna portion 44 by the wings of an inverted thumb nut 47 secured to the antenna portion 44 by a screw 48. The diodes 46 are electrically connected through the nut 47 to a circuit board 50 which is supported by the base of the horn antenna 25 and carries the electrical components required for actuating the alarm 32 in response to the diodes 46 detecting a radar signal received through the aperture 28 and the cavity of the horn antenna 25. A power supply cord 54 supplies 12 volt DC power to the circuit board 50 for operating the components and the alarm 32, and usually, the power supply cord 54 carries a plug (not shown) which is adapted to be inserted into the cigarette lighter socket on the dashboard of an automobile or other motor vehicle.
As mentioned above, the length of the horn antenna 125 is selected in order to limit the spacing between the front wall 17 and the rear wall 18 of the housing 12 and thereby provide for a more compact radar detector 10. That is, if the horn antenna 25 was designed for optimum performance and maximum sensitivity to weak radar signals, the antenna would have a length substantially greater than the length of the antenna illustrated, and a substantially larger housing would be required to enclose the antenna. As a result of the compromise design for the horn antenna 25, the gain of the antenna is significantly reduced due to phase errors at the entrance of the antenna cavity and the incorrect angles of the tapering walls forming the forward end portion 2 of the antenna.
In accordance with the present invention, a dielectric lens 60 is mounted on the radar detector housing 12 and is effective to correct the deficiencies of the horn antenna 125. The lens 60 shown in FIGS. 1-3 includes a plano-convex lens portion 62 having a substantially part-spherical outer surface 63 and a flat inner surface 64. The lens 60 is molded of an acrylic plastics material and includes a pair of integrally molded arcuate support legs 66 (FIG. 3) which extend from the surface 64 and are arranged in diametrically opposed relation. As shown in FIG. 3, each of the legs 66 carries a pad of pressure sensitive adhesive 67 which is normally protected by a release strip 68. The strips 68 are removed when it is desired to mount the lens 60 on the front wall 17 of the radar detector housing 12. The spacing between the legs 66 is sufficient for the legs to straddle the aperture 28 within the front wall 17, and the adhesive pads 67 rigidly secure the lens 60 to the housing 12 with the plano-convex portion 62 covering the aperture 28.
The configuration of the lens 60 is effective to make the face of the microwave front adjacent the walls of the antenna portion 42 lag the phase of the microwave at the center of the aperture 28 or the mouth of the horn antenna cavity. This causes a curve to be formed in the electromagnetic field across the aperture 28 with the phase delay at a maximum at the center of the aperture 28 and progressively decreasing towards the edges of the aperture or towards the tapering walls of the antenna portion 42. Thus the antenna 25 receives a more planar wave, which increases the gain of the antenna and the sensitivity of the detector 10 to lower levels of microwave signals.
The increase in gain and sensitivity provided by the plano-convex lens portion 62 is effective for a very wide frequency band including the "K-Band" and the "X-Band" and with either pulse or continuous signals and all polarized speed radar signals. The plano-convex lens also has minimal reflected wave interference characteristics and reduces the reception of false alarms. Thus the assembly of the lens in accordance with the invention significantly improves the operating range of the radar detector by focusing and concentrating weak radar signals so that the detector is activated at a further distance from the transmitter of the signals. In other words, the invention provides for a better match between the cavity of the horn antenna 25 and the detector diodes 46.
Referring to FIGS. 4 and 5, it is also within the scope of the invention to construct or mold a plano-convex dielectric microwave lens 70 of an acrylic plastics material and to assemble the lens as a part of the radar detector when the detector is assembled. The lens 70 includes a rectangular portion 72 which projects into the tapered wall portion 42' of a horn antenna 25' constructed substantially the same as the horn antenna 25 mentioned above. The rectangular portion 72 of the lens 70 has an inner convex or substantially part-spherical surface 73 which is interruped by tapered side walls 74 and end walls 76 corresponding to the tapered walls of the portion 42' of the horn antenna 25'.
The lens 70 also includes a peripherally extending flange portion 78 which is positioned or sandwiched between the flange portion 29' of the antenna 25' and the front wall 17' of the detector housing 12'. A rectangular aperture 28' is formed within the front wall 17' and corresponds in size to the mouth of the cavity within the horn antenna portion 42', as shown in FIG. 5. A set of screws 27' secure the antenna 25' to the front wall 17' and clamp the flange portion 78 of the lens 70 therebetween. While the lens 70 functions in the same manner as the lens 60 described above, the modification shown in FIGS. 4 and 5, provides a particular advantage in that the lens 70 does not increase the size of the radar detector assembly, which is particularly desirable when space is limited, for example, on the dashboards of some automobiles. In addition, the lens 70 also functions as an insulator cover for the cavity within the horn antenna 25'.
In reference to FIG. 6, a plano-convex microwave lens 70' is constructed similarly to the lens 70, but with the rectangular portion 72' projecting outwardly from the horn antenna 25' through the aperture 28' instead of into the horn antenna cavity as shown in FIG. 5. In this modification, the opposite side surfaces 74' are parallel but are interrupted by the convex or substantially part-spherical surface 73'. In all other respects, the lens 70' functions in the same manner as the plano-convex lenses 60 and 70. It is also within the scope of the invention to mold the microwave lens as an integral part of a plastic front wall of a radar detector and thereby reduce the cost of manufacturing a radar detector in accordance with the invention.
While the forms of radar detectors herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise forms of detectors, and that changes may be made therein without departing from the scope and spirit of the invention as defined in the appended claims.
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A radar detector adapted to be carried by a motor vehicle, includes a housing enclosing a compact horn antenna having a tapering wall portion which defines a cavity extending from an aligned aperture within the housing. A plano-convex dielectric lens extends across the aperture and cavity and introduces a microwave phase delay decreasing from the center of the cavity towards the tapered wall portion of the horn antenna to compensate for the deficiencies in the compromised design of the antenna and for significantly increasing the sensitivity and gain of the detector. The dielectric lens may project outwardly from the housing or inwardly into the antenna cavity and may be molded as an integral part of the front wall of the detector housing. In one embodiment, the lens is also adapted to be conveniently attached to an existing radar detector.
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BACKGROUND
[0001] 1. Field
[0002] Embodiments of the present application relate to an optical transceiver, in particular, the application relates to a physical arrangement of a housing of the optical transceiver.
[0003] 2. Description of Related Art
[0004] An optical transceiver generally includes an optical transmitter to transmit an optical signal, an optical receiver to receive another optical signal, a circuit to communicate with the optical transmitter, the optical receiver and the host system, and a housing, typically made of metal, to install the optical transmitter, the optical receiver, and the circuit therein. Thus, an optical transceiver realizes the full-duplex optical communication. As the transmission speed of an optical transceiver continuously increases, components installed within an optical transceiver have generated more heat, which leads to needs for a mechanism for the optical transceiver to dissipate heat further efficiently.
[0005] On the other hand, both of the optical transmitter and the optical receiver process electrical signals but signal levels are far different. That is, the optical transmitter switches a large current to drive a light-emitting device, while, the optical receiver receives a faint signal converted from the received optical signal. Accordingly, the optical receiver is necessary to be isolated from EMI noises caused by the optical transmitter. Generally, this isolation is carried out by distinguishing the receiver ground from the transmitter ground. However, when all the housing of the optical receiver, that of the optical transmitter and the transceiver housing are made of metal, the electrical isolation of the optical receiver from the optical transmitter has been left to be a subject to be solved.
SUMMARY
[0006] An aspect according to an example of the present application relates to an optical transceiver. The optical transceiver of the example comprises an optical transmitter, an optical receiver, a metal frame, and a bottom cover. The metal frame mounts the optical transmitter and the optical receiver thereof; and openings corresponding to the optical transmitter and the optical receiver. The bottom cover is made of metal and has thermal conductivity greater than that of the metal frame. A feature of the optical transceiver of the example, the optical transmitter is directly in contact with the bottom cover through the opening for the optical transmitter; while, the optical receiver is set in another opening for the optical receiver but electrically isolated from the bottom cover and the metal frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other purposes, aspects and advantages will be better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
[0008] FIGS. 1A and 1B show an outer appearance of an optical transceiver according to an example of the present application;
[0009] FIGS. 2A and 2B show an inside of the optical transceiver 1 ;
[0010] FIG. 3 is an outer appearance of a frame;
[0011] FIG. 4A is a perspective view of an assembled support 31 ; while, FIG. 4B is an exploded view of the support;
[0012] FIG. 5 is a plan view of the support;
[0013] FIG. 6 shows a process to assemble the support with the frame;
[0014] FIGS. 7A and 7B show processes to assemble the support with the frame subsequent to the process shown in FIG. 6 ;
[0015] FIG. 8 magnifies a process to assemble the support with the frame subsequent to the process shown in FIG. 7B ;
[0016] FIGS. 9A and 9B show a process to set an optical receiver on the support;
[0017] FIG. 10A is a perspective view of a metal cover, and FIG. 10B is a cross section of the metal cover;
[0018] FIGS. 11A and 11B show a process to assemble the metal cover with the support as putting the optical receiver between them;
[0019] FIG. 12 is a cross section showing the assembly of the metal cover with the support;
[0020] FIG. 13A is a perspective view of another support, and FIG. 13B is a side view of the another support;
[0021] FIG. 14 is a cross section shown an assembly of the metal cover with the another support shown in FIG. 13A ;
[0022] FIG. 15 is a perspective view showing a bottom cover of another example of the present application;
[0023] FIG. 16 magnifies a front portion of the another bottom cover and the frame;
[0024] FIG. 17 magnifies a front portion of the frame to be engaged with the bottom cover;
[0025] FIG. 18A magnifies a side portion of the frame providing a groove, and FIG. 18B is a cross section of the groove;
[0026] FIG. 19A is a perspective view of the bottom cover with a snapping mechanism and FIG. 19B magnifies an edge of the bottom cover providing a hook to be slid within the groove of the frame; and
[0027] FIG. 20 shows a repulsive mechanism provided in one of the bottom cover and the frame.
DETAILED DESCRIPTION
[0028] FIGS. 1A and 1B show an outer appearance of an optical transceiver according to an example of the present application, where FIG. 1A views the optical transceiver 1 from a rear top; while, FIG. 1B views it from a front bottom. The optical transceiver 1 provides a frame 2 , a bottom cover 3 , and a lid 4 as a housing. One end of the frame 2 is provided with an optical receptacle 12 to receive an external optical connector, which is not shown in figures. We call that a side where the optical receptacle 12 is provided is the front, the other side, where an electrical plug 13 is provided, is the rear, the side where the lid 4 is assembled is the top, and the side where the bottom cover 3 is provided is the bottom. Moreover, the longitudinal direction extends from the front to the rear, while, the lateral direction crosses the longitudinal direction. However, these directions of the front, rear, top and bottom are defined only for the explanation sake, and do not restrict the scope of the invention. The frame 2 is preferably made of aluminum alloy, zinc alloy, and so on from viewpoints of the productivity and the cost thereof. The bottom cover 3 , which is assembled to a bottom of the frame 2 as shown in FIG. 1B , is preferably made of copper alloy from a viewpoint of the heat dissipating function. The lid 4 is assembled with the frame 2 as exposing the electrical plug 13 .
[0029] FIGS. 2A and 2B show an inside of the optical transceiver 1 , where FIG. 2A views the optical transceiver 1 from the rear bottom; while, FIG. 2B views it from the front top. The frame 2 provides two sides 5 extending longitudinally from the rear end of the optical receptacle 12 . A center portion of respective sides 5 is removed to form a cut 7 for receiving sides of the lid 4 . The bottom 6 of the frame 2 provides a plurality of openings 9 , where the number of the openings 9 in the present example corresponds to a number of optical components installed within the optical transceiver 1 . An example of the optical transceiver shown in the figures has three openings 9 , one is for an optical transmitter 17 , one is for an optical receiver 24 , and one is for an optical source 14 . The bottom 6 further provides a center beam 8 extending in a longitudinal direction between the openings 9 .
[0030] The optical transmitter 17 has a housing larger than that of the optical receiver 24 . That is, the housing 18 of the optical transmitter 17 is made of metal and has a rectangular shape to enclose semiconductor optical devices as optically active devices and some optical components such as a lens and so on as optically passive devices. FIG. 2B shows a top 19 of the metal housing 18 of the optical transmitter 17 , and two optical ports, 22 a and 22 b, to output modulated optical signal to the optical receptacle 12 and to enter local light coming from the optical source 14 .
[0031] For the optical receiver 24 , it also provides a metal housing 25 with a rectangular shape, namely, the housing 25 provides a top 26 , a bottom 27 , and four sides, 28 a to 28 d. The housing 25 installs a photodiode (hereafter denoted as PD) as an optically active device and some optically passive devices, typically lenses. Three sides, 28 a to 28 c, of the housing 25 provides lead pins, 30 a to 30 c, while, the last side 28 d provides an input port 29 a for a received optical signal and another port 29 b for a local optical signal.
[0032] The optical receptacle 12 provides two optical ports, 12 a and 12 b, where the former 12 a couples with the optical port 22 a of the optical transmitter 17 , while, the latter 12 b couples with the optical port 29 a of the optical receiver 24 . The optical source 14 provides two ports, 14 a and 14 b, the former 14 a couples with the port 22 b of the optical transmitter 17 , while the latter 14 b couples with the port 29 b of the optical receiver 24 .
[0033] Thus, the optical transmitter 17 receives the local light in the port 22 b from the port 14 a of the optical source 14 , modulates thus received light, and outputs thus modulated optical signal to the port 12 a of the optical receptacle 12 from the port 22 a. While, the optical receiver 24 receives the local light in the port 29 b from the port 14 b of the optical source 14 and the signal light in the other port 29 a from the port 12 b of the optical receptacle 12 , multiplexes these two light and detects the phase and the amplitude of the optical signal coming from the optical receptacle 12 .
[0034] The sides of the bottom 6 , or the bottom of two sides 5 , provide grooves 11 extending longitudinally. Setting the bottom cover 3 from the rear of the optical transceiver 1 as sliding the edges thereof within the grooves 11 , the bottom cover 3 is assembled with the frame 2 . The bottom 20 of the housing 18 for the optical transmitter 17 is in physical contact with the bottom cover 3 to enhance the heat dissipating function of the optical transmitter 17 . The assembly of the bottom cover 3 with the frame 2 , in particular, a mechanism to fit the bottom cover 3 with the frame 2 will be described later.
[0035] FIG. 3 is an outer appearance of the frame 2 without installing any assemblies, 14 , 17 , and 24 . The opening 9 for the optical receiver 24 provides a step 10 in the center beam 8 and the inside of the side 5 (not shown in FIG. 3 ). As described later, the step 10 receives a flange, 39 and 53 , of the support 31 to assemble the optical receiver 24 with the frame 2 . The support 31 is made of electrically insulating material, typically an insulating resin, to isolate the metal housing 25 of the optical receiver 24 from the metal frame 2 .
[0036] FIG. 4A is a perspective view of the assembled support 31 , FIG. 4B is an exploded view of the support 31 , and FIG. 5 is a plan view of the support 31 . The support 31 includes a female part 32 and a male part 33 . The female part 32 includes front and rear arms, 35 and 36 , and a longitudinal bar 34 connecting the front and rear arms, 35 and 36 , where they form a “C” like plane shape. The front and rear arms, 35 and 36 , extend from respective end of the longitudinal bar by substantially a right angle. The longitudinal bar 34 provides a cut 37 in a center thereof to expose read pins 30 c of the optical receiver 24 . The longitudinal bar 34 also provides projections 38 , which is shown in FIG. 5 but hidden in FIGS. 4A and 4B , in the outer side of the front and the rear of the longitudinal bar 34 . The outer side of the longitudinal bar 34 also provides in the bottom thereof the flange 39 extending outwardly to be received in the step 10 of the opening 9 .
[0037] The rear arm 35 has a flat surface 42 to support the bottom 27 of the housing 25 . That is, the rear arm 32 has a height substantially equal to a height of the portion of the longitudinal bar 34 left by the cut 37 . The rear arm 35 further provides a projection 43 and a hole 44 in this order from the tip thereof. The projection 43 protrudes inwardly, while, the hole 44 passes through the whole rear arm 35 . The front arm 36 provides a saddle 45 to support the port 29 a of the optical receiver 24 and a groove 46 in the tip thereof. The groove 46 has a hollow in the bottom thereof.
[0038] The male part 33 also provides a front arm 49 , a rear arm 48 , and a longitudinal bar 47 connecting two arms, 48 and 49 . Two arms, 48 and 49 , extend substantially perpendicular to the longitudinal bar 47 towards the female part 32 . The longitudinal bar 47 provides a cut 51 in a center thereof through which the lead pins 30 a are exposed. The top of the longitudinal bar 47 is chamfered in the outer corner thereof. The longitudinal bar 47 , instead of the chamfered corner, may have a rounded top.
[0039] Similar to the projections in the longitudinal bar 34 of the female part 32 , the longitudinal bar 47 of the male part 33 also provides circular projections 52 in front and rear of the outer surface, whose top corner is also chamfered. Moreover, the longitudinal bar 47 also provides in a bottom thereof a flange 53 similar to the flange 39 in the female part 32 extending outwardly.
[0040] The rear arm 48 provides a top flat surface 56 also to support the bottom 27 of the housing 25 , and a combination of a projection 57 and an opening 58 . The projection 57 protrudes outwardly, while, the opening passes through the whole rear arm 48 . On the other hand, the front arm 49 provides a saddle 59 to support the port 29 b and a projection 60 in a tip thereof. The projection 60 mates with the groove 46 formed in the front arm 36 of the male part 32 .
[0041] Referring to FIG. 5 , assuming a length L from the front arm to the rear arm, a distance from the rear arm 48 to the front arm 49 of the male part 33 is longer than a distance from the rear arm 35 to the front arm 36 of the female part 32 . Accordingly, assembling the male part 33 with the female part 32 , the rear and front arms, 48 and 49 , of the male part 33 push the rear and front arms, 35 and 36 , of the female part 32 outwardly; concurrently, the rear and front arms, 35 and 36 , of the female part 32 push the rear and front arms, 48 and 49 , of the male part 33 inwardly, which rigidly assembles the male part 32 with the female part 33 .
[0042] Referring to FIGS. 6 to 8 , a process to assemble the support 31 with the frame 2 is shown. First, the female part 32 in the longitudinal bar 34 is arranged along the longitudinal direction of the opening 9 , and the flange 39 in the bottom of the longitudinal bar 34 is inserted into a gap formed between the bottom cover 3 and the step 10 of the bottom 6 of the frame 2 , which is formed along an edge of the opening 9 . Second, as shown in FIG. 7A , the male part 33 in the longitudinal part 47 thereof is arranged also along the longitudinal direction of the opening 9 , the flange 53 is inserted into the gap formed between the bottom cover 3 and the step 10 of the frame 2 so as to contact the upper surface of the flange 53 with edge of the step 10 defining the gap.
[0043] Then, the male part 33 is inclined so as to direct the rear and front arms, 48 and 49 , upwardly. Pushing the rear and front arms, 48 and 49 , downwardly, the opening 58 of the male part 33 receives the projection 43 of the rear arm 35 of the female part 32 , then, the projection 57 of the male part 33 is inserted into the opening 44 of the female part 32 . Moreover, the projection 60 of the male part 33 is set within the groove 46 in the female part 32 . Thus, rear arms, 48 and 35 , and the front arms, 49 and 36 , are rigidly assembled to each other.
[0044] Next, as shown in FIGS. 9A and 9B , the optical receiver 24 is set on the support 31 as facing the ports, 29 a and 29 b, to the optical receptacle 12 . Finally, a metal cover 61 fixes the housing 25 in a preset position on the support 31 . The metal cover 61 , as shown in FIG. 10 , is formed by a metal plate only by cutting and bending. The metal cover 61 , which has a reversed U-shaped cross section to open downwardly, includes a top 62 and two sides 63 bent downwardly at the side of the top 62 . The top 62 provides tabs 64 in the front and rear thereof. The tabs 64 is formed by two longitudinal slits and slightly bent downwardly. The tabs 64 push the top 26 of the housing 25 downwardly against the support 31 .
[0045] The two sides 63 , which are bent downwardly at respective sides of the top 62 , provide a cut 65 through which the lead pins, 30 a and 30 c, of the optical receiver 24 are exposed. The sides 63 also provide, in the rear and the front thereof, skirts, 66 and 67 , with circular openings, 68 and 69 , in a center thereof. The circular openings, 68 and 69 , mate with the projections, 38 and 52 , of the support 31 shown in FIG. 4B and FIG. 5 . That is, the projections, 38 and 52 , are hooked with the circular openings, 68 and 69 , of the cover 61 . Moreover, the rear skirt 66 provides a hook 70 hooked with the rear end of the longitudinal bars, 34 and 54 , of the female and male parts, 31 and 32 . Hooking the hook 70 with the rear end of the longitudinal bars, 34 and 54 , the metal cover 61 refines the shape thereof. The rear and the front skirts, 66 and 67 , as described above, are bent downwardly at the sides of the top 62 , but an angle of the rear and the front skirts, 66 and 67 , with respect to the top 62 is slightly smaller than a right angle, which further refines the shape of the cover 61 .
[0046] FIGS. 11A and 11B show a process to assemble the cover 61 with the support 31 as putting the optical receiver 24 between them. First, hooking the projections, 38 and 52 , in both sides of one of the front and rear of the longitudinal bar, 34 and 54 , with the corresponding openings, 68 or 69 , among the openings, 69 and 68 , of the front skirt 67 and the rear skirt 58 of the cover 61 , respectively, as expanding a span between the corresponding skirts 67 or 68 in the two front or two rear skirts, 67 and 68 ; the cover 61 is able to pivot by the hooked projections 38 and 52 as the axis of the rotation. Then, pivoting the cover 61 to hook the rest projections 38 and 52 in the front or rear of the longitudinal bars, 34 and 54 , of the support 31 , the cover 61 is assembled with the support 31 as aligning the optical receiver 24 in the preset position on the support 31 . Because the rear and front tabs 64 of the top 62 of the cover 61 press the top 26 of the optical receiver 24 downwardly, which inversely lifts the cover 61 upwardly, the hooking of the projections 38 and 52 with the openings, 68 and 69 , is secured. Moreover, the rear and front skirts, 66 and 67 , of the cover 61 press the support 31 inwardly to enhance the support of the housing 25 of the optical receiver 24 . Thus, the optical receiver 24 is securely set on the support 31 . Moreover, the support 31 in respective flanges, 39 and 53 , is reliably inserted within the gap formed between the step 10 of the frame 2 and the bottom cover 3 ; accordingly, the optical receiver 24 is securely set within the optical transceiver 1 through the support 31 and the cover 61 .
[0047] FIG. 12 is a cross section of the optical transceiver 1 taken along a line intersecting the front skirts 67 , in which FIG. 12 omits the optical receiver 24 set on the support 31 . As shown in FIG. 12 , the front skirts 67 , where the openings 69 are provided in the center thereof, hook the projections 38 and 52 of the support 31 , and put the front portion of respective longitudinal bars, 34 and 47 , therebetween.
[0048] Accordingly, the support 31 is securely held by the cover 61 . Moreover, because the tabs 64 of the cover 61 push the top 26 of the housing 25 downwardly, which also pushes the support 31 downwardly because the optical receiver 24 is set on the support 31 , and the projections, 38 and 52 , are further tightly fastened with the openings 68 and 69 .
[0049] FIG. 13A is a perspective view showing a modified support 31 A and FIG. 13B is a side view of a support 31 A. The modified support 31 A provides, in addition to arrangements shown in FIG. 5 , ribs 54 beneath the projections 38 and 52 in outer surface of respective longitudinal bars, 34 and 47 . The ribs 54 , which may have a triangular cross section, are crushable when the modified support 31 A is set within the frame 2 .
[0050] FIG. 14 is a cross section taken along the lateral direction at a portion where the front skirt 67 of the cover 61 is engaged with the projections 38 and 52 of the modified support 31 A. An assembly of the modified support 31 A with the frame 2 is carried out by procedures substantially same with the process already described. That is, the female part 32 in the flange 39 thereof is first set within the gap formed between the bottom 6 of the frame 2 and the step 10 of the bottom cover 3 ; then, the male part 33 in the flange 53 thereof is also set within the gap formed between the step 10 of the bottom 6 of the frame 2 and the bottom cover 3 as fitting the projections, 43 and 57 , with the corresponding openings, 58 and 44 , in respective arms, 35 and 48 , and the projection 60 with the groove 46 . Synchronizing with the fitting between the female part 32 and the male part 33 , the ribs 54 in the outer surface thereof are crushed by the bottom 6 of the frame 2 . Thus, the support 31 A may be further tightly set within the opening 9 of the frame 2 .
[0051] Although the modified support 31 A provides ribs 54 in the outer surfaces of respective longitudinal bars, 34 and 57 , the modified support 31 A may further provide other crushable ribs in the top surface of the flanges, 39 and 53 , or the top surfaces, 42 and 56 . These ribs on the flanges, 39 and 53 , may be crushed when the flanges, 39 and 53 , are set within the gap formed between the step 10 of the bottom 6 of the frame 2 and the bottom cover 3 by abutting against the step 10 .
[0052] Next, a mechanism to fit the bottom cover 3 with the frame 2 will be described in detail. FIG. 15 is a perspective view of the optical transceiver 1 viewed from the bottom thereof. Although the bottom cover 3 shown in FIG. 2B covers a front end of the frame 2 , namely, a portion neighbor to the optical receptacle 12 , the bottom cover 3 A of the present example ends just front of the optical receptacle 12 . As already described, the bottom cover 3 A covers the whole bottom of the frame 2 to hide the openings 9 and may be made of, for instance, copper (Cu) or copper alloy; while, the frame 2 may be made of, for instance, aluminum (Al), aluminum alloy, zinc (Zn), zinc alloy, and so on. Generally, the bottom cover 3 A may be made of material having thermal conductivity higher than that of material for the frame 2 . The example shown in FIG. 15 , the frame 2 is formed by die-casting of aluminum or zinc, while, the bottom cover 3 A is formed by a copper plate whose thermal conductivity is preferably higher than 280 W/m/K.
[0053] When the frame 2 is made of zinc alloy and formed by die-casting and is to be plated with nickel (Ni), the bottom cover 3 A, which is made of copper alloy, may be also plated with nickel after the bottom cover 3 A is assembled with the frame 2 by the combined process of the strike or flash plating, the electro-plating and nickel plating. In an alternative, the frame 2 and the bottom cover 3 A may be individually plated and assembled together after the plating.
[0054] The frame 2 , as already described in FIGS. 1A to 2B , provides two sides 5 extending longitudinally in both sides of the bottom 6 . Moreover, each of the sides 5 provides the groove 11 . The bottom cover 3 A is slid from the rear of the frame 2 as respective cuffs in respective side edges are guided within the groove 11 . Sliding the bottom cover 3 A to cover the bottom 6 of the frame 2 , the optical transmitter 17 and the local optical source 14 are in contact with the bottom cover 3 A through respective openings 9 . However, the optical receiver 24 mounted on the support 31 is still electrically isolated from the bottom cover 3 A.
[0055] The center beam 8 between the openings 9 is formed thicker to secure the stiffness of the frame 2 . The sides 5 of the example shown in FIG. 2B provide large cuts 7 removing the whole sides 5 to expose the bottom 6 in the center portion thereof. That is, each of the sides 5 is divided into a front portion and a rear portion. The bottom 6 is exposed between these two portions of each of the sides 5 . Accordingly, when no center beam 8 is formed in thicker, the stiffness of the frame 2 along the longitudinal direction becomes insufficient.
[0056] Moreover, the optical transmitter 17 and the local optical source 14 are directly in contact with the bottom cover 3 made of copper alloy through the openings 9 , and these modules, 14 and 17 , therefore enhance the heat dissipating efficiency.
[0057] FIG. 16 magnifies a front portion of the bottom cover 3 A; while, FIG. 17 also magnifies a front portion of the center beam 8 as removing the bottom cover 3 A. The bottom cover 3 A provides an opening 3 a in a front center thereof, while, the center beam 8 of the frame 2 provides a projection 8 a. Sliding the bottom cover 3 A on the bottom 6 of the frame 2 , the projection 8 a engages with the opening 3 a to prevent the bottom cover 3 A from slipping off from the frame 2 . Although the example provides the opening 3 a in the bottom cover 3 A and the projection 8 a in the center beam 8 , a snapping mechanism opposite to the example, that is, the projection in the bottom cover 3 and a hollow receiving the projection in the center beam 8 may be practical. Also, the example of the snapping mechanism shown in figures provides an opening to be latched with the projection; but the snapping mechanism may provide, as an alternative, a hollow to receive the projection. Moreover, the example shown in the figures provides the optical receptacle 12 in a position offset from the center of the frame 2 , the position of the optical receptacle 2 is not restricted to this position. An arrangement of a center receptacle may be applicable to the optical transceiver 1 .
[0058] The opening 3 a of the present example may have a diameter larger than an outer diameter of the projection 8 a by about 0.1 mm to facilitate the engagement between them. The height of the projection 8 a is optional, but preferably less than a thickness of the bottom cover 3 A. The present example of the frame 2 provides the projection 8 a with a height of 0.1 to 0.2 mm. Moreover, the projection 8 a and/or the opening may have chamfered edge.
[0059] FIG. 18A magnifies a front portion of the frame 2 including the optical receptacle 12 , in particular, FIG. 18A shows the groove 11 to set the bottom cover 3 A, while, FIG. 18B is a cross section of the groove 11 . The groove 11 is formed by a rib 11 a and a hollow 11 b formed between the rib 11 a and the body of the side 5 a. The rib 11 a has a length from the bottom of the hollow 11 b to the top thereof smaller than the length from the bottom of the hollow 11 b to a surface of the side 5 a by an amount corresponding to a thickness of the bottom cover 3 A.
[0060] FIG. 19A is a perspective view of the bottom cover 3 A of the present example. As shown in FIG. 19A , the side edges 3 b of the bottom cover 3 A are bent twice to form the hook 3 b, with the U-shaped cross section. The tip 3 d of the hook 3 b is set within the hollow 11 b of the groove 11 when the bottom cover 3 A is slid on the bottom 6 of the frame 2 until the projection 8 a is engaged with the opening 3 a of the bottom cover 3 A. Because the hook 3 b is formed in respective sides of the bottom cover 3 A, the stiffness of the bottom cover 3 A is secured along the longitudinal direction.
[0061] FIG. 19B magnifies the hook 3 b in the edge of the bottom cover 3 A. As described above, the hook 3 b is formed by bending the bottom plate 3 A twice but angles by the bending are slightly different. That is, the first bending in the tip side 3 d of the bottom cover 3 A makes an angle less than a right angle; while, the second bending 3 c closer to the center of the bottom cover 3 A makes a substantially right angle. Accordingly, when the tip 3 d of the hook 3 b is set in the hollow 11 b of the groove, the U-shaped hook tightly catches the rib 11 a of the groove 11 .
[0062] FIG. 20 is a perspective view showing another snapping mechanism between a bottom cover 3 B and the frame 2 . The example shown in FIG. 20 provides in the bottom cover 3 B thereof a repulsive mechanism to give a repulsive force against the bottom cover 3 B in addition to the opening 3 a. That is, the repulsive mechanism includes a protrusion 3 t and a lateral slit 3 s behind the protrusion 3 t. Sliding the bottom cover 3 B from the rear of the frame 2 to the front end of the groove 11 , the protrusion 3 t abuts against the rear wall of the front end of the optical transceiver 1 . The lateral slit 3 s is formed behind the projection 3 t to provide areas 3 n with a shortened length between the lateral slit 3 s and the edge of the bottom cover 3 B. Moreover, the tip of the protrusion 3 t protrudes from the front edge of the bottom cover 3 B, then, the tip of the protrusion 3 t first comes in contact with the rear wall 2 a of the front portion of the frame 2 . Then, the portions 3 n with the shortened length to the edge in both sides of the protrusion 3 t elastically push the bottom cover 3 B rearward, but the engagement of the projection 8 a with the opening 3 a compensates this rearward motion of the bottom cover 3 B. Thus, the bottom cover 3 B may be further tightly set with the frame 2 .
[0063] Although the example shown in FIG. 20 provides the mechanism to cause repulsive force in the bottom cover 3 B, this mechanism may be realized in the frame 2 in the front portion thereof. Thus, according to examples described above, the bottom cover, 3 , 3 A and 3 B, may be securely assembled with the frame 2 . Because the bottom cover 3 is made of copper (Cu) with relatively larger thermal conductivity, the bottom cover 3 securely assembled with the frame 2 enhance the heat dissipating function of the components installed within the optical transceiver 1 , typically, an optical transmitter 17 , and/or a local signal source when the optical transceiver 1 is applied to, what we call, the optically coherent communication system.
[0064] While particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.
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An optical transceiver that copes with both the enhanced heat dissipation from heat generating components and the electrical isolation of components processing faint signals from other components generating EMI noises is disclosed. The optical transceiver provides, in addition to a bottom of a frame, a bottom cover made by material with higher thermal conductivity. The former components are directly mounted on the bottom cover through openings in the frame, while, other component to be electrically isolated from the chassis are mounted by putting an insulating support between them and the bottom cover.
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FIELD OF INVENTION
The present invention relates to airborne instrumentation used for measuring cloud microphysical parameters. In particular, the present invention relates to probe tips for use with airborne instruments.
BACKGROUND OF THE INVENTION
The existence of small ice particles has remained a highly debatable issue in the cloud physics community. The first measurements of ice cloud particle sizes were obtained in the 1930's with the help of airborne impactors, yet almost eighty years later, researchers have yet to establish a consensus on whether observations of small ice particles with diameters <100 μm represent naturally occurring ice particles, or are the result of shattering of larger ice particles with the measuring probe's arms.
The presence of small ice particles may play a crucial role in the conversion of water vapor into precipitation. Furthermore, this may significantly affect radiation transfer in clouds and eventually affect the radiation budget of the Earth. Currently, small ice particles are included in many weather prediction and climate models, despite the fact that their natural occurrence has not yet been fully demonstrated.
The majority of airborne probes that are designed to measure cloud particles sizes use a laser-based measurement method, e.g. as illustrated in FIGS. 1A and B. The laser is shone between two supporting arms 1 which point into the air stream. As cloud particles with diameters from sub-micron to several centimeters cross through the laser beam 2 , the laser light is blocked or scattered (depending on the instrument) by the cloud particles. Changes to the laser beam can be measured by various types of detectors from which the shapes, sizes and concentrations of the cloud particles can be determined. Existing technology uses semi-spherical or rounded arm tips 3 for the particle measurement probes. As shown for example in FIG. 1A , the semi-spherical tips generate large amounts of shattered, splashed and/or bounced particle fragments that are deflected into the sample volume of the probes.
It has been assumed for many years that cloud particles that shattered, splashed or bounced off of the protruding measurement arms, and which subsequently passed through the laser beam, would have an insignificant effect on the measurements of the cloud particle sizes and concentrations. This assumption is no longer deemed to be correct, and significant effort has been made to understand this phenomenon. Data processing methods to correct for the distortions in the natural cloud particle spectra caused by the particle shattering have been developed (Korolev et al., Journal of Atmospheric and Oceanic Technology, 2005, 22:528-542; Lawson et al., Journal of Applied Meteorology and Climatology, 2006, 45:1291-1303) and alternate methods of data collection using non-airborne instrumentation have also been pursued (Mertes et al., Aerosol Science and Technology, 2007, 41:848-864).
Despite these efforts, there continues to be a need for improved ice cloud particle measuring instrumentation that reduces the cloud particle shattering effect previously seen in cloud particle spectra.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide improved airborne instrumentation used for measuring cloud microphysical parameters.
The invention relates to modified probe tips having an asymmetric shape to minimize both the surface area and length of edges which, upon impact, deflect particles towards the sample volume of the probe. The outer part of the tips consists of a pyramidal section having either flat or concave surfaces in order to minimize water shedding from the outer part of the tip towards the inner part and to prevent water from getting into the optical widows.
The invention further relates to an area of the probe arm in front of the optical window having a trap for water shedding along the arm surface, to prevent this water from entering the optical window. The water trap may comprise a narrow groove that expands towards its edges. The purpose of this expansion is to generate the air suction inside the groove to channel the shedding water away from the optical window.
There is accordingly provided herein an instrument for obtaining airborne measurements of cloud microphysical parameters. The instrument comprises supporting arms mounted thereon, optics and a detector for measuring the cloud microphysical parameters. The supporting arms define an optical path of the instrument. The instrument further comprises tips affixed to the supporting arms having an outer portion for deflecting particles away from the optical path of the instrument and an inner portion opposite the outer portion, The outer portion of the tips comprise a pyramidal section having a centre ridgeline and flat or concave surfaces effective to reduce water shedding from the outer portion of the tip towards the inner portion.
Also provided herein is a probe tip for airborne instruments used to measure cloud microphysical parameters. The probe tip has an outer portion for deflecting particles away from an optical path of the instrument, and an inner portion opposite the outer portion. The outer portion of the tip comprises a pyramidal section having a centre ridgeline and flat or concave surfaces effective to reduce water shedding from the outer portion of the tip towards the inner portion.
There is also provided a method of reducing particle shattering during collection of airborne measurements of cloud microphysical parameters. The method comprises steps of:
providing an airborne cloud particle measuring instrument with supporting arms mounted onto the instrument, optics and a detector for measuring the cloud microphysical parameters, the supporting arms defining an optical path of the instrument; providing tips for the supporting arms having an outer portion for deflecting particles away from the optical path of the instrument and an inner portion opposite the outer portion, the outer portion of the tips comprising a pyramidal section having a centre ridgeline and flat or concave surfaces effective to reduce water shedding from the outer portion of the tip towards the inner portion; and collecting measurements in flight of cloud microphysical parameters using said airborne cloud particle measuring instrument, wherein the particle shattering observed in the collected measurements is reduced.
In an embodiment of the above instrument and method, the optics are laser-based optics. As an example, the instrument may be an OAP-2DC, OAP-2DP, HVPS, CIP, FSSP, CPI, CAPS and SID-type airborne cloud particle instrument.
In further embodiments, the supporting arms each comprise an optical window through which light from the optics of the instrument passes along said optical path. The supporting arms may optionally include a water trap to prevent water shed along the arm surface from entering the optical window. In such embodiments, the water trap may preferably form a narrow groove forward of the optical window that expands towards its edges to channel the shedding water away from the optical window.
According to further embodiments of the invention, the centre ridgeline may have a concave curvature, or it may be straight. Similarly, the outer surfaces of the pyramidal section may be flat or concave.
The modified arm tips and water trap for the airborne cloud particle measurement probes mitigate the effect of ice particle shattering and droplet splashing on the measurements of cloud particle sizes, shapes and concentrations.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings wherein:
FIG. 1 is a conceptual diagram of the mechanism of particle shattering during sampling by (A) OAP-2DC, OAP-2DP, HVPS, and CIP-type airborne cloud particle instruments, and (B) FSSP, CPI, CAPS and SID-type airborne cloud particle instruments, due to the mechanical impact with probe parts upstream of the sample area;
FIG. 2 is a photographical representation of particle shattering caused by mechanical impact with probe parts upstream of the sample area in a OAP-2DC arm during wind tunnel testing (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s);
FIG. 3 is a photographical representation of conical FSSP arm tips, the FSSP probe installed inside a wind tunnel compartment;
FIG. 4 is a photographical representation of the conical FSSP arm tips shown in FIG. 3 during exposure to high speed supercooled liquid spray, and illustrating the ice build-up on the tip surface exposed to the airflow;
FIG. 5 is a close-up view of the conical FSSP arm tips shown in FIG. 4 , showing (A) the streaks of frozen water shed along the inner tip's surface formed when the tip heaters were turned off; and (B) refrozen water on the unheated section of the arm tip in the form of an ice ridge, resulting from the water shed along the inner tip surface;
FIG. 6 is a photographical representation of conical OAP-2DC arm tips based on the design published in Korolev et al., J. Atm. Ocean. Techn (2005; supra) during wind tunnel testing (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s), and showing refrozen water on the unheated section of the arm. The build up of the refrozen water around the whole arm suggests that the water sheds along both inner and outer surface of the arm, and when water sheds along the inner part of the arm surface it may get into the optical window;
FIG. 7 is a photographical representation of conical FSSP arm tips based on the design published in Korolev et al., J. Atm. Ocean. Techn (2005; supra) installed inside a wind tunnel compartment during wind tunnel testing (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s) and showing build up of refrozen water around the whole unheated section of the arm, suggesting that the water sheds along both inner and outer surfaces of the arm and that water shed along the inner part of the arm surface may get into the optical window;
FIG. 8 shows (A) modified pyramidal OAP-2DC arm tips according to an example of one embodiment of the invention, and (B) the arm tips of (A) mounted onto the forward portion of an OAP-2DC measuring probe; the outer part of the tips consisting of either flat or concave surfaces in order to minimize water shedding from the outer part of the tip towards the inner part and to prevent water from getting into the optical windows;
FIG. 9 shows modified pyramidal arm tips according to further examples of an embodiment of the invention, having a curved pyramidal outer tip portion with concave ridgeline (A), a curved pyramidal outer tip portion with straight ridgeline (B), and a flat pyramidal outer tip portion with straight ridgeline (C);
FIG. 10A is an expanded view of the bottom pyramidal OAP-2DC arm tip shown in FIG. 8A ; illustrating the optical window of the probe and a water trap for directing water shed along the arm surface away from the optical window;
FIG. 10B is an expanded view of a possible alternate embodiment of the pyramidal OAP-2DC arm tip shown in FIG. 8A ;
FIG. 11 is a photographical representation of pyramidal OAP-2DC arm tips according to an embodiment of the invention, mounted onto the forward portion of an OAP-2DC measuring probe installed inside a wind tunnel compartment during wind tunnel testing (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s) and showing minimal build up of refrozen water around the inner part of the arm surface, suggesting significant reduction in the amount of water shed along the inner arm surface and therefore reduced amounts of water getting into the optical window;
FIGS. 12A and B illustrate modified OAP-2DC arms of additional exemplary embodiments of the invention, each having different arm configurations;
FIGS. 13A and B illustrate modified OAP-2DC arms of further exemplary embodiments of the invention, each having different arm configurations; and
FIGS. 14A-D illustrate modified Cloud Particle Imager (CIP) tip arms of yet further exemplary embodiments of the invention, incorporating a pyramidal CIP arm tip design.
DETAILED DESCRIPTION
High speed video recording of bouncing and shattering of ice particles conducted in wind tunnels has been obtained by NASA in cooperation with Environment Canada confirming that ice particles can shatter and bounce into the sample volume of the particle probes. This is clearly evident in the photograph shown in FIG. 2 , where ice particles 4 can be seen bouncing off the semi-spherical probe tip 3 of the probe arm 1 during wind tunnel testing.
Until now, it has been generally believed that the shattered particles could be identified and eliminated during analysis of the cloud particle spectral data, and thus no attempts have been made to redesign the probes' arm tips to mitigate shattering.
The present inventor has modified the probe tips with a view to minimizing the effect of cloud particle shattering. This approach is particularly desirable over the data correction methods currently in use, for instance, since (i) ice particle shattering with standard OAP-2DC arms is thought to result in the overestimation of the measured concentration ten fold or more; and (ii) for some instruments (e.g. OAP-2DC) existing algorithms are incapable of filtering out all shattering events.
The well-known semi-spherical probe tips were replaced with (i) conical and (ii) pyramidal probe tips and tested in wind tunnel experiments to ascertain which design has the greatest effect in reducing the effect of ice shattering on measurements.
The configuration of the wind tunnel testing compartment can be seen in FIG. 3 , in which a FSSP probe is installed having conical tips 3 on the probe arms 1 . When exposed to high-speed supercooled liquid spray within the test environment, ice build-up 5 can be seen on the tip surface exposed to the airflow ( FIG. 4 ). However, as is better seen in the close-up view of the conical FSSP arm tips in FIG. 5 , when the tip heaters are turned off streaks of frozen water A can be observed. These are shed along the inner tip's surface and cause a build up of refrozen water on the unheated section of the arm tip in the form of an ice ridge B. The water shed along the inner tip surface may also enter the optical window 10 of the probe arm.
Wind tunnel testing was also undertaken using an OAP-2DC probe fitted with conical arm tips. This conical OAP-2DC arm tip design is based on the design published in Korolev et al., J. Atm. Ocean. Techn (2005; supra). As is observed in FIG. 6 and similar to the results obtained using conical FSSP probe tips, refrozen water builds up on the unheated sections of the OAP-2DC arms during wind tunnel tests (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s). The build up of the refrozen water 6 around the whole arm suggests that the water sheds along both inner and outer surfaces of the arm. Thus, when water sheds along the inner part of the arm surface it may enter the optical window 10 and interfere with the optical measurements of the probe.
For comparative purposes, conical FSSP arm tips based on the design published in Korolev et al., J. Atm. Ocean. Techn (2005; supra) were also tested as described above for the OAP-2DC probe (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s). Results of the wind tunnel experiments, portrayed in the photograph of FIG. 7 , showed refrozen water 6 built up around the whole unheated section of the arm, similarly suggesting that the water sheds along both inner and outer surfaces of the arm and that the water shed along the inner part of the arm surface may get into the optical window 10 .
FIG. 8A shows modified pyramidal OAP-2DC arm tips according to an example of one embodiment of the invention. According to the example shown, the tips have an outer pyramidal tip portion 12 designed to deflect water, ice or other cloud particles away from the inner surface of the probe tip. The pyramidal tip portion 12 has a center ridgeline 13 and outer surfaces 15 a and 15 b . The pyramidal tips can be installed on the arms 1 of an OAP-2DC probe, which are in turn mounted onto the forward portion 11 of the instrument as illustrated in FIG. 8B according to means commonly known in the art, for instance via mounting flanges 9 .
In further exemplary embodiments, as illustrated in FIGS. 9A-B , the outer surfaces 15 a and 15 b of the probe tips may be concave. Alternatively, the outer surfaces 15 a and 15 b of the probe tips may be flat as can be seen in FIG. 9C . In addition, the center ridgeline 13 of the probe tips may be concave as illustrated in FIG. 9A , or straight as illustrated in FIGS. 9B and C. In certain embodiments it may be desirable to incorporate concavity into outer surfaces 15 a and 15 b and/or curvature into the center ridgeline 13 of the outer pyramidal portion 12 , to further mitigate the shedding from the outer part of the tip towards the inner part and reduce the shattering effect caused by small water, ice or other cloud particles during operation. However, in other embodiments a straight center ridgeline 13 and flat outer surfaces 15 a and 15 b of the probe tips may be sufficient for reducing the shattering effect.
FIG. 10A depicts the bottom pyramidal OAP-2DC arm tip shown in FIG. 8A in expanded view, in order to better illustrate the optical window 10 of the probe and an optional water trap 17 . The water trap 17 may comprise a notch, trough or other formation in the upper surface of the probe arm 1 effective to direct water which is shed along the inner arm surface away from the optical window 10 . The water trap 17 may be machined or otherwise formed to the desired depth and dimensions based on the type of cloud particle instrumentation. As depicted, the water trap 17 is machined into the probe arm immediately forward of the optical window. A possible alternate embodiment of the water trap 17 can also be seen in FIG. 10B .
Pyramidal arm tips as described above and illustrated in FIGS. 8-10 were mounted onto the forward portion of an OAP-2DC measuring probe installed inside a wind tunnel compartment and tested according to similar wind tunnel testing used for the conical arm tips (Cox Wind Tunnel, D˜2.5 cm, TAS˜70 m/s). The results of this testing are depicted in FIG. 11 , and show that minimal amounts of refrozen water build up around the inner parts of the arm surfaces, suggesting a significant reduction in the amount of water shed along the inner arm surface and therefore reduced amounts of water getting into the optical window. Accordingly, these tests suggest that the effect on cloud particle size distribution measurements by water, ice or other cloud particle shattering on the arms of cloud microphysical instruments can be significantly reduced through the use of pyramidal arm tips as described herein. The pyramidal arm tips are a substantial improvement over the semi-spherical arm tips commonly used in the art, and also represent a marked improvement over the conical tip option as described herein.
Based on the observations made during testing, pyramidal arm tips as described herein reduce the effect of shattering, splashing and bouncing on the measurements of particle shape, size and concentration. Preliminary estimates suggest that concentrations of cloud particles may be changed by up to a factor of twenty, depending on the size of the cloud particles. The suggested solution significantly reduces the effect of the shattering, splashing and bouncing on measurements.
Additional embodiments of the pyramidal probe tips of the invention can be envisioned, for instance as illustrated in FIGS. 12-14 . Modified OAP-2DC arms having different arm configurations are seen in FIGS. 12A and B and FIGS. 13A and B, each having pyramidal arm tips with outer surfaces 15 a and 15 b and a center ridgeline 13 . Similarly, modifications to Cloud Particle Imager (CIP) tip arms can be envisioned, such as that illustrated in FIGS. 14A-D whereby pyramidal arm tips with outer surfaces 15 a and 15 b and a center ridgeline 13 are incorporated into the CIP tip design. Similar modifications may be made to incorporate pyramidal probe tips into other similar airborne cloud particle instruments, for instance OAP-2DP,HVPS, FSSP, CPI, CAPS and SID-type airborne cloud particle instruments.
One or more currently preferred embodiments have been described by way of example. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims.
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An instrument for obtaining airborne measurements of cloud microphysical parameters. The instrument comprises supporting arms mounted thereon, optics and a detector for measuring the cloud microphysical parameters The supporting arms define an optical path of the instrument and comprise probe tips affixed thereto. The probe tips comprise an outer portion for deflecting particles away from the optical path of the instrument and an inner portion opposite the outer portion. The outer portion of the tips have a pyramidal section with a centre ridgeline and flat or concave surfaces effective to reduce water shedding and particle shattering during in-flight collection of data.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a two-stage oil bypass filter device. More particularly, the present invention relates to a new and improved two-stage oil bypass filter assembly, having a unique evaporation plate and novel filter cartridge for employing electrical energy and mechanical pressure to remove impurities from the oil circulating within internal combustion engines, and other applications.
2. Description of the Related Art
The use of oil reconditioning devices, particularly as employed in internal combustion engines is well known. As an engine functions, the lubricating oil within it is subject to contamination primarily in two forms. First, particulates, including metal particles and carbon particles that accumulate within the oil. Second, volatile liquid contaminants such as water and uncombusted fuel, derived from the combustion process, are continually introduced into the oil as the engine runs or is turned off and cools. For this reason, the oil used to lubricate internal combustion engines is changed often, in some instances as often as every 3,000 miles of travel for the vehicle. This is a very expensive, time consuming, and environmentally unsound practice. Therefore, it would be highly desirable to have a system whereby the lubricating oil would be subject to the removal of contaminants as it is continuously circulating through an internal combustion engine.
Perhaps the most familiar device is the standard full flow oil filter present on all automobile and truck engines. This primary full flow filter device is attached to an engine and the oil flows through it to effect the removal of particulate contamination. While being somewhat effective, this oil filter arrangement does not eliminate the need to change the engine oil on a regular basis because a standard primary full flow filter eliminates only the large particle contaminants from the oil, namely, those particles that are greater than 25 microns in size, and no liquid contaminants.
As an improvement and addition to the standard oil filter, many improved secondary by-pass oil reclamation devices have been invented and patented. Pertinent prior art which is directed toward these oil reclamation devices include U.S. Pat. Nos. 3,915,860, 4,227,969, 4,189,351, 4,289,583, 4,369,110, 4,943,352 and 5,322,569, all incorporated by reference herein. In addition to being mechanical particulate contaminant removing filters, these devices remove volatile liquid contaminants from oil by employing an evaporation plate in various configurations.
In U.S. Pat. No. 3,915,860 an oil reconditioning device is provided with a vaporization plate component and a particulate filtration component. The vaporization plate is heated by electrical power. Oil is forced to flow through the filter component via the inherent oil pressure present in the engine.
The disadvantages of this device include inefficiency in the heating of the vaporization plate. The fact that the filter element is of a case cannister design rather than a spin-on cannister design makes initial mounting and subsequent replacement of the consumable portion of the unit, namely the filter media element difficult. Because the evaporation plate surfaces are not in close proximity to the heating element, much more electrical energy is required to effect vaporization of the volatile contaminants within the oil. Therefore, it would be highly desirable to have an oil reconditioning device with greater ease of mounting and filter replacement, as well as one which operates at greater efficiency with respect to vaporization of volatile contaminants.
U.S. Pat. Nos. 4,227,969, 4,189,351, and 4,289,583 disclose a novel oil reclamation device which attempts to solve these problems. While providing an improved heat transmitting element, and evaporator plate, this oil reclamation unit has several shortcomings. First, the filter unit is of the case cannister design, making it more difficult to install and replace. To effectively replace the filter unit, the top part containing the heating element must be removed first, then the oil diffuser plate must be removed. Additionally, four gaskets must be replaced and properly positioned. Upon removal of the filter unit, two of these four gaskets are located at the very bottom of the cannister housing, submerged in a standing pool of oil. Therefore, it can be a very messy job replacing the filter unit. This makes replacement or repair more time consuming and expensive, and either operation is prone to contaminate the work area with spilled oil.
Second, the evaporator assembly is poorly secured to the filter element by standard wing nuts, and the cannister housing is known to leak oil.
Additionally, while improved, the evaporator plate is still not optimally efficient. The heating element is only partially in contact with the evaporation plate. Only about one quarter of the evaporation plate is efficiently heated through contact with the heating element, with the result that more electrical energy is required to remove volatile contaminants from the oil.
Finally, the oil reclamation devices that are the subject of these three patents employ a pre-filter flow reducer with a circumferential groove through which oil is directed. Because the metering element is encountered by contaminated oil before passing through the filter unit, it is much more prone to clogging.
Therefore, it would be highly desirable to have an oil reclamation device which employed a spin-on cartridge design, an efficient heating element/evaporation plate configuration, and a metering element that was positioned post-filter with respect to oil flow thereby making it much less likely that the metering element would become clogged and require repair or replacement, or any other related type of servicing.
The inventive oil reclamation device described in U.S. Pat. No. 4,943,352 incorporates essentially the same design as the prior art patents discussed above, with the notable improvement that the filter unit employs a spin-on filter cartridge. However, the heating element and evaporation plate configuration is again not optimal as only a small portion of the heating element actually makes contact with the evaporation plate. Additionally, the volume and surface area capacities of the evaporation chamber in this device are inadequate for the oil flow rates expected in most of the applications for which it is employed. As a result, volatile contaminants are not effectively and efficiently eliminated from the circulating oil.
Therefore, it would be highly desirable to have a new and improved two-stage oil bypass filter with an energy efficient heating element/evaporation plate configuration, and an oil additives system incorporated into a spin-on filter design, to enable a continuous introduction of oil additives substances into the circulating oil.
U.S. Pat. No. 4,369,110 teaches an oil filter for use on internal combustion engines having an improved spin-on filter element. Oil is first directed to the base of the filter element then forced upwardly into the filter medium before passing on to the evaporation plate assembly. However, once within the evaporation chamber potentially only a small portion of the oil to be cleaned has the potential to come into contact with the heating element. This design is inefficient because the heating element is very small with respect to the size of the evaporation chamber volume, and the amount of oil expected to be in that chamber at any given time. Moreover, the heating element is not positioned to heat the walls of the chamber in any way, making contact between the oil and the heating element essential in the oil reconditioning process. Even if the diffuser plate was heated directly, it still appears to be too small in proportion to the oil within the chamber to remove volatile contaminants from the oil in an efficient manner. Finally, because of the size of the evaporation chamber housing, this filtration unit would be difficult to install in restricted spaces, such as those encountered in truck engine compartments.
Therefore, it would be highly desirable to have a new and improved oil filtration unit with an efficient heating element/evaporation plate configuration, all in a unit that was compact in size and readily adapted to being installed in tight spaces, namely on truck engines.
The type of inventive oil reclamation device described in, and represented by, U.S. Pat. No. 4,943,352 incorporates a pre-filter metering element or flow reducing element in which the contaminated oil is directed into and through the flow reducing element prior to any contact with the filter media within the filter cartridge. Because the oil encounters the flow reducing element before its passage through the filter, the pressure at which oil enters the filtration unit is considerably reduced.
Thus, it follows that as the filter element becomes clogged with contaminants, the reduced oil pressure lessens the ability of the contaminated oil to fully utilize the total or optimal volume of filter media, and the flow of oil is prematurely reduced.
While the inventive oil reclamation device described in, and represented by, U.S. Pat. No. 5,322,596 incorporates a post-filter metering element or flow reducing element as well, the amount and nature of the filtration of oil is limited by the annular cartridge design and the resultant limited filtration distance inherent in the reclamation device overall is not desirable.
Therefore, it would be highly desirable to have an oil reclamation device which employed a metering or flow reducing element after the contaminated oil passed through the filter cartridge to maintain, to the fullest extent possible, the driving force of the entering oil pressure along with a maximum distance and maximum volume of filter media contacted and utilized in which the contaminated oil would be filtered to remove particulate contaminants.
Finally, all of the prior art devices mentioned above incorporate metal outer housings surrounding the vaporization plate or evaporation chamber mechanism. These outer housings necessarily reach high temperatures of 190 degrees to 250 degrees Fahrenheit during operation as the heating element is mechanically attached to the outer housing itself. As a result, the outer housings get very hot themselves, and as such become a safety hazard. External heated metal housings expose repair and maintenance technicians to the threat of burns.
Therefore, it would be highly desirable to have an oil reclamation device that incorporated a non-heat conducting material into its outer housing to significantly reduce or eliminate the threat of burning individuals performing repair or routine maintenance operations on the device.
SUMMARY OF THE INVENTION
Therefore, the principal object of the present invention is to provide a new and improved two-stage oil bypass filter device having a more effective and efficient heat transfer and vaporization surface configuration as well as a post-filter flow reducing element and an oil preheating staging area.
It is a further object of the present invention to provide such a new and improved two-stage oil bypass filter device that incorporates a filter element that is readily replaced and which directs the flow of contaminated oil throughout the entire filter medium.
It is yet a further object of the present invention to provide such a new and improved two-stage oil bypass filter device in which customized oil additive combinations are readily mixed with oil being simultaneously subjected to the removal of particulate and volatile contaminants, as required by varying applications.
It is yet another object of the present invention to provide such a new and improved two-stage oil bypass filter device having a housing composed of non-heat conducting material to enhance safety.
Briefly, the above and further objects of the present invention are realized by providing a new and improved two-stage oil bypass filter device to enable effective and efficient removal of both solid particulate and volatile oil contaminants while also allowing the addition and mixing of certain oil additives as required by specific internal combustion engine or industrial applications. The novel two-stage oil bypass filter device includes a cone-shaped vaporization plate having a heating element located below the surfaces to be heated to provide for more effective and efficient heating of those surfaces critical to removing volatile contaminants, a horseshoe-shaped oil staging channel to provide preheating of the oil, a post-filter flow reducer to greatly reduce the possibility of clogging, a readily replaceable spin-on filter cartridge having a centrally located oil feed tube and an oil diffuser plate which directs the oil to be filtered to all parts of the filter media within the cartridge, an additives package configuration within the filter cartridge for continuous addition and mixing of oil additive substances to the oil being filtered, and a high grade, high impact thermoplastic cap housing to prevent external heating and considerably reduce the potential for burn accidents.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other objects and features of this invention and the manner of attaining them will become apparent, and the invention itself will be best understood by reference to the following description of the embodiment of the invention in conjunction with the accompanying drawings, wherein:
FIG. 1 is an exploded partially cut-away perspective view of the novel two-stage oil bypass filter device with the novel filter cartridge not attached to the novel head assembly;
FIG. 2 is a perspective view of the novel two-stage oil bypass filter device when fully assembled showing the filter cartridge attached thereto;
FIG. 3 is a partially exploded sectional perspective view of the vaporization cone component of the novel two-stage oil bypass filter device showing the heating element;
FIG. 4 is a longitudinal sectional view of the head assembly;
FIG. 5 is a front elevational view of the novel two-stage oil bypass filter device;
FIG. 6 is a top plan view of the novel two-stage oil bypass filter device;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 4; and
FIG. 8 is a sectional view taken along line 8--8 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and more particularly to FIG. 1 thereof, there is shown a new two-stage oil bypass filter device 10 which is constructed in accordance with the present invention. The novel two-stage oil bypass filter device 10 is used to remove both particulate and volatile contaminants from oil being simultaneously circulated to lubricate an internal combustion engine, for example, a vehicle engine, or other industrial applications in which oil is used to lubricate a machine for instance, and in such applications where oil is circulated and maintained at a certain pressure within a closed system. The novel two-stage oil bypass filter device is mounted in close proximity to the application and oil is sent to and from the filter device unit by way of hoses, pipes or other conduits.
The novel two-stage oil bypass filter device 10 is constructed of two primary assemblies. The first being the head assembly 20, which includes the thermoplastic cap component 11, the vaporization cone component 40, and the base plate component 50. The second being the spin-on oil filter cartridge assembly 30, which includes the oil filter cartridge housing 70 and the additives package 60.
Referring now to FIG. 1 in greater detail, the components making up the head assembly 20 are housed within the thermoplastic cap 11 which is secured to the other components of the head assembly 20 by four dome nuts as represented by dome nuts 15 and 17, positioned within recesses in the thermoplastic cap 11. Within the thermoplastic cap 11, the vaporization cone component 40 and the base plate component 50 are secured together by four threaded bolts as represented by threaded bolt 26. Bolt head 28 lies within a recess in base plate 42, and is exposed for easy unfastening. Four intermediately positioned keps nuts, as represented by keps nut 31, secure the vaporization cone component 40 to the base plate component 50. The keps nut 31 is first threaded onto the threaded portion of the threaded bolt 26 in order to secure the vaporization cone component 40, then the dome nut 15 is threaded onto the remaining threaded portion of the threaded bolt 26 to secure the thermoplastic cap 11.
A threaded aperture 19 on the top surface of the thermoplastic cap 11 allows for the fitting of a vapor valve 13, such as a ball check valve having a vapor outlet 22. Two slots in the construction of the thermoplastic cap 11, as represented by slot 55, allow for the protrusion of two mounting brackets, as represented by mounting bracket 55. The mounting bracket 51 is affixed to the base plate component 50 by a suitable means such as welding, or is cast into the component. Each mounting bracket includes two or more mounting holes, as represented by mounting hole 53, and in this way the head assembly 20 can be securely mounted in an optimal position for operation of the novel two-stage oil bypass filter device. The cap 11 is preferably made of high grade, high impact thermoplastic material for safety reasons, as metal cap materials retain heat and can be a burn danger in repairing or replacing a filter device.
In between the base plate 42 and the vaporization cone 33 is a gasket 95 to provide for a tight seal to prevent any oil from leaking from the head assembly 20. Within an o-ring accepting groove 25 circling around the entire circumference of the upper portion of the vaporization cone component 40, is an o-ring 24 forming a seal between the thermoplastic cap 11 and the vaporization cone component 40 to prevent leakage of oil from the head assembly 20. The gasket 95 and the o-ring 24 are made from suitably heat resistant materials such as heat resistant rubber, cork or other synthetic substances.
In greater detail, the vaporization cone component 40 is made up of single unitary aluminum piece having a center portion shaped like a cone. This vaporization cone 33 has a partially hollow center cavity 64 for accepting an electrical heating element not shown here(see FIG. 3). The electrical heating element is supplied with power through wires within a metal casing (not shown here)that pass through an electrical conduit channel 66.
The lower portion of the vaporization cone component 40 contains a horseshoe shaped oil staging channel 39 which first accepts oil flowing from the flow reducing element 59 through threaded aperture 68. Once the oils staging channel 39 is filled to capacity with oil, the oil travels up through an oil feed passageway 37 to reach the slotted oil reservoir 35 located at the apex of the cone-shaped vaporization cone 33. Oil then uniformly spills through the slots in the slotted oil reservoir 35, in a uniform thin oil film, and down the cone shaped vaporization cone 33, which has been heated by the heating element (not shown).
Before reaching the vaporization cone component 40, the contaminated oil first passes into the base plate component 50 through the oil inlet nipple 44, passing along the horizontal oil inlet channel 46 and down the vertical oil inlet channel 48. With the oil filter cartridge 30 firmly secured to the base plate 66 by threading the female threaded aperture 71 of the filter unit 30, to the threaded portion 62 of the base plate component 50, the oil will then pass into the oil feed tube 77.
The oil feed tube 77 is centrally located within the oil filter housing 70, and is configured in an inverse conical shape. The oil feed tube is integrally connected to the oil diffuser plate 80 which contains numerous small apertures, as represented by aperture 82. Lying in the space below the oil diffuser plate 80 within the oil filter cartridge 30 is the additives package 60, constructed of a sack 84 made of suitable materials, such as natural or synthetic fabrics containing oil additives 86. These additives include certain elemental and chemical substances, including but not limited to silicone polymers, organic copolymers, zinc dithiophosphates, hindered phenols, aromatic amines, sulfurized phenols, or more generally organic complexes containing nitrogen or sulphur amines, sulfides and phosphites, and other oil conditioning substances, which when added to oil protect metal surfaces (bearings, gears, rings, etc.), extend the range of lubricant applicability or extend the life of the oils lubricating capacity. Moreover, certain oil additives can act as emulsifiers, demulsifiers, tackiness agents, bactericides, anti-wear agents, detergents, friction modifiers, dispersants, corrosion and rust inhibitors, seal swell agents, and viscosity modifiers as required by varying internal combustion engine and industrial applications.
After passing through the additives package 60, oil moves through aperture 82 in oil diffuser plate 80 and into the oil filter medium 79. This filter medium 79 is preferably composed of compressed long-strand unbleached cotton fibers, king-strand unbleached cotton fibers, spun cotton fibers or a pleated filter media material. These materials are known to remove particles, ranging from 1 to 3 microns in size, from the oil.
Oil exits the filter cartridge 30 through a plurality of oil filter return ports, as represented by oil filter return port 73. There may be between 5 and 8 or more oil filter return ports located on the upper surface (known as the base plate)of the filter housing 70.
Oil passing from the filter cartridge, exits out the oil filter port 73 and into the oil staging channel 39 of the vaporization cone component 40 through the metering jet or flow reducer 59. This flow reducer 59 is threaded into the base plate 42 within threaded aperture 68, with an equal diameter aperture above it, spanning the gasket 95. The flow reducer 59 has a 0.022 inch or greater flow channel, and acts to govern the overall flow of oil throughout the two-stage oil bypass filter device 10. Flow rates of 3 to 6 gallons per hour are normal for this size and type of flow reducer. Flow rates can be altered, to accommodate differing application conditions or specification requirements by changing the nature of the post-filter metering jet element or flow reducer 59. The filter housing base plate seating gasket 75 maintains an oil tight seal between the oil filter cartridge 30 and the base plate component 50, preventing leakage therefrom.
Considering now the two-stage oil bypass filter device 10 in greater detail with reference to FIGS. 2, 3, 5 and 6, the head assembly 20 includes an oil outlet nipple 88 which can be positioned in either of two different threaded portions 99 and 102, to provide for versatility in mounting and connecting the entire unit. When the oil outlet nipple 88 is inserted into one threaded portion, either 99 or 102, then the other threaded portion would accept a plug 91. In this way the oil inlet nipple 44 and the oil outlet nipple 88 may be positioned directly adjacent to each other (as shown in FIGS. 2 and 5) or on opposite sides of the head assembly 20 (as shown in FIGS. 7 and 8).
Turning now to FIG. 3, the vaporization cone component 40 is isolated and shown in greater detail. Four bolt thru-holes, as represented by thru-hole 93 are centrally located within four corresponding bolt thru-hole columns integrally molded into the vaporization cone component 40. Heating element 97, provided with electrical power via electrical conduit 90, fits up into cavity 64 to efficiently heat the entire vaporization cone structure 33 from below, which is a significant improvement over the prior art. Two sets of electrical wire pairs run within the electrical conduit, configured to run off of 12/24 volts or 120/220 volts, or any other appropriate voltage applicable to the intended implementation of the device, depending on the application requirements and specifications.
Turning now to FIG. 7, the oil feed passageway 37 is clearly shown within the slotted oil reservoir 35 at the apex of the vaporization cone 33. The four or more slots formed in the slotted oil reservoir 35 enable the oil to more uniformly cover the heated surface of the vaporization cone 33, even when the unit is in a tilted posture. For example, when a vehicle equipped with the novel two-stage oil bypass filter device is proceeding along a steep grade, the unit is functioning in a tilted posture, yet because oil will spill out of the slots, the oil more uniformly spreads out over more surface area of the vaporization cone. In this way, the novel two-stage oil bypass filter device of the present invention will function far more efficiently in a tilted configuration than any other filter unit described in the prior art.
Considering now the two-stage oil bypass filter device 10 in greater detail with reference to FIGS. 4 and 8, the head assembly 20 is shown with the thermoplastic cap 11 fastened to the tightly secured vaporization cone component 40 and base plate component 50. Mounting brackets, as represented by mounting bracket 51, are cast into the base plate component 50, as a single unitary piece preferably cast in high grade aluminum. Between the base plate component 50 and the vaporization cone component lies gasket 95, having aperture 68 to allow oil to flow from flow reducer 59 into the oil staging channel 39 to be preheated by heating element 97. Plug 91 is shown as a standard hex head bolt plug, but could be replaced with a flush fitting if needed to accommodate installation in restricted space.
In operation, the two-stage oil bypass filter device commences operation by accepting contaminated oil into the oil inlet nipple 44. The oil then travels down horizontal oil inlet channel 46, down vertical oil inlet channel 48, through the oil filter cartridge threaded aperture 71, down through the inverse cone shaped oil feed tube 77 where it penetrates the fabric sack 84 of the additives package 60 and mixes with the oil additives 86 inside. Emerging from the oil additives package 60 with one or more oil additives mixed therein, the oil passes through the apertures 82 of the oil diffuser plate 80 and directly into the filter media 79.
From the filter media, where the oil is cleansed of its particulate contaminants, the oil exits the filter cartridge through the oil return ports 73 where the oil first encounters the post-filter flow reducer 59 which governs the oil flow rate throughout the two-stage oil bypass filter device 10.
Emerging from the flow reducer the oil fills into the oil staging channel 39 in the lower portion of the vaporization cone component 40, where because of contact with heating element 97, the oil begins to increase in temperature. When filled to capacity within the oil staging channel 39, oil is then forced to flow upwards along the oil feed passageway 37 before exiting the passageway 37 at the top of the vaporization cone 33. The oil is in contact with the very hot vaporization cone 33 surface area. The high temperature on the vaporization cone 33 surface is relatively uniform throughout the entire cone surface area. The oil finally flows over the slotted oil reservoir 35 at the apex of the vaporization cone 33, in a thin uniform film of oil. Due to extreme temperatures on the surface of the cone, volatile contaminants within the oil are vaporized and exit through the vapor outlet valve 13. Temperatures typically reach 190 to 220 degrees Fahrenheit on the polished metal surface of the cone.
The thin uniform film of oil which forms on the surface of the cone-shaped vaporization plate 33 enhances the vaporization process. In this way, a maximum efficiency for volatile contaminant vaporization and removal from the oil is achieved. Vaporized volatile contaminants readily exit the device 10 through the vapor outlet valve 13 and the vapor outlet port 22 to be re-combusted, exhausted or recycled. The substantially contaminant free oil then exits the two-stage oil bypass filter device through oil outlet port 88, where it returns by gravity feed to an oil sump to be re-circulated to lubricate parts in the application process, whether it be an internal combustion engine or some other industrial application.
By employing the novel two-stage oil bypass filter device described herein, vehicles in normal operation can expect to extend their oil drain interval to between about 125,000 to 250,000 miles while maintaining the same batch of oil. In the same way, industrial machine tools also greatly extend the life of the circulated oil by approximately 5 to 10 times the normal drain interval. Therefore, while employing this device, rather than routinely changing the oil, only the novel bypass filter cartridge need be changed.
It should be understood, however, that even though these numerous characteristics and advantages of the invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, chemistry and arrangement of parts within the principal of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A new and improved two-stage oil bypass filter device is provided to enable effective and efficient removal of both solid particulate and volatile oil contaminants while also allowing the addition and mixing of certain oil additives as required by specific internal combustion engine or industrial applications. The novel two-stage oil bypass filter device includes a cone-shaped vaporization plate having a heating element located below the surfaces to be heated to provide for more effective and efficient heating of those surfaces critical to removing volatile contaminants, a horseshoe-shaped oil staging channel to provide preheating of the oil, a post-filter flow reducer to greatly reduce the possibility of clogging, a readily replaceable spin-on filter cartridge having a centrally located oil feed tube and an oil diffuser plate which directs the oil to be filtered to all parts of the filter media within the cartridge, an additives package configuration within the filter cartridge for continuous addition and mixing of oil additive substances to the oil being filtered, and a high grade, high impact thermoplastic cap housing to prevent external heating and considerably reduce the potential for burn accidents.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to techniques for performing mathematical operations within computer systems. More specifically, the present invention relates to a method and an apparatus for efficiently performing a square root operation in circuitry within a computer system.
[0003] 2. Related Art
[0004] In order to keep pace with continually increasing microprocessor clock speeds, computational circuitry within the microprocessor core must perform computational operations at increasingly faster rates. One of the most time-consuming computational operations is a square root operation. Performing a square root operation involves finding the square root Q of a radicand R.
[0005] Computer systems often perform square root operations using a technique that iteratively performs subtraction and/or addition operations on a remainder calculated thus far, r, to retire a fixed number of bits of Q in each iteration.
[0006] Unfortunately, each iteration involves selecting and performing a number of addition and/or subtraction operations that require time-consuming carry completions. Hence, hardware implementations of existing square root techniques tend to be relatively slow.
[0007] What is needed is a method and an apparatus for performing a square root operation that takes less time than existing techniques.
SUMMARY
[0008] One embodiment of the present invention provides a system that performs a square root operation that calculates an approximation of a square root, Q, of a radicand, R. The system calculates Q by iteratively selecting an operation to perform based on higher-order bits of a remainder, r, and then performs the operation. This operation can include subtracting two times a square root calculated thus far, q, and a coefficient, c, from r, and adding c to q. During this operation, the system maintains r in carry-save form, which eliminates the need for carry propagation while updating r, thereby speeding up the square root operation. Furthermore, the selection logic, which decides what operation to perform next, is simpler than previous square-root implementations, thereby providing another important speedup.
[0009] In a variation on this embodiment, maintaining r in carry-save form involves maintaining a sum component, r s , and a carry component, r c .
[0010] In a variation on this embodiment, the operation additionally maintains q in carry-save form by maintaining a sum component, q s , and a carry component, q c . In this embodiment, initializing q involves setting q s =0 and q c =0.
[0011] In a variation on this embodiment, the operation does not maintain q in carry-save form, and the operation uses an on-the-fly technique to update q.
[0012] In a variation on this embodiment, the system initializes r, q and c by: setting r s =R and r c =0; setting q=0; and setting c=1.
[0013] In a variation on this embodiment, the operation can involve multiplying both r s and r c by 2 and dividing c by 2.
[0014] In a variation on this embodiment, the operation can involve multiplying both r s and r c by 2, dividing c by 2, and inverting the most significant bits of r s and r c .
[0015] In a variation on this embodiment, the operation can involve multiplying both r s and r c by 4, dividing c by 4 and then inverting the most significant bits of r s and r c .
[0016] In a variation on this embodiment, the operation can involve subtracting (2q+c) from r s and r c , adding c to q s and q c , multiplying both r s and r c by 2, dividing c by 2, and then inverting the most significant bits of r s and r c .
[0017] In a variation on this embodiment, the operation can involve subtracting (4q+4c) from r s and r c , adding 2c to q s and q c , multiplying both r s and r c by 2, dividing c by 2, and then inverting the most significant bits of r s and r c .
[0018] In a variation on this embodiment, the operation can involve adding (2q+c) to r s and r c , subtracting c from q s and q c , multiplying both r s and r c by 2, dividing c by 2, and then inverting the most significant bits of r s and r c .
[0019] In a variation on this embodiment, the operation can involve adding (4q+4c) to r s and r c , subtracting 2c from q s and q c , multiplying both r s and r c by 2, dividing c by 2, and then inverting the most significant bits of r s and r c .
BRIEF DESCRIPTION OF THE FIGURES
[0020] [0020]FIG. 1A illustrates a set of regions defined by higher-order bits of sum and carry words for a remainder in accordance with an embodiment of the present invention.
[0021] [0021]FIG. 1B illustrates a corresponding hardware implementation of a square root circuit in accordance with an embodiment of the present invention.
[0022] [0022]FIG. 2A illustrates another set of regions defined by higher-order bits of sum and carry words for the remainder in accordance with another embodiment of the present invention.
[0023] [0023]FIG. 2B illustrates a corresponding hardware implementation of a square root circuit in accordance with an embodiment of the present invention.
[0024] Table 1 lists actions that facilitate rounding in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0025] The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0026] The square root operation computes {square root}{square root over (R)} for a given R, where R is also referred to as the “radicand” and {square root}{square root over (R)} is referred to as the “significand.” The IEEE standard on binary floating-point arithmetic requires that.
R∈[1,4) (1)
[0027] Normally, significands are in the range [1,2), but because the exponents of radicands must be even, odd exponents of radicands are decremented by one and the significand of those radicands are doubled, which explains the extended range for R. With condition (i) on R the range for {square root}{square root over (R)} is
{square root}{square root over (R)}ε[1,2)
[0028] We also require that the computed result {square root}{square root over (R)} is rounded to the nearest number with L fractional bits. This means that the computed result has an error of at most ulp/2, where ulp=2 −L for some L>0. The abbreviation ulp stands for “unit of least-significant position.”
[0029] Technique A
[0030] Technique A computes an approximation of the square root Q, where the formula
Q 2 =R
[0031] expresses the desired relation between Q and R. The technique uses variables q, r, and c. The invariant for these variables is as follows.
q 2 +c*r=R (2)
[0032] The variable q represents the square root calculated “thus far,” and c*r represents the remainder “thus far.”
[0033] Technique A appears below, where conditions B0 through B2 are yet to be defined.
q:=0; c:=1; r:=R; n:=0; while B0 do { if B1 then {r:=r*2; c:=c/2; n:=n+1} elseif B2 then {r:=r−2*q−c; q:=q+c} fi
[0034] For later use, we have introduced the variable n to count the number shifts on c.
[0035] Obviously, the initialization q:=0; c:=1; r:=R establishes invariant (2) before the start of the repetition in Technique A. An alternative initialization, which you may find in many textbooks on computer arithmetic, is q:=1; c:=1; r:=R−1.
[0036] Each of the statements in the if-then-else statement maintains invariant (2), irrespective of the conditions B1 and B2. For example, if invariant (2) holds before statement r:=r−2*q−c; q:=q+c, then after execution of this statement we have
( q + c ) 2 + c * ( r - 2 * q - c ) = ( q 2 + 2 * q * c + c 2 ) + ( c * r - 2 * c * q - c 2 )
= q 2 + c * r
[0037] Thus, invariant (2) also holds after the statement.
[0038] How do we determine B0 through B3? There are several ways to do this. The following way yields Technique A.
B 0 =n<L+ 1
B 1=( r< 2 q+c )
B 2=(2 q+c≦r )
[0039] It turns out that with these choices for B0 through B2, each time the technique executes the alternative with condition B2, then in the following repetition step the technique executes the alternative with condition B1. This property follows from the fact that 0≦r<4q+4c is an additional invariant of this technique.
[0040] Technique A computes the unique binary representation of square root q, producing one bit in each repetition step. Execution of alternative B1 selects 0 as the next square-root bit and execution of alternative B2 followed by alternative B1 selects 1 as the next square-root bit. Notice that c represents the unit of the added bit, when the bit is added.
[0041] The termination condition B0 follows from the precision needed in the square root q and the observation that c=2 −n is an invariant of the technique. If the required precision in q is L fractional bits, then the termination condition n<L+1 produces a final result q with L fractional bits and an error of at most ulp=2 −L , i.e., {square root}{square root over (R)}∈[q, q+ulp). Because Technique A increments n at least in every other step, this technique is guaranteed to terminate.
[0042] In order to obtain the correct rounded result, the technique must determine whether q must be rounded up to q+ulp. For this purpose, the technique computes
r h :=r− 2* q−c; q h :=q+c
[0043] with c=2 −(L+1) . Notice that q h lies exactly halfway between two adjacent floating-point numbers, and invariant (2) still holds for q h and r h . Accordingly, the sign of r h points in the direction of the ideal result {square root}{square root over (R)} relative to q h . Consequently, if r h <0 then q is the rounded result, and if r h ≧0 then the rounded result is q+ulp.
[0044] The technique for square root with the above choices for B0 through B2 is also called restoring square root. Some of us may have learned this technique in elementary school for the decimal system.
[0045] Adding Alternatives
[0046] In the following techniques, we make two changes. First, we allow more alternatives that maintain invariant (2). Second, we use carry-save additions for the additions to r in the technique. These carry-save additions keep r in carry-save form.
[0047] Let us look at some additional alternatives first.
elseif B 3 then { r:=r+ 2* q−c; q:=q−c}
elseif B 4 then { r:=r− 4* q− 4* c; q:=q+ 2* c}
elseif B 5 then { r:=r+ 4* q− 4* c; q:=q− 2* c}
elseif B 6 then { r:=r* 4; c:=c/ 4}
[0048] The first alternative allows a decrement of c to q and the second and third alternatives allow an increment and decrement of 2*c to q, respectively. The fourth alternative allows a quadrupling of r. Note that each of the statements
r:r+ 2* q−c; q:=q−c
r:=r− 4* q− 4* c; q:=q+ 2* c
r:=r+ 4* q− 4* c; q:=q− 2* c
[0049] and
r:=r* 4; c:=c/ 4
[0050] maintains invariant (2), irrespective of the conditions B3, B4, B5, and B6. For example, if invariant (2) holds before statement r:=r−4 *q−4*c; q:=q+2*c, then after execution of this statement we have
( q + 2 * c ) 2 + c * ( r - 4 * q - 4 * c ) = ( q 2 + 4 * q * c + 4 * c 2 ) +
( c * r - 4 * c * q - 4 * c 2 )
= q 2 + c * r
[0051] Thus, invariant (2) also holds after the statement.
[0052] Carry-Save Addition
[0053] The second change involves keeping the remainder r in carry-save form. That is, instead of a single remainder r, we have a pair r 0 , r 1 , where r 0 +r 1 =r. The pair r 0 , r 1 is produced by full adders, each of which produce a sum bit and a carry bit, also called the parity and majority bit respectively. One variable, say r 0 , represents all the sum bits and the other variable, say r 1 , represents all the carry bits. By storing r in carry-save form, the implementation does not need to resolve the carry bits for each addition, and thereby avoids a computation that can take an amount of time proportional to the logarithm of the number of bits in the worst case.
[0054] We use an addition function add(x,y,z) that takes three inputs and renders two results add 0 (x,y,z) and add 1 (x,y,z) such that
add 0 ( x,y,z )+add 1 ( x,y,z )= x+y+z.
[0055] In this disclosure, we denote an addition of z to r=r 0 +r 1 with this addition function as
r0,r1:=add( r 0, r 1, z )
[0056] The meaning of this notation is that r 0 gets assigned the value add 0 (r 0 , r 1 ,z) and r 1 gets assigned the value add 1 (r 0 , r 1 ,z).
[0057] We also use a two's complement representation. Recall that in a two's complement representation subtracting z is the same as adding −z, where −z is the bit-wise complement of z plus a carry at the least-significant bit position. Because the least significant bit of the carry bit vector r 1 is always 0, we can change this bit to 1 when we add −z. Consequently, in additions of the form add(r 0 , r 1 , z), z may be a negative number.
[0058] The variable q can also be split into a sum q 0 and a carry q 1 , and additions to q can be performed by a carry-save adder. Alternatively, q can be calculated “on the fly,” because the changes to q are simple additions of c, 2c, −c, or −2c. In a following section, we show that computing binary representations of q and q−2*c on the fly helps speed up the square-root technique. As a consequence, in one embodiment of the present invention we refrain from splitting q into q 0 and q 1 .
[0059] Finally, we add one more alternative to the repetition. This alternative executes a translation of (r 0 , r 1 ) over (t,−t). Here t can be any binary number and t can be positive or negative. Notice that (r 0 +t)+(r 1 −t)(r 0 +r 1 , so these translations maintain invariant (2).
[0060] Technique B appears below. As before, we use B0 to express the termination condition. Later, we give a precise expression for B0. We have expressed each of the conditions for the alternatives as a condition on (r 0 , r 1 ). Thus, these conditions define regions in the (r 0 , r 1 ) plane. For the moment, we have given each of these regions an appropriate name, without specifying where the region is.
q:=0; c:=1; r0:=R; r1:=0; n:=0; while B0 do { if ((r0,r1) in 2X) then { r0,r1:=r0*2,r1*2; c:=c/2; n:=n+1} elseif ((r0,r1) in 4X) then { r0,r1:=r0*4,r1*4; c:=c/4; n:=n+2 } elseif ((r0,r1) in SUB1) then { r0,r1:=add(r0,r1,−2q−c); q:=q+c} elseif ((r0,r1) in SUB2) then { r0,r1:=add(r0,r1,−4q−4c); q:=q+2c} elseif ((r0,r1) in ADD1) then { r0,r1:=add(r0,r1, 2q−c); q:=q−c)} elseif ((r0,r1) in ADD2) then { r0,r1:=add(r0,r1, 4q−4c); q:=q−2c)} elseif ((r0,r1) in TRANS) then { r0,r1:=r0+t,r1−t} fi }
[0061] Recall that the above technique maintains invariant (2) irrespective of the choice of regions 2X through TRANS.
[0062] Defining Regions
[0063] The regions and operations on (r 0 , r 1 ) are almost identical to the regions and operations on (r 0 , r 1 ) in the division techniques explained a in related patent application filed on the same day as the instant application by inventor Josephus C. Ebergen, entitled “Method and Apparatus for Efficiently Performing a Square Root Operation,” (Attorney Docket No. SUN-P8849-SPL), which is hereby incorporated by reference. Similar to the various optimizations of the division algorithm, we choose two sets of regions and associated operations for the square-root algorithm.
[0064] [0064]FIGS. 1A and 2A illustrate the regions associated with two different square root techniques in accordance with an embodiment of the present invention. Note that the two most significant bits in the two's complement representation of r 0 and r 1 determine the regions associated with the operations. For the TRANS operation we choose a translation over (+t, −t) or (−t, +t), where t=2 K+1 and K+1 is the position of the most significant bit of r 0 and r 1 .
[0065] [0065]FIGS. 1A and 2A illustrate the regions in which specific operations apply. In particular, these operations include 2X, 2X*, 4X*, SUB1+2X*, SUB2+2X*, ADD1+2X*, and ADD2+2X*. The region 2X* indicates the operations for 2X followed by a translation. Similarly, the region SUB2+2X* indicates the operations SUB2 followed by the operations for 2X followed by the operations for TRANS. As explained in the above-cited related patent application, performing the operations 2X* and 4X* on (r 0 , r 1 ) can be implemented by a left shift of r 0 and r 1 followed by inversion of the most significant bits of r 0 and r 1 . This simplifies the implementations of the operations 2X* and 4X*.
[0066] Hardware implementations of the different techniques are illustrated in FIGS. 1B and 2B. These figures provide a rough schematic showing the elementary modules in an implementation. These modules are a carry-save adder, indicated by “CSA,” a multiplexer, indicated by a trapezoid, the selection logic, indicated by “SLC,” and the implementations of the other actions of the techniques, indicated by 2X, 2X*, 4X*, or just *.
[0067] These figures do not show the accumulation of quotient digits or any other operations on the quotient. The figures also do not show implementations of any post-processing steps, like the implementation of any restoration step, rounding, or conversion that must occur for the quotient after termination of the technique. These may be implemented using any one of a number of standard techniques.
[0068] Note that splitting the multiplexer in two parts, as illustrated in FIG. 2B, may have some advantages. First, the implementation illustrated in FIG. 2B uses only one carry-save adder, whereas implementation illustrated in FIG. 1B uses four carry-save adders, which consume a significant amount of area and energy. Second, the implementation of FIG. 1B avoids a large fan-in and a large fan-out for the final multiplexer, assuming that stages are cascaded. The large fan-in and fan-out with one multiplexer slows down the critical path for all of the alternatives. Splitting the multiplexer into two decreases the critical path delay for the alternatives that exclude the carry-save adder and it increases the critical path delay for the alternatives that include the carry-save adder. Increasing the difference between path delays for the respective alternatives may be bad for a synchronous circuit implementation, but an asynchronous implementation may be able to take advantage of this difference by achieving an average-case delay that is less than the critical path delay of the implementation with the large multiplexer. This situation may apply if the alternatives that exclude carry-save addition occur more frequently than the alternatives that include carry-save addition.
[0069] On-the-Fly Conversion Process
[0070] The above-described square-root operation computes a result in the form of a redundant binary representation with digit set {−1,0,1} or {−2,−1,0,1,2} for example. If the operation computes one digit of the redundant binary representation per repetition step, then the unique binary representation of the result can be computed “on the fly” as is described in a following section.
[0071] Note that many division and square root techniques successively approximate the final result q by performing one of following operations to q in each repetition step. Here c is of the form c=2 −n−1 , where 2 −n is the unit of the least-significant position in q.
q:=q− 2* c; c:=c/ 2
q:=q−c; c:=c/ 2
q:=q; c:=c/ 2, that is, q remains unchanged
q:=q+c; c:=c/ 2
q:=q+ 2* c; c:=c/ 2
[0072] Many techniques use only the middle three operations; some use all five. Basically, these techniques calculate a binary representation for q with redundant digit set {−2,−1,0,1,2}.
[0073] The problem with redundant binary representations is that such representations are not unique. Having the unique binary representation of q may be important. When the unique binary representation of q is available in each repetition step, savings can be obtained in time, energy, and area. For example, many square-root techniques need to compute r:=r−2*q+c in some step. This computation can be done with one full adder for each bit if r is in carry-save form and q is in a unique binary representation. If both r and q are in carry-save representation, however, then the computation requires at least two full adders in sequence for each bit, thus wasting more time, area, and energy.
[0074] Fortunately, if the technique computes a redundant binary representation of q with redundant digit set {−2,−1,0,1,2} and the technique computes one digit in each repetition step, then the unique binary representation of q can be calculated on the fly.
[0075] Details of Conversion Process
[0076] Let us assume that Q denotes the binary representation of q and that the unit of the least-significant bit of Q is 2 −n . Furthermore, assume that c=2 −n−1 . In other words, 2*c equals the unit of the least-significant position in Q. Consequently, an implementation of q:=q+c is simply postfixing Q with a 1. Similarly, implementing q:=q−c is simply postfixing Q with −1.
[0077] In order to construct the unique binary representation of q, instead of the redundant representation with digit set {−1,0,1}, we maintain invariant I0:
[0078] Q 0 is the unique binary representation of q
[0079] Q −1 is the unique binary representation of q−2*c
[0080] If initially the invariant I0 holds, then each of the following statements maintains invariant I0.
q:=q−c; c:=c/ 2; Q 0 , Q −1 :=Q −1 1, Q −1 0
q:=q; c:=c/ 2; Q 0 , Q −1 :=Q 0 0 , Q −1 1
q:=q+c; c:=c/ 2; Q 0 , Q −1 :=Q 0 1, Q 0 0
[0081] If we include the operations q:=q+2*c and q:=q−2*c, then we maintain invariant I1:
[0082] Q +1 is the unique binary representation of q+2*c
[0083] Q 0 is the unique binary representation of q
[0084] Q −1 is the unique binary representation of q−2*c
[0085] Q −2 is the unique binary representation of q−4*c
[0086] If initially the invariant I1 holds, then each of the following statements maintains invariant I1:
q:=q− 2* c; c:=c/ 2; Q +1 , Q 0 , Q −1 , Q −2 :=Q −1 1, Q −1 0, Q −2 1, Q −2 0
q:=q−c; c:=c/ 2; Q +1 , Q 0 , Q −1 , Q −2 :=Q 0 0, Q −1 1, Q −1 0, Q −2 1
q:=q; c:=c/ 2; Q +1 , Q 0 , Q −1 , Q −2 :=Q 0 1, Q 0 0, Q −1 1, Q −1 0
q:=q+c; c:=c/ 2; Q +1 , Q 0 , Q −1 , Q −2 :=Q +1 0 , Q 0 1, Q 0 0, Q −1 1
q:=q+ 2* c; c:=c/ 2; Q +1 , Q 0 , Q −1 , Q −2 :=Q +1 , Q +1 0, Q 0 1, Q 0 0
[0087] Termination and Rounding
[0088] One embodiment of the present invention determines the termination condition B0 and rounds the result according to the IEEE standard on floating-point numbers. First, notice that the range for r satisfies
r=r 0 +r 1 ∈[−8, 8) (4)
[0089] Secondly, for R∈[1,4), q∈[1,2], and R=q 2 +c*r, we have
| {square root}{square root over (R)}−q|≦ ½*| R−q 2 |=½* c*|r|≦ 4* c
[0090] In other words, {square root}{square root over (R)}×−q∈[−4*c, 4*c). The length of this error interval is 8*c, with c=2 −n . Because upon termination the length of the error interval must be at most 2 −L =ulp, the termination condition becomes 8*c≦2 −L or
B 0=( n<L+ 3)
[0091] Consequently, upon termination q has L+2 fractional bits, two more than the specified format.
[0092] Upon termination, the result of the square-root technique is rounded to nearest even number, according to the IEEE standard. Note that for a radicand R with L fractional bits, the square root {square root}{square root over (R)} never lies exactly halfway between two floating-point numbers. This means that for a square root technique, rounding to nearest even number yields the same result as rounding to nearest number.
[0093] Note that when a square-root technique terminates, a restoration step may be necessary. This restoration step adjusts the values of q and r to q h and r h respectively, such that q h lies exactly halfway between two floating-point numbers within the error interval around q and the invariant still holds, i.e., q h 2 +c*r h =R. Moreover, the restoration step restores r h in its unique binary representation.
[0094] At the end of the restoration step, the ideal result {square root}{square root over (R)} still lies within an error interval of length at most ulp around q h , and the sign of r h points in the direction of the ideal result relative to q h . Consequently, if r h <0, then the truncation q 1 of q h to the specified IEEE format is the rounded result, otherwise q 1 +ulp is the rounded result.
[0095] The final adjustments to q and r depend on the last two bits of q and are summarized as follows.
TABLE 1 Last two digits of q Actions 00 q h = q − 2 * c; r h = r + 4 * q − 4 * c 01 q h = q + c; r h = r − 2 * q − c 10 q h = q; r h = r 11 q h = q − c; r h = r + 2 * q − * c
[0096] Note that it is unnecessary to calculate the binary representations of q+2*c, q−2*c, and q−4*c, because they have already have been calculated on the fly. The binary representations for these values are given by Q 1 , Q −1 , and Q −2 , respectively. The adjustments to r are the same as those made in a repetition step.
[0097] The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description only. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims.
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One embodiment of the present invention provides a system that performs a carry-save square root operation that calculates an approximation of a square root, Q, of a radicand, R. The system calculates Q by iteratively selecting an operation to perform based on higher-order bits of a remainder, r, and then performs the operation. This operation can include subtracting two times a square root calculated thus far, q, and a coefficient, c, from r, and adding c to q. During this operation, the system maintains r in carry-save form, which eliminates the need for carry propagation while updating r, thereby speeding up the square root operation. Furthermore, the selection logic, which decides what operation to perform next, is simpler than previous square-root implementations, thereby providing a further speedup.
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BACKGROUND OF THE INVENTION
This invention relates generally to floor stripping devices, and more particularly concerns improvements in the driving and blade support means for same.
U.S. Pat. No. 3,376,071 discloses a floor stripping machine of the type in which the present invention is usable to great advantage. Such machine incorporates a cutting blade carried by a head pivotally mounted to a frame. Problems with machines as disclosed in that patent include failure of rapidly oscillating head driving connecting rods and associated parts and bearings; insufficient lubricating of such rods, parts and bearings, undue wear of the oscillating head at its pivots; unwarranted high cost of repair and replacement of such elements; and difficulty with clamping a blade to the bottom side of the head.
U.S. Pat. Nos. 4,512,611, 4,504,093, 4,483,566, 4,452,492, 4,365,843 and 4,365,842 to applicant disclose improvements over said U.S. Pat. No. 3,376,071.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide an additional solution to the above described problems and disadvantages. Basically, the invention is embodied in:
(a) a connecting element having a first tubular part and a second tubular part, said parts having spaced, parallel axes, said second tubular part pivotally connected to the head,
(b) a drive shaft extending within said first tubular part, said shaft operatively connectible to the drive to be rotated thereby,
(c) said connecting element including two parallel and spaced legs extending between said first and second tubular parts and integrally merging with the sides thereof at locations spaced from the opposite ends thereof,
(d) two annular bearings respectively carried by and within said first tubular part, said bearings respectively receiving two spaced eccentrics to oscillate said first tubular part, said head and said blade as said eccentrics are rotated by the shaft,
(e) said head consisting of lightweight metal having two flanges connected by a web, the flanges locally thickened to define two lugs, said legs rotatable in planes intersecting the respective lugs,
(f) and bearing bushings received in and carried by said lugs to form bearing openings for a pivot shaft connected to the frame, said bushings being self-lubricated adjacent the shaft.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a side elevation showing a floor stripping machine incorporating the invention;
FIG. 2 is a top plan view of the FIG. 1 machine;
FIG. 3 is an enlarged elevation taken on lines 3--3 of FIG. 4;
FIG. 4 is a section taken on lines 4--4 of FIG. 3;
FIG. 5 is a section taken on lines 5--5 of FIG. 3;
FIG. 6 is an enlarged section taken through connecting structure seen in FIG. 4;
Fig. 7 is an end elevation view of the FIG. 6 connecting structure;
FIG. 8 is a side elevation;
FIG. 9 is a perspective view;
FIG. 10 is a fragmentary front elevation, showing the head of FIG. 8;
FIG. 11 is a fragmentary plan view on lines 11--11 of FIG. 8, and FIG. 11a is a view like FIG. 11;
FIG. 12 is a view like FIG. 10, but showing a modification;
FIG. 13 is an elevation showing details of an improved version;
FIGS. 14 and 15 are sections on lines 14--14 and 15--15 of FIG. 13; and
FIG. 16 is a section on lines 16--16 of FIG. 15.
DETAILED DESCRIPTION
Referring now to the drawings and initially, to FIGS. 1 and 2, inclusive, for this purpose, it will be seen that one type of machine in which the invention may be incorporated has been designated in its entirety by reference number 10. Mounted on the machine 10 are a pair of rubber tires 12 which permit the machine 10 to be easily transported and maneuvered. The wheels 12 are carried by an axle 14 which in turn passes through the rear portions of the base frame 16. Mounted on the frame 16 is an electrical motor 18. The machine 10 may alternately be powered by an internal combustion engine. The motor 18 is held in place by four mounting bolts 19 which pass through slots 20 in the frame 16. When the bolts 19 are loosened the motor can be moved forward or backward on the frame 16 by reason of the slots 20 to adjust the tension in the drive belt 21. Covering the motor 18 and attached to the frame 16 is a cover shroud 22. The shroud 22 slides over the side walls 23 of the frame and is held in place by bolts 24 as can be seen in FIG. 1. Positioned on the front of the frame 16 is a nose weight 25. The weight is held in place by means of a releasable wire clip 26 which fastens the forward edge of the shroud 22 with the weight 25. The weight provides the necessary weight on the cutting edge 28 which will later be described.
The handle bar 29 comprises a pair of elongated tubular members 30 which are attached at their lower ends to the shroud 22, and at their upper ends are joined by tubular cross members 31 and 32. Hand grips 33 are used to handle and maneuver the machine 10.
FIGS. 3 through 5 show the cutter head subassembly 36 in detail. The frame 16 previously mentioned is substantially U-shaped with a horizontal web portion 34 and a pair of vertical flanges 35 as can best be seen in FIG. 5. At the forward end of the frame 16 positioned between the webs 35 is the cutting head 38. The head 38 is formed with a web 40 and a pair of flanges 42. The cutting head is pivotally mounted at the upper end to the frame 16 by a pin 44 which passes through both pairs of flanges 35 and 42. Passing through the pair of flanges 35 and journalled thereto is a rotatably mounted drive shaft 46 which is shown in FIGS. 4 and 6. The shaft 46 is journalled at its outer ends in a pair of roller bearings 48 which are in turn bolted to the frame flanges 35 by means of bolts 50. Retaining the cam shaft in the bearings 48 are pair of locking sleeves 52 which are mounted on the shaft 46 immediately outward of the bearings 48. Keyed to one end of the shaft 46 is a sheave 54 adapted to carry a V-belt. Mounted on the shaft 56 of the motor 18 is a similar sheave 58 which lies in the same plane of rotation as sheave 54. The two sheaves 54 and 58 are connected by means of a rubber V-belt 21. The tension in the V-belt 21 may be adjusted as previously discussed.
The shaft 46 extends within a first tubular part 90 of a connecting element 91, the latter also incorporating a second and smaller diameter tubular part 92. As disclosed in my prior patents, those tubular parts comprised steel interconnected by a steel plate 93 welded to outer side portions of the sections, as at 94 and 95. See FIG. 7. That construction has became disadvantageous, including assembly difficulty.
Shaft 46 carries two axially spaced eccentrics 96 and 97. See in FIG. 7 the axis 96c of eccentric 96 offset from the axis 46a of shaft 46. Each eccentric is cylindrical to rotate within a bearing, such as a bushing, the two bushings indicated at 98 and 99 and received in counterbores 98a and 99a in the pipe section, and against step shoulders 98b and 99b. The large space 100 thus provided between the eccentrics provides a lubricant (grease) reservoir, for long lasting lubrication of the two bearings, as the shaft rotates and on the eccentrics oscillate the shaft section 90, and the element 91 back and forth, as will be described. Shaft section 46b extends between and interconnects the two eccentrics.
Note that the eccentrics have oppositely facing end portions or faces 96a and 97a, which, due to their flaring eccentricity, tend to positively displace the grease as the eccentrics rotate. This serves to urge grease radially outwardly, and axially toward the bushings and the bearing surfaces of the eccentrics and bushings, for enhancement of lubrication. Note that faces 96a and 97a intersect the outer surfaces of the eccentrics in planes 96b and 97b that are at angles α relative to the shaft axis, angles α being less than 90°. Grease is introduced to space 100 via a grease fitting 101 in shaft 90, as shown.
Annular elastomeric seals 102 and 103 are located at opposite ends of the bushings, and pressed into the shaft counterbores 102a and 103a, as shown. Those seals exert pressure on the shaft eccentrics to prevent escape of grease.
At the opposite end of element 91 is a bearing shaft 68 journaled via bushings 66 to the pipe section 92. Shaft 68 is in turn mounted to cutting head 38. When shaft 56 is rotated, element 91 is oscillated back and forth to cause head 38 to move back and forth about the axis of pipe 44, as indicated by arrows in FIG. 3.
At the lower extremities of the cutting head 38 the flanges 42 become wider to accomodate the cutting blade shoe 70. The shoe 70 is adjustably held against the cutting head by two pairs of bolts 72 and 74. The bolts 72 pass through openings 75 in the rear of the blade shoe 70 and are threaded into the ends of the connecting rod shaft 58. The bolts 74 pass through openings 76 and are threaded into the ends of shaft 77. The purpose of the blade shoe 70 is to rigidly hold the cutting blade 78 in its cutting position. Located on the back edge of the blade shoe 70 are a pair of adjusting bolts 80 and locking nuts 81 which allow for adjustment of the position of the blade stop 82 which in turn adjusts the amount of blade edge exposure. The front edge 83 of the blade shoe 70 is tapered to provide a maximum amount of rigidity to the cutting blade and yet permit a shallow angle of slope between the cutting blade 78 and the flooring surface being stripped.
FIGS. 8, 10 and 11 show a modified head 138 consisting of lightweight metal such as aluminum, or aluminum alloys, or magnesium, or magnesium alloys. The head has two elongated flanges 142 interconnected by a web 140. The flanges are locally thickened near upper ends of the flanges to define two widened lugs 242 that form widened bearing openings 150 for a pivot shaft 144. The latter is connected to the frame flanges 135 (corresponding to flanges 35 in FIG. 5). The bearing openings (and the lugs) have lengths "1" in excess of 3/4 inch, and preferably are between 3/4 and 11/2 inches in length. As a result, destructive wear of the head metal surrounding the openings 150 is eliminated, and in particular for heavy duty operation where stripping forces are extensive.
The openings are sized to closely receive the pivot shaft 144, and define a common axis 144a. FIG. 11a shows modification, with a steel tube 344 received in openings 150, and in turn receiving the shaft 144. Tube 344 helps distribute loading to insure against destructive wear of the lightweight metal lugs 242.
FIGS. 8 and 9 also show the use of the modified blade holder plate 170 attached to the head 138 at its bottom side 138a. Blade 178 is clamped against that side, by the plate. Two shafts, 177 and 168 extend parallel to the web 140 and through flanges 142 to provide shaft projections 177a and 168a at the exterior side of each flange. Two pairs of fasteners 200 and 201 extend in parallel relation through suitable openings in the holder plate and in the blade, at opposite ends of the shafts, respectively. The fasteners have heads 200a and 201a that clamp split washers 202 and 203 against the bottom of the holder plate. Also, the fasteners have threaded shanks 200b and 201b received in threaded engagement with threaded openings 177b and 168b in the shaft projections 177a and 168a. Accordingly, tightening of the blade in position as shown in FIG. 9 may be accomplished using one hand 210 only, i.e. by manipulation of the wrench 204 in grip engagement with the fastener heads, and the blade may be held and positioned by the other hand 211.
The operation of the stripping machine 10 varies with the type of floor being removed. The steeper the angle of the blade 78 with the floor the deeper the blade will dig. The angle can be varied by lifting the wheels 12 off the floor. The angle can also be varied by extending the blade 78 further past the edge of the shoe 70. When removing a plywood or particle board floor an extra long blade which extends an additional four inches or more past the edge of the shoe 70 has proven very useful. The longer the blade 78 is extended out of the shoe the less the angle between the cutting blade and floor. The amount of weight applied to the cutting edge 28 is also variable depending upon the flooring being removed. The weight can be varied by the amount of pressure applied by the hands to the handle bar 29. Generally, the machine best operates when the handle bar 29 is lifted up until the wheels are one-half inch off the floor. When an exceptionally tough flooring is being removed, a blade with teeth formed on the cutting edge has been found to be very effective.
FIG. 12 is a view like FIG. 10, with corresponding elements having the same identifying numbers. It differs from FIG. 10 in the provision of bushings 280 and 281 fitted and retained in bores 282 and 283 in lugs 242. The bushings may endwise fit against stop shoulders 284 and 285 in the lugs. The bushings may advantageously be self-lubricated, as provided by annular material 280a and 281a carried in metallic (as for example bronze) sleeves 280b and 281b press-fitted in bores 282 and 283. Material 280a and 281a may for example consist of molybdenum disulfide. One example of such bushings are known "OILITE" bushings.
Pivot shaft 144 (typically steel) is received in, and has low friction running fit in, the bores of the annuli 280a and 281a, for long lasting, low wear operation.
FIGS. 13-16 show an improved form of the head 338 and connector 391. (Elements corresponding to those of FIGS. 1-11 have the same numbers, with a "3" preceding each number).
Connector 391 is a casting made of lightweight metal such as zinc or aluminum, and has first and second tubular parts 390 and 392, the outer diameter of part 390 for example being about 15/8 inches, and that of part 392 being about 11/4 inches. Self lubricated bushings or bearings 398 and 399 are press fitted into bores 398a and 399a of part 390. Shaft 346 is as decribed before, and as shown in FIG. 6, where it bears number 46.
The connector 391 also includes two legs 400 and 401 which extend substantially parallel between tubular parts 390 and 392 and merge therewith, at the opposite ends of the legs, at locations spaced from the opposite ends of the tubular parts 390 and 392. The legs have first webs 401a and 401b which define planes 402 normal to parallel axes 403 and 404 defined by parts 390 and 392. Those planes also intersect the enlarged, heavy duty lugs 442 integral with head 338, for maximum strength.
The legs also have second webs 401c and 401d defining planes 405 normal to planes 402, and parallel to spaced parallel axes 403 and 404. Second webs 401c and 401d merge with the tubular parts or elements 390 and 392 along the sides thereof facing one another, as shown. Webs 401a and 401b intersect webs 401c and 401d at mid-region 406 (see FIG. 16), and all four webs taper outwardly, away from that region, as shown to form a cross. Accordingly, a high strength, low weight, connection of parts 390 and 391 is formed, utilizing a light-weight, unitary metal casting. Mid-region 406 is enlarged, for added strength, and webs 401a-401d maximally resist relative bending of parts 390 and 392.
The flanges 342 have widths "w" that increase in dimension in direction toward the plate 370 and blade 378, as shown in FIG. 15, and the tubular part 392 is confined between those flanges, with the webs 401a-401d merging with part 392 between the flanges of increased width near plate 370.
Self-lubricated bushings are employed at 380 and 381, in the two lugs 342, to receive tubular shaft 344. "OILITE" bushings may be used for this purpose.
The head 338 may also consist of the same light-weight metal as connector 390, whereby a very lightweight assembly is provided for minimum vibration transmission to the user.
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Apparatus usable in power-operated floor stripping apparatus that includes a frame, a drive carried on the frame, wheels supporting the frame, a handle to guide the frame, and a cutting blade carried by a head which is pivotally mounted to the frame, the apparatus comprising a lightweight rugged connecting element having a first tubular part and a second tubular part, those parts having spaced, parallel axes, the second tubular part pivotally connected to the head. The connecting element includes two parallel and spaced legs extending between the first and second tubular parts and integrally merging with the sides thereof at locations spaced from the opposite ends thereof. First webs on each leg have edges tangent with the tubular parts, and they define planes intersecting thickened lugs on the head, and also eccentrics on a drive shaft. Second webs on the legs intersect the first web at enlarged areas of the legs.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/952,249 filed on Jul. 27, 2007 entitled “System and Method of Intelligent Ordering Across Multiple Providers,” which is hereby incorporated by reference as if set forth in full in this application for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to electronic commerce systems, and, more particularly, to a computer based system for facilitating transactions between buyers and sellers.
BACKGROUND OF THE INVENTION
[0003] Sales of goods and services are typically made using traditional ordering techniques. For instance, a potential buyer reviews goods or services from multiple providers, and then the potential buyer places an order based on a particular seller's quality, price, location or the like. One known method for ordering a product or service is initiating the process by electronic means, such as a text message.
[0004] Many of these systems require that certain preferences be predetermined. For example, if a customer desires a taxi, the customer can electronically contact the taxi company with a predetermined destination such as “home”. The drawback in the current example is that the customer cannot choose a new location during the ordering process other than one which was predetermined and already provided to the taxi company. In another example, food may be ordered in a similar manner. The customer may set up a profile with the food provider. Later, when the customer wants to electronically order the food, electronic contact is made, and the preset order is processed.
[0005] Typically when a customer sends an order for a particular product or service, the order is sent directly to the company as the provider. In an example such as this, a customer desires a taxi; the customer sends a request to a particular taxi company for a car. The operator then will make a determination as to the best taxi for the customer based upon their particular fleet. The drawback to this method is that the customer is limited to the single, particular taxi company which may not have the best available taxi available for that customer as compared to a competitor. If a customer wants to pick from multiple taxi companies, then the customer must know contact information for all different providers and must contact them individually. Another drawback for this system is that there must be an operator involved; therefore the system requires the cost of an operator to make the decision and communicate to the taxi driver.
[0006] A system choosing from multiple providers may also involve a call center or operator who chooses a provider for the customer's request. For example, a customer desires a tow truck and sends an electronic message to a towing service. The towing service then uses a call center to call various operators of tow trucks to find which truck can respond. The drawback of this system is the need for additional labor to make phone calls, and the potential for the address to be not communicated clearly to the different tow truck drivers depending on the person making the call and the person receiving the call.
[0007] A common method of allocating the location for the product or service to be delivered involves locating the customer's address based on the GPS unit on the mobile phone. In an example such as this, a taxi driver would be dispatched to the location where the customer is currently located once the request for service is sent. The drawback in this system is that the customer may not want to have the taxi in that current location. The customer could desire for the taxi to be waiting at a later time or at a different location. In a similar example, a customer may order some goods to be delivered to a particular location and not want them sent to where the customer is located based on a GPS system. Systems using a GPS as a locator cannot handle this type of request.
[0008] A practice in electronic text messaging or an SMS based system involves using abbreviations or other type of notations that convey a request in a method that is understandable by the sender. For example, a customer sends an order for flowers to be delivered to a particular address using a notation of the letter “S” to designate the “South”. The receiver on the end may not interpret this correctly and the flowers are sent to an incorrect address. Another practice in electronic text messaging based systems is not providing complete information. For example, a customer sends an order for food items to be delivered to a desired location and the customer omits sending a postal code or city. The ordering system may not be able to complete the order correctly without the missing information.
[0009] Other methods involving ordering services or goods involve transferring the funds during the ordering process to a third party intermediary. For example, when ordering a food item, the customer will be billed by their mobile phone carrier for the price of the item. The provider then must have an account with the carrier and collect the funds from said carrier. Using a third party creates a drawback by requiring an extra step in the transaction and creating the potential for complications if an order is not processed correctly.
[0010] Prior ordering techniques have many short comings. The present invention addresses many of these short comings to provide an improved system for purchasing goods and services.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides a computer system and method for facilitating a transaction between a buyer and a seller. The seller is one of multiple available providers of a product and/or service. Initially, the buyer sends out an order, and the order is automatically verified. A seller is then determined based on at least one desirable characteristic of that particular seller. Then, the order is automatically translated into a format understandable by the desired seller. The order is communicated to the desired seller and the status of the order is later communicated to the buyer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 Illustrates a representative system of the prior art;
[0013] FIG. 2 Illustrates one embodiment of the present invention;
[0014] FIG. 3 Illustrates a second embodiment of the present invention;
[0015] FIG. 4 Illustrates a third embodiment of the present invention;
[0016] FIG. 5 Illustrates a fourth embodiment of the present invention;
[0017] FIG. 6 Illustrates a modular, high-level design of the process of the present invention;
[0018] FIG. 7 Illustrates the Receive order and Prepare to Process module of the present invention;
[0019] FIG. 8 Illustrates the Parse Message module of the present invention;
[0020] FIG. 9 Illustrates the Validate Address module of the present invention; and
[0021] FIG. 10 Illustrates the Send Order module of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 Illustrates a representative system of the prior art. The system includes a device 110 running an application 111 . Device 110 may be a mobile phone or other computer device or system. Application 111 may be an SMS application, or Web browser.
[0023] Device 110 transmits information over a communication channel 113 to a provider 116 . Communication channel 113 may be an SMS gateway or Internet connection. Provider 116 may be a vendor who provides a service or a product.
[0024] In a typical embodiment of the prior art, a user would send a message on application 111 of device 110 over communication channel 113 to each individual provider 116 . This would involve sending and receiving messages through the system to each provider until a single provider is able to meet the user's needs.
[0025] FIG. 2 Illustrates a representative system in which the preset invention may be implemented. The system includes a client device 210 , running a software application 211 , connected to a server 212 via a communication channel 213 . Client device 210 may be, for example, a computer, iPhone, Blackberry, PDA, or a mobile phone running software application 211 such as an SMS application, a text messaging application, a web browser, a wap browser, a Brew applet, a Java applet, an email application, a blackberry application, an iPhone application, a Google android application, or other known methods of sending electronic messages. Communication channel 213 may be an SMS, an Email, or a Data gateway. It may alternatively comprise an Internet connection or other known connection methods. Server 212 may be a computer or processor operating software application 214 .
[0026] Server 212 will be connected with client device 210 , and one or more providers 216 via communication channels 215 . Providers 216 may be vendors who provide services or products. The provider may be a service such as a taxi, transportation, or towing service and a product such as food, beverages, flowers, entertainment, and general consumer goods. The provider can also provide any other commercially available service or product. Providers 216 utilize devices to electronically receive order information. For example, a computer, iPhone, Blackberry, PDA, or a mobile phone running software a application such as an SMS application, a text messaging application, a web browser, a wap browser, a Brew applet, a Java applet, an email application, a blackberry application, an iPhone application, a Google android application, or other known methods of sending and receiving electronic messages may be utilized by provides 216 to receive messages related to buyer orders. Communication channel 215 may be an internet connection or other known connection methods.
[0027] In one embodiment, software application 214 will be a program which may be implemented as follows. First, it may verify the user's eligibility to order. If a customer is ineligible to order, and there are no suitable providers 216 participating, or if the order cannot be accepted by a provider, a message is sent to the user indicating that the order cannot be completed. If the order information cannot be recognized, is incomplete, or needs clarification, the system will communicate with the user over communication channel 213 , to client device 210 , asking for an input on software application 211 to confirm the order information or resend in a proper format.
[0028] Second, in one embodiment, software application 214 will interpret/validate the order information. Third, it may check for suitable participating providers 216 for fulfillment. Fourth, it may automatically select a provider based on its ability to fulfill, geographic proximity to the user, and/or estimated time for order fulfillment by obtaining information from providers 216 over connection channel 215 . Other selection criteria may be used. Fifth, it may reformat the order data as necessary so that the provider's native electronic ordering system can recognize it. Sixth, it may attempt to establish a connection with the provider by communicating over communication channel 215 and attempt to queue an order with the selected provider. Finally, if the order is successfully queued, it may send a confirmation message to client device 210 , for software application 211 , via communication channel 213 and the order will be fulfilled by the selected provider. This implementation is one method for the present invention, however variations and steps may be adjusted accordingly. The user may then obtain the status of the order or cancel the order by using client device 210 with software application 211 through communication channel 213 with server 212 running software application 214 connected to provider 216 over communication channel 215 .
[0029] FIG. 3 illustrates a second embodiment for selecting a provider using an SMS message from a mobile phone. A mobile phone 310 with an SMS application 311 sends a message to a carrier 317 over an SMS gateway 313 . Carrier 317 then relays the message to a SMS aggregator 318 over similar SMS gateway 313 . The SMS aggregator then communicates the message over a communication channel 215 to server 212 . Communication channel 215 may be the internet between SMS aggregator 318 and server 212 , and communication channel 215 may also be another network, such as a wireless network, between software application 214 and provider 216 during a single transaction. Other commercially available media for electronic communication may be used for communication channel 215 .
[0030] Next, Server 212 operates as previously stated using software application 214 with communication channel 215 , SMS aggregator 318 , communication channel 313 , and carrier 317 to interface with mobile device 310 instead of using communication channel 213 and client device 210 as shown in FIG. 2 . The software application selects desired provider 216 using communication channel 215 .
[0031] Mobile phone 310 can be any device capable of communicating messages over mobile phone networks including a PDA, an iPhone, a Blackberry or a Google Android device. SMS application 311 can be any application capable of sending SMS text messages over mobile networks or the Internet. Carrier 317 is any mobile phone carrier including CDMA, IDEN, GSM, TDMA, UMTS, WIMAX, LTE and future mobile phone based networks. SMS aggregator 318 converts SMS messages received to a format understandable and transmittable over communication channel 215 . SMS aggregator 318 can also convert messages received over communication channel 215 into SMS messages to be sent over SMS gateway 313 .
[0032] FIG. 4 illustrates a third embodiment where the provider is a taxi company. Mobile phone 210 with software application 211 communicates to server 212 via communication channel 213 . Server 212 uses a software application 414 and communicates with an address verification server 419 via communication channel 215 . Server 212 also communicates with providers 416 via communication channel 215 .
[0033] In one embodiment, software application 414 operates first by verifying the user's eligibility to order. If a customer is ineligible to order, and there are no suitable taxi companies 416 participating, or if the order cannot be accepted by a taxi company, a message is sent to the user indicating that the order cannot be completed. If the order information cannot be recognized, is incomplete, or needs clarification, the system will communicate with the user over communication channel 213 , to client device 210 , asking for an input on software application 211 to confirm the order information or resend in a proper format. Second, the software application may parse the message contents to obtain any keywords such as the address and unit number. Third, it may check if that address is valid using address verification server 419 over communication channel 215 . Address verification server 419 can be an external or online module which verifies the accuracy of addresses such as Google Maps, NAVTEQ, or Mapquest. Fourth, it may check for suitable participating taxi companies 416 for fulfillment. Fifth, it may automatically select a taxi company based on car availability, geographic proximity to the user, and/or estimated time for fulfillment. Other selection criteria may be used. Sixth, it may reformat the order data as necessary so that the taxi company's native electronic ordering system can recognize it. Seventh, it may attempt to establish a connection with the provider by communicating over communication channel 215 and attempt to queue an order with the taxi company. Finally, if the order is successfully queued, it may send a confirmation message to client device 210 , for software application 211 , via communication channel 213 and the order will be fulfilled by the taxi company. This implementation is one method for the present invention, however variations and steps may be adjusted accordingly. The user may then obtain the status of the order or cancel the order by using client device 210 with software application 211 through communication channel 213 with server 412 running software application 414 connected to provider 416 over communication channel 215 .
[0034] FIG. 5 illustrates a fourth embodiment for selecting a taxi over SMS from a mobile phone. Mobile phone 310 with SMS application 311 sends a message to carrier 317 over SMS gateway 313 . Carrier 317 then relays the message to SMS aggregator 318 over similar SMS gateway 313 . SMS aggregator 318 then communicates the message over communication channel 215 to server 212 . Server 212 then operates as previously stated using software application 414 with communication channel 215 , SMS aggregator 318 , communication channel 313 , and carrier 317 to interface with mobile device 310 instead of using communication channel 213 and client device 210 as shown in FIG. 2 . Software application 414 selects desired taxi company 416 using communication channel 215 .
[0035] Turning now to the process flowcharts for the present invention, FIG. 6 shows a modular, high-level design of the overall process. The following process applies to the ordering of a taxi, however this process can be used for any other provider for a service or product with slight modifications.
[0036] The first component of the overall process 600 is a Receive Order and Prepare to Process module 610 . The second component is a Parse Message module 620 . The third component is a Validate Address module 630 . The final component is a Send Order module 640 . Together, they provide the overall step-by-step process provided by the present invention.
[0037] Overall process 600 is also connected to five optional modules. These modules can be used at any time by the user but are not required for the operation of overall process 600 . The first optional module is a register module 650 . This module allows for the user to pre-register for the system. This may allow such benefits as pre-stored information and other preferences. For example, a user may want to pre-register with a food provider so that a menu item is delivered when an order is placed. The second module is a unregister module 660 . This always a user to remove pre-registered information including settings. The third module is a cancel module 670 . This module allows the user to cancel an order at any time during and after the process has begun. The fourth module is a status module 680 . This module allows the user to obtain status information on an order in progress. The fifth module is a help module 690 . This module allows the user to obtain information from the system on commands which can be used. This module may also help the user if they are in need of any assistance with the system.
[0038] FIG. 7 further illustrates Receive Order and Prepare to Process module 610 . The first step of this process starts with the order received from a user as shown in step 710 . At step 711 , the system will check if an order is already in process. If the customer is already waiting for a good or service (e.g., a taxicab) at step 721 or an order has already been initiated at step 723 , then the system will reply to the user with a message such as “Only 1 order at a time” at step 720 . If there is no order in progress at step 722 , the system will continue on to the next step 730 .
[0039] At step 730 , the system will check if the user is previously registered. If the customer is registered at step 740 , the process of this module will be complete. If the customer is not registered at step 741 , the system will implicitly register the user at step 751 by taking the user's mobile phone number at step 750 . The customer is now registered at step 760 and the process of this module is complete.
[0040] Continuing on from FIG. 7 , FIG. 8 further illustrates Parse Message module 620 . At Step 810 , the customer is registered and the system will use the address originally sent, or at step 811 , the system will use a resent address. At step 820 , the system will parse the message to figure out what type of order is being sent. In this example process, the order is a taxicab order as shown in step 821 .
[0041] Also during parse message at step 820 , the system will check to see if an address parameter is present. If the address is present at step 830 , the process of this module will be complete. If the parameter is not present, it will then depend on the number of iterations the system has parsed the address with no address present. If it is the second iteration at step 832 , the system will send a reply to the user with a message such as “Request to send address” at step 834 and the process will start over at user sending address at step 811 when the address is received. If it is the third iteration at step 833 , the system will reply to the user with a message such as “Request Unknown” at step 838 and the process of this module will be complete with no order being processed.
[0042] If parse message at step 820 is on its first iteration with no address present at step 831 , the system will check for previous orders for that user at step 836 . If there is no previous order at step 841 , the system will reply to the user with a message such as “request to send address” at step 842 and the process will start over at user sending address at step 811 on its second iteration. If there is a previous order at step 840 , the system will send a message to the user asking if they would like to use the previous address at step 850 with a message such as “Previous Address?” at step 851 .
[0043] Continuing to the next step 870 , the system will process the previous address as long as both a message for the previous address confirmation has been sent at step 860 and a reply from the user has been received at step 861 . The system will then complete the process in this module using the previous address at step 880 , or it will ask the user to resend the address at step 881 and the process will start over at the user sending an address at step 811 on its second iteration.
[0044] FIG. 9 further illustrates Validate address module 630 . Continuing on from FIG. 8 , the address will either be from what was submitted at step 910 , or from a previous address at step 911 . This address will be validated at step 920 . The method of validation being used in this example is a web-based verification service shown in step 921 . The web-based verification service may be a mapping tool provided by systems such as Google Maps, NAVTEQ, or Mapquest. Other commercially available systems may be used for address verification. The next step in the process will depend on the validity of the address.
[0045] If the validation was successful and there is exactly one match at step 930 , the system will use the address as received or an alternative address at step 940 that is the same. The system will then check to see if there is a participating operator in that area at step 950 . If no operator is found at step 961 , the system will reply to the user with a message such as “Area not served” at step 962 and the process will be completed with no order possible. If an operator is found at step 960 , the module is complete.
[0046] If the validated address process at step 920 only finds zip code accuracy at step 931 , the system will check if there is a participating operator in the area at step 941 . If there is no operator at step 971 , the system will reply to the user with a message such as “Area not served” at step 981 and the process will be completed with no order possible. If there is an operator found at step 970 , the system will reply to the user by providing the operator name and phone number at step 980 and the process will be completed with no order possible.
[0047] If the validated address process at step 920 finds one near match at step 932 , the system will send an alternative address and ask the user to confirm at step 942 . The reply will state, for example, “Alt. Address” with the alternative address provided at step 951 . The system will then send one address at step 953 to the user. Once the address is sent and the user has responded at step 963 , the system will process the alternative address reply at step 972 . If the user states the alternative address is incorrect at step 983 , the process will be completed with no order possible. If the user states the alternative address is correct, it will use the alternative address at step 982 and use the process under alternative address at step 940 to complete the process of this module as stated previously.
[0048] If the validated address process at step 920 finds two or more near matches at step 933 , the system will send alternative address and ask the user to confirm at step 943 . The reply will state, for example, “Alt. Addresses” with the alternative addresses provided at step 952 . The system will then send two addresses to the user at step 954 . Once addresses are sent and the user has responded at step 963 , the system will process the alternative address reply at step 972 to complete the module as stated previously.
[0049] If the validated address process at step 920 finds no match on the first attempt at step 934 , it will reply to user with a message such as “Please Resend request” at step 944 . If the validated address process at step 920 finds no match on its second attempt at step 935 , it will reply to user with a message such as “Sorry, cannot find address” at step 945 and the process will be completed with no order possible.
[0050] FIG. 10 further illustrates Send Order module 640 . Continuing on from FIG. 9 , at step 1010 , the operator is found. At step 1020 , the system will connect to the operator queue. At step 1030 , the system will extract the street name, type, and direction from the address. At step 1040 , the system will find/replace words in street names according to the particular operator's rules. At step 1050 , the system will query the operator's databases for the street name. At step 1060 , the system will separate the operator matches into direction, type, and name. At step 1070 , the system will search for matching street, type, and name.
[0051] If a match is not found at step 1072 , the system will reply to the user with a message such as “Order Failed”. The process will be complete with no order possible.
[0052] If a match is found at step 1073 , the system will send the operator a matched address to queue at step 1080 . The system will then send the order to queue at step 1081 and verify that it was queued successfully at step 1082 . If the order failed at step 1092 , the system will send a message to the user that the order failed at step 1090 and the process will be complete with no order possible. If the order is added successfully at step 1093 , the system will send a message to the user that the order was successful at step 1094 and the process of this module as well as the entire process will be complete with a completed order.
[0053] While the specification has been described in detail with respect to specific embodiments of the invention, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the appended claims and their equivalents.
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The present invention provides a computer system and method for facilitating a transaction between a buyer and a seller. The seller is one of multiple available providers of a product and/or service. Initially, the buyer sends out an order, and the order is automatically verified. A seller is then determined based on at least one desirable characteristic of that particular seller. Then, the order is automatically translated into a format understandable by the desired seller. The order is communicated to the desired seller and the status of the order is later communicated to the buyer.
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FIELD OF INVENTION
[0001] The invention relates to protein kinase inhibitors and to their use in treating disorders related to abnormal protein kinase activities such as cancer and inflammation. More particularly, the invention relates to alkoxy indolinone based derivatives and their pharmaceutically acceptable salts employable as protein kinase inhibitors.
BACKGROUND
[0002] Protein kinases are enzymes that catalyze the phosphorylation of hydroxyl groups of tyrosine, serine, and threonine residues of proteins. Many aspects of cell life (for example, cell growth, differentiation, proliferation, cell cycle and survival) depend on protein kinase activities. Furthermore, abnormal protein kinase activity has been related to a host of disorders such as cancer and inflammation. Therefore, considerable effort has been directed to identifying ways to modulate protein kinase activities. In particular, many attempts have been made to identify small molecules that act as protein kinase inhibitors.
[0003] Several pyrrolyl-indolinone derivatives have demonstrated excellent activity as inhibitors of protein kinases (Larid et al. FASEB J. 16, 681, 2002; Smolich et al. Blood, 97, 1413, 2001; Mendel et al. Clinical Cancer Res. 9, 327, 2003; Sun et al. J. Med. Chem. 46, 1116, 2003). The clinical utility of these compounds has been promising, but has been partially compromised due to the relatively poor aqueous solubility and/or other drug properties. What is needed is a class of modified pyrrolyl-indolinone derivatives having both inhibitory activity and enhanced drug properties.
SUMMARY
[0004] The invention is directed to alkoxy indolinone based derivatives and to their use as inhibitors of protein kinases. It is disclosed herein that alkoxy indolinone based derivatives have enhanced and unexpected drug properties that advantageously distinguish this class of compounds over known pyrrolyl-indolinone derivatives having protein kinase inhibition activity. It is also disclosed herein that alkoxy indolinone based derivatives are useful in treating disorders related to abnormal protein kinase activities such as cancer.
[0005] One aspect of the invention is directed to a compound represented by Formula (I):
In Formula (I), R 1 is selected from the group consisting of hydrogen, halo, (C1-C6) alkyl, (C3-C8) cycloalkyl, (C1-C6) haloalkyl, hydroxy, (C1-C6) alkoxy, amino, (C1-C6) alkylamino, amide, sulfonamide, cyano, substituted or unsubstituted (C6-C10) aryl; R 2 is selected from the group consisting of hydrogen, halo, (C1-C6) alkyl, (C3-C8) cycloalkyl, (C1-C6) haloalkyl, hydroxy, (C1-C6) alkoxy, (C2-C8) alkoxyalkyl, amino, (C1-C6) alkylamino, (C6-C10) arylamino; R 3 is selected from the group consisting of hydrogen, (C1-C6) alkyl, (C6-C10) aryl, (C5-C10) heteroaryl, and amide; R 4 , R 5 , R 6 and R 8 are independently selected from the group consisting of hydrogen and (C1-C6) alkyl; R 7 is (C1-C6) alkyl; R 9 is selected from the group consisting of hydroxy, (C1-C6) O-alkyl, (C3-C8) O-cycloalkyl, and NR 10 R 11 ; where R 10 and R 11 are independently selected from the group consisting of hydrogen, (C1-C6) alkyl, (C1-C6) hydroxyalkyl, (C2-C6) dihydroxyalkyl, (C1-C6) alkoxy, (C1-C6) alkyl carboxylic acid, (C1-C6) alkyl phosphonic acid, (C1-C6) alkyl sulfonic acid, (C1-C6) hydroxyalkyl carboxylic acid, (C1-C6) alkyl amide, (C3-C8) cycloalkyl, (C5-C8) heterocycloalkyl, (C6-C8) aryl, (C5-C8) heteroaryl, (C3-C8) cycloalkyl carboxylic acid, or R 10 and R 11 together with N forms a (C5-C8) heterocyclic ring either unsubstituted or substituted with one or more hydroxyls, ketones, ethers, and carboxylic acids; n is 1, 2, or 3; and m is 0, 1, or 2. Alternatively, this aspect of the invention also is directed to a pharmaceutically acceptable salt, its tautomer, a pharmaceutically acceptable salt of its tautomer, or a prodrug of Formula (I).
[0006] A first preferred subgenus of this first aspect of the invention is directed to the compound, salt, tautomer, or prodrug represented by Formula (II):
In Formula (II), R 12 is selected from the group consisting of hydrogen, (C1-C6) alkyl, and (C3-C8) cycloalkyl. Other groups are as defined in Formula (I). In preferred embodiments, R 1 and R 2 are independently selected from the group consisting of hydrogen and fluoro; R 3 and R 4 are methyl; R 5 , R 6 , R 8 , and R 12 are hydrogen; R 7 is (C1-C6) alkyl; n is 1 or 2; and m is 0 or 1. Preferred species include the following compounds:
[0007] A second preferred subgenus of this first aspect of the invention is directed to a compound, salt, tautomer, or prodrug represented by Formula (III):
In Formula (III), the various R groups are the same as Formula (I). In preferred embodiments, R 1 and R 2 are independently selected from the group consisting of hydrogen, halo, cyano; R 3 is selected from the group consisting of hydrogen, (C1-C6) alkyl, (C6-C10) aryl, (C5-C10) heteroaryl, and amide; R 4 , R 5 , R 6 and R 8 are independently selected from the group consisting of hydrogen and (C1-C6) )alkyl; R 7 is (C1-C6) alkyl; n is 1 or 2; m is 0 or 1; and R 10 and R 11 are selected from the group consisting of hydrogen, (C1-C6) alkyl, (C1-C6) hydroxyalkyl, (C2-C6) dihydroxyalkyl, (C1-C6) alkoxy, (C2-C6) alkyl carboxylic acid, (C1-C6) alkyl phosphonic acid, (C1-C6) alkyl sulfonic acid, (C2-C6) hydroxyalkyl carboxylic acid, (C1-C6) alkyl amide, (C3-C8) cycloalkyl, (C5-C8) heterocycloalkyl, (C6-C8) aryl, (C5-C8) heteroaryl, (C4-C8) cycloalkyl carboxylic acid, or R 10 and R 11 together with N forms a (C5-C8) heterocyclic ring either unsubstituted or substituted with one or more hydroxyls, ketones, ethers, and carboxylic acids.
[0008] In a first subgroup of this second subgenus, m is 0. Preferred species of this first subgroup are represented by the following structures:
[0009] In a second subgroup of this second subgenus, m is 1. Preferred species of this second subgroup are represented by the following structures:
[0010] Further species of the second aspect of the invention are represented by the following structures:
wherein: R 9 is selected from the group consisting of radicals represented by the following structures:
[0011] Another aspect of the invention is directed to a method for the modulation of the catalytic activity of a protein kinase with a compound or salt of any one of the compounds of Formulas (I-III). In a preferred mode, the protein kinase is selected from the group consisting of VEGF receptors and PDGF receptors.
BRIEF DESCRIPTION OF FIGURES
[0012] FIG. 1 illustrates a scheme that is used for the synthesis of the 3-alkoxy-4-acylaminoamide derivatives starting from methyl 3-hydroxy-4-aminobutanoate hydrochlorides and the activated acylating agent 1-3.
[0013] FIG. 2 illustrates a scheme that is used for the synthesis of the 2-alkoxy-3-acylaminoamide derivatives starting from methyl 2-hydroxy-3-aminopropionate hydrochlorides and the activated acylating agent 1-3.
[0014] FIG. 3 illustrates a scheme that is used for the synthesis of the (2S)-2-alkoxy-4-acylamino-amide derivatives starting from methyl (2S)-2-hydroxy-4-aminobutanoate hydrochloride and the activated acylating agent 1-3.
DETAILED DESCRIPTION
EXAMPLES 1-8
[0015] The synthesis of acids (1-4) and amides (1-5) is shown in FIG. 1 . Variations from this general synthetic procedure can be understood and carried out by those skilled in the art. Thus, the compounds of the present invention can be synthesized by those skilled in the art.
EXAMPLE 1
[0016] 4 -({5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-3-methoxy-butyric acid
To a suspension of methyl 4-amino-3-hydroxybutyrate (1.0 equiv, which was prepared by refluxing the free amino acid in dry methanol with 1.2 equiv HCl) and DIEA (5 equiv) in DCM, Mmt-Cl (1.1 equiv) was added portion-wise at 25° C. After stirring overnight, the DCM was removed under reduced pressure. The residue was suspended in ethyl acetate, washed with brine (3×), dried over anhydrous Na 2 SO 4 . The ethyl acetate was then removed, and the residue was dried overnight under high vacuum, and subjected to flash chromatography to give compound 1-1. To a solution of compound 1-1 in dry DMF, NaH (1.5 equiv) was added under argon. After stirring at 25° C. for 1 h, Mel (5 equiv) was added to the solution, and the resulting suspension was gently shaken at 25° C. overnight. The DMF was removed under vacuum; the residue was suspended in ethyl acetate, washed with brine (3×), and dried over anhydrous Na 2 SO 4 . After the ethyl acetate was removed via evaporation the resulting residue was treated with 1% TFA in DCE/DCM for 30 min. The organic solvents were then removed under reduced pressure, and the resulting residue was triturated with hexane (3×) to obtain the free amino acid 1-2. This amino acid was used directly in the next step without any purification and characterization. Thus, to a solution of 1-2 (2 equiv) and DIEA (5 equiv) in DMF, compound 1-3 (1 equiv) was added at 25° C. After stirring for 30 min (LC-MS show the complete consumption of 1-3), KOH (5 equiv) in water was added, and the solution was stirred for another 2h (LC-MS demonstrated a complete hydrolysis). The solvents were removed under reduced pressure, and HCl (1N, excess) was added to give a precipitate. This precipitate was collected and washed (by water) by filtration, dried under high vacuum to give the title compound (95% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 21 H 22 FN 3 O 5 : 416, obtained: 416. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 12.18 (b, 1H), 10.90 (s,1H), 7.75 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.64 (t, J=6.0 Hz, 1H), 6.92 (m, 1H) 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 3.73 (m, 1H), 3.43-3.31 (m, 2H), 3.22 (s, 3H), 2.52-2.35 (m, 2H), 2.43 (s, 3H), 2.41 (s, 3H).
EXAMPLE 2
[0017] 3-Ethoxy-4-({5-[5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-butyric acid
A similar route as that for the synthesis of Example 1 was used to prepare the title compound. Iodoethane was used instead of iodomethane to obtain the 3-ethoxy compound (9.7% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 22 H 24 FN 3 O 5 : 430, obtained: 430.
EXAMPLES 3-8
[0018] The general procedure for the synthesis of amides (1-5): An amine (2 equiv) was added to a solution of the acid (1-4), HATU (1.05 mmol), and DIEA (5 equiv) in DMF (5 mL). After the solution was stirred at 25° C. for 2h, aqueous HCl (2 mL, 1N) was added. This solution was subjected to preparative HPLC to obtain the pure amide product, which was subsequently characterized by LC-MS and NMR spectroscopy.
EXAMPLE 3
[0019] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (3-dimethylcarbamoyl-2-ethoxy-propyl)-amide
Preparative HPLC gave 13 mg of the title compound (41%) from 30 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 24 H 29 FN 4 O 4 : 457, obtained: 457. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.2 Hz, 1H), 7.72 (s, 1H), 7.60 (t, J=6.0 Hz, 1H), 6.92 (m, 1H) 6.83 (dd, J=4.8 Hz, 8.4 Hz, 1H), 3.89 (m, 1H), 3.58-3.45 (m, 2H), 3.40-3.27 (m, 2H, buried in water signals), 2.97 (s, 3H), 2.82 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 1.07 (t, J=7.2 Hz, 3H).
EXAMPLE 4
[0020] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (3-dimethylcarbamoyl-2-methoxy-propyl)-amide
Preparative HPLC gave 46 mg of the title compound (36%) from 120 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 23 H 27 FN 4 O 4 : 443, obtained: 443. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.2 Hz, 1H), 7.71 (s, 1H), 7.63 (t, J=5.6 Hz, 1H), 6.92 (m, 1H), 6.83 (dd, J=4.8 Hz, 8.8 Hz, 1H), 3.78 (m, 1H), 3.42-3.31 (m, 2H), 3.30 (s, 3H), 2.97 (s, 3H), 2.82 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 2.63-2.43 (m, 2H).
EXAMPLE 5
[0021] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-methoxy-4-morpholin-4-yl-4-oxo-butyl)-amide
Preparative HPLC gave 48 mg of the title compound (37%) from 110 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 25 H 29 FN 4 O 6 : 485, obtained: 485. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.2 Hz, 1H), 7.71 (s, 1H), 7.63 (t, J=5.6 Hz, 1H), 6.92 (m, 1H), 6.83 (dd, J=4.8 Hz, 8.4 Hz, 1H), 3.80 (m, 1H), 3.55 (m, 4H), 3.47 (m, 4H), 3.38 (m, 2H), 3.31 (s, 3H), 2.60 (m, 1H), 2.45 (m, 1H), 2.43 (s, 3H), 2.41 (s, 3H).
EXAMPLE 6
[0022] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid [4-(4-hydroxy-piperidin-1-yl)-2-methoxy-4-oxo-butyl]-amide
Preparative HPLC gave 20 mg of the title compound (33%) from 50 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 26 H 31 FN 4 O 5 : 499, obtained: 499. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.6 Hz, 1H), 7.72 (s, 1H), 7.63 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.4 Hz, 8.4 Hz, 1H), 3.92 (m, 1H), 3.78 (m, 1H), 3.68 (b, 1H), 3.30 (s, 3H), 3.15 (m, 1H), 3.01 (m, 1H), 2.60 (m, 1H), 2.55 (m, 2H), 2.50 (m, 1H), 2.45 (m, 2H), 2.43 (s, 3H), 2.41 (s, 3H), 1.70 (m, 2H), 1.30 (m, 2H).
EXAMPLE 7
[0023] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-methoxy-4-oxo-4-pyrrolidin-1-yl-butyl)-amide
Preparative HPLC gave 40 mg of the title compound (32%) from 110 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 25 H 29 FN 4 O 4 : 469, obtained: 469. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.6 Hz, 1H), 7.71 (s, 1H), 7.63 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, 8.8 Hz, 1H), 3.82 (m, 1H), 3.50-3.25 (m, 6H), 3.30 (s, 3H), 2.55-2.45 (m, 2H), 2.43 (s, 3H), 2.41 (s, 3H), 1.86 (m, 2H), 1.76 (m, 2H).
EXAMPLE 8
[0024] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid[2-methoxy-3-(methoxy-methyl-carbamoyl)-propyl]-amide
Preparative HPLC gave 15 mg of the title compound (15%) from 80 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 23 H 27 FN 4 O 5 : 459, obtained: 459. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.90 (s, 1H), 7.76 (dd, J=2.4 Hz, 9.2 Hz, 1H), 7.72 (s, 1H), 7.68 (t, J=6.0 Hz, 1H), 6.93 (m, 1H), 6.84 (dd, J=4.4 Hz, 8.4 Hz, 1H), 3.79 (m, 1H), 3.66 (s, 3H), 3.50-3.35 (m, 2H), 3.31 (s, 3H), 3.13 (s, 3H), 2.55-2.45 (m, 2H), 2.43 (s, 3H), 2.41 (s, 3H).
EXAMPLES 9-15
[0025] The synthesis of acids (2-3) and amides (2-4) is shown in FIG. 2 . Variations from this general synthetic procedure can be understood and carried out by those skilled in the art. Thus, the compounds of the present invention can be synthesized by those skilled in the art.
EXAMPLE 9
[0026] 3-({5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-2-methoxy-propionic acid
To a suspension of methyl 3-amino-2-hydroxypropionate (1.0 equiv, which was prepared by refluxing the free amino acid isoserine in dry methanol with 1.2 equiv HCl) and DIEA (5 equiv) in DCM, Mmt-Cl (1.1 equiv) was added portion-wise at 25° C. After stirring overnight, the DCM was removed under reduced pressure. The residue was suspended in ethyl acetate, washed with brine (3×), dried over anhydrous Na 2 SO 4 . The ethyl acetate was then removed, and the residue was dried overnight under high vacuum, and subjected to flash chromatography to give compound 2-1. To a solution of compound 2-1 in dry DMF, NaH (1.5 equiv) was added under argon. After stirring at 25° C. for 1 h, Mel (5 equiv) was added to the solution, and the resulting suspension was gently stirred at 25° C. overnight. The DMF was removed under vacuum; the residue was suspended in ethyl acetate, washed with brine (3×), and dried over anhydrous Na 2 SO 4 . After the ethyl acetate was removed via evaporation the resulting residue was treated with 1% TFA in DCE/DCM for 30 min. The organic solvents were then removed under reduced pressure, and the resulting residue was triturated with hexane (3×) to obtain the free amino acid 2-2. This amino acid was used directly in the next step without any purification and characterizations. Thus, to a solution of 2-2 (2 equiv) and DIEA (5 equiv) in DMF, compound 1-3 (1 equiv) was added at 25° C. After stirring for 30 min (LC-MS show the complete consumption of 1-3), KOH (5 equiv) in water was added, and the solution was stirred for another 2h (LC-MS demonstrated a complete hydrolysis). The solvents were removed under reduced pressure, and HCl (1N, excess) was added to give a precipitate. This precipitate was collected by filtration, washed with water and dried under high vacuum to give the title compound (99% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 20 H 20 FN 3 O 5 : 402, obtained: 402. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 12.83 (b, 1H), 10.90 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.69 (t, J=6.0 Hz, 1H), 6.92 (m, 1H), 6.82 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 3.90 (m, 1H), 3.55 (m, 1H), 3.41 (m, 1H), 3.32 (s, 3H), 2.42 (s, 3H), 2.40 (s, 3H).
EXAMPLE 10
[0027] 2-Ethoxy-3-({5-[5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-propionic acid
A similar route as that for the synthesis of Example 9 was used to prepare the title compound. Iodoethane was used instead of iodomethane to obtain the 2-ethoxy compound (38% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 21 H 22 FN 4 O 5 : 416, obtained: 416. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 12.80 (b, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.2 Hz, 1H), 7.71 (s, 1H), 7.68 (t, J=6.0 Hz, 1H), 6.92 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 4.00 (dd, J=5.2 Hz, J=7.6 Hz, 1H), 3.58 (m, 2H), 3.41 (m, 2H), 2.43 (s, 3H), 2.41 (s, 3H), 1.14 (t, J=6.8 Hz, 3H).
EXAMPLES 11-15
[0028] The general procedure for the synthesis of amides (compounds 2-4): A corresponding amine (2 equiv) was added to a solution of the acid (compound 2-3), HATU (1.05 mmol), and DIEA (5 equiv) in DMF (5 mL). After the solution was stirred at 25° C. for 2h, aqueous HCl (2 mL, 1N) was added. This solution was subjected to preparative HPLC to obtain the pure amide product, which was subsequently characterized by LC-MS and NMR spectroscopy.
EXAMPLE 11
[0029] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-dimethylcarbamoyl-2-ethoxy-ethyl)-amide
Preparative HPLC gave 46 mg of the title compound (62%) from 70 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 23 H 27 FN 4 O 4 : 443, obtained: 443.
EXAMPLE 12
[0030] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-ethoxy-3-morpholin-4-yl-3-oxo-propyl)-amide
Preparative HPLC gave 40 mg of the title compound (49%) from 70 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 25 H 29 FN 4 O 5 : 485, obtained: 485. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.70 (m, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 4.40 (m, 1H), 3.73-3.35 (m, 12H), 2.43 (s, 3H) 2.41 (s, 3H), 1.12 (t, J=7.2 Hz, 3H).
EXAMPLE 13
[0031] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-dimethylcarbamoyl-2-methoxy-ethyl)-amide
Preparative HPLC gave 93 mg of the title compound (76%) from 115 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 22 H 25 FN 4 O 4 : 429, obtained: 429. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.90 (s, 1H), 7.75 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.72 (m, 1H), 7.71 (s, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.8 Hz, 1H), 4.40 (dd, J=4.8 Hz, J=7.2 Hz, 1H), 3.50 (m, 1H), 3.32 (m, 1H), 3.24 (s, 3H), 3.10 (s, 3H), 2.86 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H),
EXAMPLE 14
[0032] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-methoxy-3-morpholin-4-yl-3-oxo-propyl)-amide
Preparative HPLC gave 98 mg of the title compound (73%) from 115 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 24 H 27 FN 4 O 5 : 471, obtained: 471. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 10.89 (s, 1H), 7.75 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.70 (m, 1H), 6.92 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.8 Hz, 1H), 4.34 (dd, J=4.8 Hz, J=7.2 Hz, 1H), 3.85-3.30 (m, 10H), 3.26 (s, 3H), 2.44 (s, 3H), 2.42 (s, 3H).
EXAMPLE 15
[0033] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-methoxy-3-oxo-3-pyrrolidin-1-yl-propyl)-amide
Preparative HPLC gave 86 mg of the title compound (66%) from 115 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 24 H 27 FN 4 O 4 : 455, obtained: 455. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.70 (m, 1H), 7.71 (s, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.4 Hz, J=8.4 Hz, 1H), 4.20 (dd, J=5.2 Hz, J=7.2 Hz, 1H), 3.60-3.47 (m, 3H), 3.43-3.28 (m, 3H), 3.26 (s, 3H), 2.43 (s, 3H), 2.40 (s, 3H), 1.88 (m, 2H), 1.78 (m, 2H).
EXAMPLES 16-315
[0034] Still further amide examples are shown in the following table:
Ex# Core R Ex# Core R Ex# Core R 31 I p 81 II p 131 III p 32 I q 82 II q 132 III q 33 I r 83 II r 133 III r 34 I s 84 II s 134 III s 35 I t 85 II t 135 III t 36 I u 86 II u 136 III u 37 I v 87 II v 137 III v 38 I w 88 II w 138 III w 39 I x 89 II x 139 III x 40 I y 90 II y 140 III y 41 I z 91 II z 141 III z 42 I aa 92 II aa 142 III aa 43 I ab 93 II ab 143 III ab 44 I ac 94 II ac 144 III ac 45 I ad 95 II ad 145 III ad 46 I ae 96 II ae 146 III ae 47 I af 97 II af 147 III af 48 I ag 98 II ag 148 III ag 49 I ah 99 II ah 149 III ah 50 I ai 100 II ai 150 III ai 51 I aj 101 II aj 151 III aj 52 I ak 102 II ak 152 III ak 53 I al 103 II at 153 III al 54 I am 104 II am 154 III am 55 I an 105 II an 155 III an 56 I ao 106 II ao 156 III ao 57 I ap 107 II ap 157 III ap 58 I aq 108 II aq 158 III aq 59 I ar 109 II ar 159 III ar 60 I as 110 II as 160 III as 61 I at 111 II at 161 III at 62 I au 112 II au 162 III au 63 I av 113 II av 163 III av 64 I aw 114 II aw 164 III aw 65 I ax 115 II ax 165 III ax 166 IV a 216 V a 266 VI a 167 IV b 217 V b 267 VI b 168 IV c 218 V c 268 VI c 169 IV d 219 V d 269 VI d 170 IV e 220 V e 270 VI e 171 IV f 221 V f 271 VI f 172 IV g 222 V g 272 VI g 173 IV h 223 V h 273 VI h 174 IV i 224 V i 274 VI i 175 IV j 225 V j 275 VI j 176 IV k 226 V k 276 VI k 177 IV l 227 V l 277 VI l 178 IV m 228 V m 278 VI m 179 IV n 229 V n 279 VI n 180 IV o 230 V o 280 VI o 181 IV p 231 V p 281 VI p 182 IV q 232 V q 282 VI q 183 IV r 233 V r 283 VI r 184 IV s 234 V s 284 VI s 185 IV t 235 V t 285 VI t 186 IV u 236 V u 286 VI u 187 IV v 237 V v 287 VI v 188 IV w 238 V w 288 VI w 189 IV x 239 V x 289 VI x 190 IV y 240 V y 290 VI y 191 IV z 241 V z 291 VI z 192 IV aa 242 V aa 292 VI aa 193 IV ab 243 V ab 293 VI ab 194 IV ac 244 V ac 294 VI ac 195 IV ad 245 V ad 295 VI ad 196 IV ae 246 V ae 296 VI ae 197 IV af 247 V af 297 VI af 198 IV ag 248 V ag 298 VI ag 199 IV ah 249 V ah 299 VI ah 200 IV ai 250 V ai 300 VI ai 201 IV aj 251 V aj 301 VI aj 202 IV ak 252 V ak 302 VI ak 203 IV al 253 V al 303 VI al 204 IV am 254 V am 304 VI am 205 IV an 255 V an 305 VI an 206 IV ao 256 V ao 306 VI ao 207 IV ap 257 V ap 307 VI ap 208 IV aq 258 V aq 308 VI aq 209 IV ar 259 V ar 309 VI ar 210 IV as 260 V as 310 VI as 211 IV at 261 V at 311 VI at 212 IV au 262 V au 312 VI au 213 IV av 263 V av 313 VI av 214 IV aw 264 V aw 314 VI aw 215 IV ax 265 V ax 315 VI ax
In the above table, R 9 is selected from the following radicals:
These amide examples 16-315 can be made by those skilled in the art following the above procedure and/or known procedures.
EXAMPLES 316-320
[0035] The synthesis of acids (3-3) and amides (3-4) is shown in FIG. 3 . Variations from this general synthetic procedure can be understood and carried out by those skilled in the art. Thus, the compounds of the present invention can be synthesized by those skilled in the art.
EXAMPLE 316
[0036] (S)-4-({5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-2-methoxy-butyric acid
To a suspension of methyl 4-amino-2-hydroxybutyrate (1.0 equiv, which was prepared by refluxing the free amino acid in dry methanol with 1.2 equiv HCl) and DIEA (5 equiv) in DCM, Mmt-Cl (1.1 equiv) was added portion-wise at 25° C. After stirring overnight, the DCM was removed under reduced pressure. The residue was suspended in ethyl acetate, washed with brine (3×), dried over anhydrous Na 2 SO 4 . The ethyl acetate was then removed, and the residue was dried overnight under high vacuum, and subjected to flash chromatography to give compound 3-1. To a solution of compound 3-1 in dry DMF, NaH (1.5 equiv) was added under argon. After stirring at 25° C. for 1h, Mel (5 equiv) was added to the solution, and the resulting suspension was gently stirred at 25° C. overnight. The DMF was removed under vacuum; the residue was suspended in ethyl acetate, washed with brine (3×), and dried over anhydrous Na 2 SO 4 . After the ethyl acetate was removed via evaporation the resulting residue was treated with 1% TFA in DCE/DCM for 30 min. The organic solvents were then removed under reduced pressure, and the resulting residue was triturated with hexane (3×) to obtain the free amino acid 3-2. This amino acid was used directly in the next step without any purification and characterization. Thus, to a solution of 3-2 (2 equiv) and DIEA (5 equiv) in DMF, compound 1-3 (1 equiv) was added at 25° C. After stirring for 30 min (LC-MS show the complete consumption of 1-3), KOH (5 equiv) in water was added, and the solution was stirred for another 2h (LC-MS demonstrated a complete hydrolysis). The solvents were removed under reduced pressure, and HCl (1N, excess) was added to give a precipitate. This precipitate was collected and washed (by water) by filtration, dried under high vacuum to give the title compound (97% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 21 H 22 FN 3 O 5 : 416, obtained: 416. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 12.80 (b, 1H), 10.90 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.65 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 3.77 (dd, J=4.0 Hz, J=8.8 Hz, 1H), 3.40-3.30 (m, 2H), 3.30 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 1.92 (m, 1H), 1.78 (m, 1H).
EXAMPLE 317
[0037] (S)-2-Ethoxy-4-({5-[5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carbonyl}-amino)-butyric acid
A similar route as that for the synthesis of Example 316 was used to prepare the title compound. Iodoethane was used instead of iodomethane to obtain the 2-ethoxy compound (84% based on compound 1-3). LC-MS: single peak at 254 nm, MH + calcd. for C 22 H 24 FN 3 O 5 : 430, obtained: 430. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 12.70 (b, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.66 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 3.85 (dd, J=4.0 Hz, J=8.4 Hz, 1H), 3.58 (m, 1H), 3.40-3.25 (m, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 1.92 (m, 1H), 1.77 (m, 1H), 1.13 (t, J=7.2 Hz, 3H).
EXAMPLE 318-320
[0038] The general procedure for the synthesis of amides (compounds 3-4): A corresponding amine (2 equiv) was added to a solution of the acid (compound 3-3), HATU (1.05 mmol), and DIEA (5 equiv) in DMF (5 mL). After the solution was stirred at 25° C. for 2h, aqueous HCl (2 mL, 1N) was added. This solution was subjected to preparative HPLC to obtain the pure amide product, which was subsequently characterized by LC-MS and NMR spectroscopy.
EXAMPLE 318
[0039] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid ((S)-3-dimethylcarbamoyl-3-methoxy-propyl)-amide
Preparative HPLC gave 37 mg of the title compound (58%) from 60 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 23 H 27 FN 4 O 4 : 443, obtained: 443. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.72 (s, 1H), 7.65 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 4.20 (dd, J=4.0 Hz, J=8.0 Hz, 1H), 3.30 (m, 2H), 3.27 (s, 3H), 3.04 (s, 3H), 2.88 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 1.80 (m, 2H).
EXAMPLE 319
[0040] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid ((S)-3-methoxy-4-morpholin-4-yl-4-oxo-butyl)-amide
Preparative HPLC gave 32 mg of the title compound (46%) from 60 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 25 H 29 FN 4 O5: 485, obtained: 485. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.68 (s, 1H), 10.89 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.72 (s, 1H), 7.65 (t, J=5.6 Hz, 1H), 6.93 (m, 1H), 6.83 (dd, J=4.8 Hz, J=8.4 Hz, 1H), 4.19 (dd, J=4.8 Hz, J=8.0 Hz, 1H), 3.57 (m, 6H), 3.47 (m, 2H), 3.28 (m, 2H), 3.23 (s, 3H), 2.44 (s, 3H), 2.41 (s, 3H), 1.79 (m, 2H).
EXAMPLE 320
[0041] 5-[5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid ((S)-3-dimethylcarbamoyl-3-ethoxy-propyl)-amide
Preparative HPLC gave 67 mg of the title compound (57%) from 120 mg starting material (acid). LC-MS: single peak at 254 nm, MH + calcd. for C 24 H 29 FN 4 O 4 : 457, obtained: 457. 1 H-NMR (DMSO-d 6 , 400 MHz), δ 13.67 (s, 1H), 10.88 (s, 1H), 7.76 (dd, J=2.4 Hz, J=9.6 Hz, 1H), 7.71 (s, 1H), 7.56 (m, 1H), 6.91 (m, 1H), 6.83 (m, 1H), 4.25 (m, 1H), 3.45-3.25 (m, 4H), 3.03 (s, 3H), 2.83 (s, 3H), 2.43 (s, 3H), 2.41 (s, 3H), 1.80 (m, 2H).
[0042] The compounds described herein are presently representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. It will be readily apparent to one skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
[0000] VEGFR Biochemical Assay
[0043] The compounds were assayed for biochemical activity by Upstate Ltd at Dundee, United Kingdom, according to the following procedure. In a final reaction volume of 25 μl, KDR (h) (5-10 mU) is incubated with 8 mM MOPS pH 7.0, 0.2 mM EDTA, 0.33 mg/ml myelin basic protein, 10 mM MgAcetate and [γ- 33 P-ATP] (specific activity approx. 500 cpm/pmol, concentration as required). The reaction is initiated by the addition of the MgATP mix. After incubation for 40 minutes at room temperature, the reaction is stopped by the addition of 5 μl of a 3% phosphoric acid solution. 10 μl of the reaction is then spotted onto a P30 filtermat and washed three times for 5 minutes in 75 mM phosphoric acid and once in methanol prior to drying and scintillation counting.
[0044] Compounds of the present invention were tested in this assay and exhibited IC 50 between 1-5,000 nM.
[0000] PDGFR Phosphorylation Assay
[0045] NIH3T3 cells are plated in a 96 well plate in DMEM+10% FBS. Following cell attachment the cells are serum starved overnight before adding the chemical test compounds to a final concentration of 0.1% DMSO. Following a 1 hour incubation at 37° C. cells are removed from the incubator and allowed to cool to RT for 20 min before stimulation with PDGF-BB for 15 min at RT. Cells are placed on ice for 5 min, the media removed and the cells are lysed with 100 μwell lysis buffer for 1 hour at 4° C. Plates are spun at 2000 rpm for 30 min at 4° C. and solubilized phosphorylated PDGFR is quantitated by ELISA.
[0046] High binding microplates are incubated overnight at RT with anti-mouse PDGFR-b capture-antibody in PBS, washed with PBS+0.05% Tween20 and blocked for 4h at RT with PBS+1% BSA and washed again. 100 μL lysate/well is incubated overnight at 4° C. Plates are washed and wells are incubated with 100 μL/well of mouse anti-phosphotyrosine-HRP antibody for 2 h at 37° C. Plates are washed again and colorimetric detection is performed using TMB as substrate.
[0047] Most of the compounds in this invention showed IC 50 of less than 1 μM in this assay.
[0000] VEGFR Phosphorylation Assay
[0048] NIHT3T cells overexpressing mouse VEGFR-2 (FLK-1) are plated in a 96 well plate in DMEM+10% FBS. Following cell attachment for 4 hours the cells are serum starved overnight before adding the chemical test compounds to a final concentration of 0.1% DMSO. Following a 1 hour incubation at 37° C. cells are stimulated for 15 min at 37° C. with VEGF165. Cells are placed on ice for 5 min, the media removed, washed once with ice cold PBS and the cells are lysed with 50 μL/well lysis buffer for 1 hour at 4° C. Plates are spun for 10 min at 2000 rpm at 4° C. and solubilized phosphorylated VEGFR is quantitated by ELISA.
[0049] High binding microplates are incubated overnight at room temperature with VEGFR antibody in 50 pL PBS, washed with PBS+0.05% Tween20 and blocked for 4 h at RT with PBS+1% BSA and washed again. 50 μL lysate/well is incubated overnight at 4° C. Plates are washed and wells are incubated with 50 μL/well of mouse anti-phosphotyrosine-HRP antibody for 2 h at 37° C. Plates are washed again and colorimetric detection is performed using TMB as substrate.
[0050] Most of the compounds in this invention showed IC 50 of less than 1 μM in this assay.
[0000] Cellular Assay: HUVEC: VEGF Induced Proliferation
[0051] The compounds were assayed for cellular activity in the VEGF induced proliferation of HUVEC cells. HUVEC cells (Cambrex, CC-2517) were maintained in EGM (Cambrex, CC-3124) at 37° C. and 5% CO 2 . HUVEC cells were plated at a density 5000 cells/well (96 well plate) in EGM. Following cell attachment (1 hour) the EGM-medium was replaced by EBM (Cambrex, CC-3129) +0.1% FBS (ATTC, 30-2020) and the cells were incubated for 20 hours at 37° C. The medium was replaced by EBM +1% FBS, the compounds were serial diluted in DMSO and added to the cells to a final concentration of 0-5,000 nM and 1% DMSO. Following a 1 hour pre-incubation at 37° C. cells were stimulated with 10 ng/ml VEGF (Sigma, V7259) and incubated for 45 hours at 37° C. Cell proliferation was measured by BrdU DNA incorporation for 4 hours and BrdU label was quantitated by ELISA (Roche kit, 16472229) using 1M H 2 SO 4 to stop the reaction. Absorbance was measured at 450 nm using a reference wavelength at 690 nm.
DETAILED DESCRIPTION OF FIGURES
[0052] FIG. 1 shows a scheme that is used for the synthesis of the 3-alkoxy-4-acylaminoamide derivatives starting from methyl 3-hydroxy-4-aminobutanoate hydrochlorides and the activated acylating agent 1-3. The amino ester hydrochloride starting material was prepared by refluxing the free amino acid in anhydrous methanol in the presence of 1.2 eq of HCl. The amino group was protected as its monomethoxytrityl derivative in the presence of the secondary hydroxyl group to give the neutral hydroxy ester 1-1. The hydroxyl group was alkylated using methyl- or ethyl iodide to form the protected amino alkoxy ester. The Mmt group was removed in 1% trifluoroacetic acid leaving the amino hydrochloride or trifluoracetate compound 1-2. This compound was quickly acylated with the preformed acylating agent 1-3 and the methyl ester was hydrolyzed by potassium hydroxide in water/DMF to give 1-4. The free acid was then exposed to HATU, amine and diisopropylethyl amine in DMF to give the alkoxy amide 1-5.
[0053] FIG. 2 shows a scheme that is used for the synthesis of the 2-alkoxy-3-acylaminoamide derivatives starting from methyl 2-hydroxy-3-aminopropionate hydrochlorides and the activated acylating agent 1-3. The amino ester hydrochloride starting material was prepared by refluxing the free amino acid in anhydrous methanol in the presence of 1.2 eq of HCl. The amino group was protected as its monomethoxytrityl derivative in the presence of the secondary hydroxyl group to give 2-1. The hydroxyl group was alkylated using methyl- or ethyl iodide to form the protected amino alkoxy ester. The Mmt group was removed in 1% trifluoroacetic acid leaving the amino hydrochloride or trifluoracetate compound 2-2. This compound was quickly acylated with the preformed acylating agent 1-3 and the methyl ester was hydrolyzed by potassium hydroxide in water/DMF to give 2-4. The free acid was then exposed to HATU, amine and diisopropylethyl amine in DMF to give the alkoxy amide 2-5.
[0054] FIG. 3 shows a scheme that is used for the synthesis of the (2S)-2-alkoxy-4-acylamino-amide derivatives starting from methyl (2S)-2-hydroxy-4-aminobutanoate hydrochloride and the activated acylating agent 1-3. The amino ester hydrochloride starting material was prepared by refluxing the free amino acid in anhydrous methanol in the presence of 1.2 eq of HCl. The amino group was protected as its monomethoxytrityl derivative in the presence of the secondary hydroxyl group to give the neutral hydroxy ester 3-1. The hydroxyl group was alkylated using methyl- or ethyl iodide to form the protected amino alkoxy ester. The Mmt group was removed in 1% trifluoroacetic acid leaving the amino hydrochloride or trifluoracetate compound 3-2. This compound was quickly acylated with the preformed acylating agent 1-3 and the methyl ester was hydrolyzed by potassium hydroxide in water/DMF to give 3-4. The free acid was then exposed to HATU, amine and diisopropylethyl amine in DMF to give the alkoxy amide 3-5.
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Alkoxy indolinone based acid and amide derivatives have enhanced and unexpected drug properties as inhibitors of protein kinases and are useful in treating disorders related to abnormal protein kinase activities such as cancer.
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CROSS REFERENCE TO CO-PENDING APPLICATIONS
[0001] This application is a continuation of co-pending U.S. application Ser. No. 10/796,677, filed Mar. 9, 2004 and is a continuation-in-part of co-pending U.S. application Ser. No. 10/796,677, filed Mar. 9, 2004 and co-pending U.S. application Ser. Nos. 10/104,405, filed Mar. 22, 2002, the contents of each of which is incorporated herein in their entirety.
BACKGROUND
[0002] The present invention relates, in general, to fluid quick connectors which couple fluid carrying components.
[0003] Snap-fit or quick connectors are employed in a wide range of applications, particularly, for joining fluid carrying conduits in automotive and industrial application. In a typical quick connector with an axially displaceable retainer, the retainer is fixedly mounted within a bore in a housing of a connector component or element. The retainer has a plurality of radially and angularly extending legs which extend inwardly toward the axial center line of the bore in the housing. A tube or fitting to be sealingly mounted in the bore in the housing includes a radially upset portion or flange which abuts an inner peripheral surface of the retainer legs. Seal and spacer members as well as a bearing or top hat are typically mounted in the bore ahead of the retainer to form a seal between the housing and the fitting when the fitting is lockingly engaged with the retainer legs.
[0004] Radially displaceable retainers in which the retainer is radially displaceable through aligned bores or apertures formed transversely to the main through bore in the housing are also known. The radially displaceable retainer is typically provided with a pair of depending legs which are sized and positioned to slip behind the radially upset portion or flange on the fitting only when the fitting or conduit is fully seated in the bore in the connector. This ensures a positive locking engagement of the conduit with the connector as well as providing an indication that the conduit is fully seated since the radially displaceable retainer can be fully inserted into the connector only when the conduit has been fully inserted into the bore in the connector.
[0005] In most fluid quick connectors, one or more seal elements, such as resilient O-rings and and/or a rigid spacer member between two spaced O-rings, are mounted in the housing bore to form a seal between the housing and the inserted endform.
[0006] A top hat is typically mounted in the end of the bore to retain the seal elements in the bore prior to insertion of the endform into the bore in the housing or after removal of the endform from the housing. The top hat typically includes a sleeve portion which slides within the bore of the housing, and an end flange which seats in an enlarged end portion of the bore. While effective in securing the seal elements in the housing bore, the top hat represents an additional component which requires assembly time in the fluid quick connector.
[0007] In addition to retainers for fluid quick connectors which engage an upset in the form of an enlarged diameter bead or flange spaced from the tip end of an endform, it is also known to construct retainers for fluid quick connectors which secure the endform in the quick connector housing.
[0008] Regardless of the type of retainer, the housing of a fluid connector typically includes an elongated stem having one or more annular barbs spaced from a first end. The barbs provide secure engagement with a hose or conduit which is forced over the barbs to connect the housing with one end of the conduit.
[0009] Due to the secure engagement between the conduit and the housing, the open end of the axial through bore in the connector portion of a fluid connector designed with an axially displaceable retainer or the transverse bores in a connector designed to receive a radially displaceable retainer are fixed in one circumferential position depending upon the position of the tubing and the connector when the conduit and the connector are joined together. In certain applications, this could limit accessibility to and make it difficult to insert the retainer into the connector, particularly in the case of a radial retainer. Interference with surrounding components frequently makes access to the quick connector for both locking or unlocking operations difficult, if not impossible.
[0010] To address these problems, two part fluid quick connectors which are easily rotatable over 360° to facilitate insertion or removal of the retainer into or out of the quick connector have been devised. In such quick connectors, the quick connector housing, typically of one piece construction, is replaced with two engagable portions, one attachable to or mountable on a fluid component, such as a tube or conduit, and the other receiving a second conduit or endform as well as receiving the retainer for locking the first component and the endform together.
[0011] It would be desirable to provide an improved fluid quick connector which has enhanced snap on capability, and a minimal number of separate components. It would also be desirable to provide an improved fluid quick connector having a retainer configured for engagement with endforms having a reduced diameter engagement surface or groove.
SUMMARY
[0012] The present invention is an improved fluid quick connector for joining first and second endforms in fluid flow communication.
[0013] In one aspect the fluid quick connector includes a housing having a bore extending from an open end for receiving a first endform. A retainer in mountable in the housing for lockingly coupling the first endform in the housing.
[0014] The housing includes one or more latch arms extending axially from one end of the housing. The latch arms are configured for snap-in engagement with an enlarged groove in the second endform.
[0015] One or more seal elements are mounting in the bore of the housing or in the bore in the second endform for sealingly coupling the first endform to the housing or second housing. The bore in the housing has a stepped bore configuration formed of a first large diameter bore extending from the open end to at least one smaller diameter bore portions extending from the first bore portion. The inner diameter of the one smaller bore portion is sized to be concentrically disposed about the tip end of the second endform when the first endform is inserted into the housing. This places the latch arms in close proximity to the first endform which prevents radially inward movement of the latch arms in a direction which would disengage the housing from the second endform.
[0016] At the same time, the outer axial ends of the latch arms are positioned in the bore of the second endform to retain any seal elements mounted in the bore of the second endform. This eliminates the need for a separate top hat thereby reducing the cost and assembly time for the fluid quick connector.
[0017] In another aspect, the first endform has an engagement surface in the form of a reduced diameter annular groove spaced from the tip end of the first endform. The inner diameter of inner arms of a tranversably removable retainer are sized to engage the groove in the endform to locking couple the first endform in the housing. At the same time, the inner diameter of the retainer arms is smaller than the outer diameter of the tip end of the first endform so as to prevent insertion of the first endform into the bore in the housing if the retainer is in the fully latched position in the housing.
[0018] The retainer, which can be latched in a shipping position in the housing which allows insertion of the tip end of the first endform into the bore in the housing, can be transversely moved to the fully latched position in the housing only when the engagement surface or groove in the first endform is aligned with the inner arms of the retainer. This insures that the tip end of the first endform is fully inserted into engagement with the seal elements in the housing or the second endform when the first endform is lockingly coupled to the housing by the retainer.
[0019] In another aspect, the inner arms of the retainer have an extended length so as to be disposed between adjacent surfaces of the housing forming a portion of the transverse bore in the housing when the retainer is in the fully latched position of the quick connector. This places the ends of the inner arms in an engagement position with the housing to increase the pull out force resistance acting against separation of the first endform from housing.
[0020] In another aspect, the ends of the inner arms of the retainer are formed with a spherical surface. This reduces the push in force required to insert the tip end of the first endform past the retainer when the retainer is in the temporary shipping position in the housing.
[0021] Thus, there has been disclosed a unique fluid quick connector having numerous improvements over previously devised fluid quick connectors.
BRIEF DESCRIPTION OF THE DRAWING
[0022] The various features, advantages and other uses of the present invention will become more apparent by referring to the following detailed description and drawing in which:
[0023] FIG. 1 is an exploded perspective view of one aspect of a fluid quick connector;
[0024] FIG. 2 is an exploded, perspective, longitudinal cross-sectional view of quick connector shown in FIG. 1 ;
[0025] FIG. 3 is a perspective, longitudinal cross-sectional view of the assembled quick connector of FIGS. 1 and 2 shown in an assembled state;
[0026] FIG. 4 is a perspective view of the quick connector in the assembled state;
[0027] FIG. 5 is a perspective view of another aspect of a fluid quick connector;
[0028] FIG. 6 is a exploded, perspective view of the quick connector shown in FIG. 5 ;
[0029] FIG. 7 is longitudinal, cross-sectional view take along the longitudinal axis of the quick connector shown in FIG. 5 ;
[0030] FIG. 8 is an enlarged, side elevational view of the housing of the quick connector shown in FIG. 5 ;
[0031] FIG. 9 is an enlarged perspective view of the retainer of the quick connector shown in FIG. 5 ;
[0032] FIG. 10 is an end view of the quick connector shown in FIG. 5 , prior to insertion of the endform into the housing and with the retainer shown in a pre-assembly, shipping position;
[0033] FIG. 11 is an end view, similar to FIG. 10 , but showing the retainer in the fully latched position after endform insertion into the housing;
[0034] FIG. 12 is an exploded, perspective view of another aspect of the quick connector shown in a preassembled state; and
[0035] FIG. 13 is a perspective, longitudinal, cross-sectional view of the quick connector shown in FIG. 12 , but depicted in an assembled state.
DETAILED DESCRIPTION
[0036] Referring now to FIGS. 1-4 of the drawing, there is depicted a fluid quick connector 100 and, more particularly, a fluid quick connector 100 having two rotatable components, one receiving a retainer and a second mountable to or carried on a separate fluid component, such as a tubular conduit described by example only hereafter.
[0037] The fluid quick connector 100 is adapted for sealingly and lockingly, yet removably interconnecting first and second fluid members, such as conduits, in a fluid tight, leak proof, sealed connection by a snap together arrangement.
[0038] The quick connector includes a housing assembly 102 formed of the first housing 106 and a second housing 114 which are adapted to be axially connected to provide an axially extending through bore between opposite ends.
[0039] The first housing 106 can be formed as an integral extension of a fluid operative device, such as a manifold, valve, etc., or as shown in FIGS. 1 and 4 , of a one piece body, preferably of a high strength plastic or metal, having a stepped exterior surface housing extending from a lip 108 at one end to an opposed second end 110 . At least one and, preferably, a plurality of longitudinally spaced barbs or projections not shown, may be formed along the exterior of the first housing 106 adjacent the second end 110 for secure engagement with a flexible conduit, such as a plastic or elastomer conduit, which is slidably urged thereover into sealed connection with the barbs. An annular groove or recess 109 is formed in an enlarged portion 111 in the first housing 106 adjacent the lip 108 , the purpose of which will be described hereafter.
[0040] The second housing 114 is also preferably formed of a one piece, integral, unitary body, also of a high strength plastic 106 . The second housing 114 includes first and second annular ring members 116 and 118 , respectively. The first and second ring members 116 and 118 are spaced apart and interconnected by a pair of side flanges 122 which extend between peripheral edges of the first and second ring members 116 and 118 . Notches 126 are formed along one side edge of each of the side flanges 122 for receiving an interconnecting projection in the retainer 66 , as described hereafter.
[0041] Preferably, the side flanges 122 and 124 are parallel to each other and, in conjunction with the first and second ring members 116 and 118 , define transversely opening apertures 125 and 127 . The transversely extending apertures 125 and 127 communicate with a through bore which extends longitudinally through the second housing 114 from a first aperture 120 within the second ring member 118 to an aperture or bore 138 extending through a tubular extension or collar 136 projecting from the first ring member 116 and terminating in a first outer end 140 . The collar 136 serves as a top hat to retain the seal elements 60 , 62 and 64 in the bore in the first housing 106 .
[0042] The quick connector 100 further includes the generally U-shaped retainer 66 adapted to be received in the transverse apertures 125 and 127 in the second housing 114 such that spaced legs 146 of the retainer 66 will pass along either side of an exposed section of a tube or conduit 50 as the retainer 66 is inserted leg-first into the second housing 114 .
[0043] Each leg 146 includes an inner arm 148 which defines a “locking” surface adapted to axially oppose and preferably, axially engage one side of the upset bead or flange 52 of the tube 50 when the retainer 66 is fully inserted in the second housing 114 . In this manner, the locking surface on each retainer leg serves to prevent axial displacement of the upset bead 52 from the axial bore of the housing 102 beyond a predetermined point, thereby locking the conduit therein.
[0044] The retainer 66 also includes a secondary latch 149 as described in U.S. Pat. No. 5,782,502, the contents of which are incorporated herein in its entirety with respect to the description of the structure and operation of the retainer 66 .
[0045] It will also be understood that the first and second housings 106 and 114 of the connector 102 of the present invention may be used with other types of radially displaceable retainers shown in U.S. Pat. Nos. 5,542,716, 5,951,063 and 5,782,502.
[0046] Further, the swivel connection between two portions of the connector 100 can also be applied to quick connectors having axially displaceable retainers as shown in U.S. Pat. Nos. 5,542,712 and 5,456,600.
[0047] As is conventional, the side flanges 122 in the second housing 114 include a pair of centralized, axially-extending, inward opening notches, not shown, while the retainer 66 includes a catch means, such as a ramped external projection or retention barb extending outwardly on each leg. The longitudinal notches cooperate with the retention barbs to releasably secure the retainer 66 in a partially-inserted, “pre-assembly” or “shipping” position within the second housing 114 .
[0048] In this manner, the retainer 66 can be retained with the second housing 114 while otherwise permitting axial passage of the upset bead into the bore past the very same locking surfaces on the retainer legs that will later prevent axial displacement of the upset bead upon full insertion of retainer 66 into the second housing 114 .
[0049] A collar 136 includes a plurality of flexible or bendable legs, with four legs 150 , 152 , 154 , and 155 being shown in FIGS. 1-4 by example. The legs 150 , 152 , 154 and 155 each have a generally arcuate shape and form a discontinuous circular shape for the collar 136 . Two adjacent legs, such as legs 150 and 152 or legs 150 and 154 , are separated by slots 156 which allow bending of each leg 150 , 152 , 154 and 155 during connection of the first and second housings 106 and 114 .
[0050] The first and second housings 106 and 114 are swivelably and rotatably connected to each other by at least one and preferably a plurality of locking projections or fingers 160 which extend radially outward from the collar portion of the legs 150 , 152 , 154 and 155 . Each projection 160 has a tapered or angled ramp surface 162 extending from the end portion of each leg 150 , 152 , 154 and 155 . The ramp portion 162 terminates in a radially outer edge 164 which is disposed adjacent to an annular recess 166 formed between each projection 160 and the adjacent annular ring 116 of the second housing 114 .
[0051] During engagement of the first and second housings 106 and 114 , the axially extending end portion of each leg 150 , 152 , 154 and 155 passes freely through the open end of the bore in the first housing 106 inward of the lip 108 .
[0052] The ramp surfaces 160 then engage the lip 108 and cause radially inward bending of each leg 150 , 152 , 154 and 156 until the top edge 164 of each leg 150 , 152 , 154 and 156 clears the radially inner edge of the lip 108 and brings the lip 108 into engagement with the adjacent recess 166 . Each of the legs 150 , 152 , 154 and 156 then snaps radially outward.
[0053] In the interconnected position, the projections 160 lock the first and second housings 106 and 114 together against axial movement while still being rotatable within the enlarged end portion 111 of the first housing 106 .
[0054] The lip 108 also assists in non-axially joining the first and second housings 106 and 114 while providing a rotatable surface for rotational movement of the first and second housings 106 and 114 relative to each other.
[0055] Referring now to FIGS. 5-11 , there is depicted another aspect of a fluid quick connector 180 which forms a fluid coupling between a first fluid carrying component or endform 182 and a second fluid carrying component or endform 184 .
[0056] It will be understood that the first and second endforms 182 and 184 may be the integral end portions of fluid carrying conduits, valves, manifolds, pump housings, etc., or discrete members mounted on such components, or separate fluid carrying components in their own right.
[0057] As shown in FIGS. 6 and 7 , the first endform 182 generally comprises a tubular member having a surface engagement feature 186 located at a position on a tip end portion 188 extending from a tip end 190 . The surface engagement feature 186 , by example only, is an annular recess or groove 192 formed in the endform 182 . The annular recess or groove 192 has a smaller inner diameter than the inner diameter of the tip end portion 188 or the remainder of the endform 182 . A step 194 of a large inner diameter than the inner diameter of the recess 192 , but smaller than the inner diameter of the remainder of the endform 182 is also formed as part of the surface engagement feature 186 and extends as a transition surface between the groove 192 and the remainder of the endform 182 . It will be understood that the surface engagement feature 186 can function, as described hereafter, without the step 194 .
[0058] The second endform 184 is shown by example only as having a necked down or small diameter portion 196 extending from a larger inner diameter and larger outer diameter end portion 198 which extends linearly from a first end 200 . A bore extends from the first end 200 of the second endform 184 at a first 202 . The bore 202 steps down to a smaller diameter bore portion 204 and then to a third yet smaller diameter bore portion 206 . It will be understood that the bore extending through the second endform 184 may have other configurations including more or less stepped down or stepped up diameter portions.
[0059] An annular recess or groove 208 is formed in the bore portion 202 spaced inward from the first open end 200 of the second endform 184 . The purpose of the recess 208 will be become apparent from the following description.
[0060] As shown in FIGS. 6, 7 and 8 , the quick connector 180 includes a housing 210 formed, by example, as a one-piece, unitary body of, typically a plastic, but also of other materials. The housing 210 includes a first pair of spaced, arcuate ring members 211 and 212 and a second pair of arcuate ring member 213 and 214 . A pair of spaced, generally parallel second pair ring members 213 and 214 . The ring members 211 , 212 , 213 , and 214 are joined to each other by a pair of side flanges 216 and 218 which extend between the ends of the ring members 211 , 212 , 213 , and 214 . A recess 220 , only one of which is shown in FIGS. 5 and 6 , is formed on one edge of the side flanges 216 and 218 for receiving a portion of a retainer as described hereafter. The ring members 212 and 214 and the interconnecting portions of the side flanges 216 and 218 form a first aperture 222 at a first end of the housing 210 . Similarly, the ring members 211 and 212 and the opposite end portions of the side flanges 216 and 218 form a second bore 224 . The first and second bores 222 and 224 are co-axial.
[0061] The spaced apart ring members 211 and 212 form a first bore 226 which is aligned with a second transverse bore 228 formed between the opposite ring members 213 and 214 . The transverse bores 226 and 228 form a through transverse bore extending through the housing 210 which intersects a longitudinal through bore formed by the bores 222 and 224 .
[0062] Notches 230 and 232 are formed on an inner surface of the side flanges 216 and 218 for receiving a retainer in a pre-assembled, shipping position as described hereafter.
[0063] In this aspect of the quick connector 180 , the housing 210 is rotatably latched to the second endform 184 . It will be understood that the features of the quick connector 180 may also be employed in quick connector housings which are fixedly and non-rotatably latched to another fluid component or endform.
[0064] The housing 210 includes a collar 236 which is formed of at least one or, more typically, a plurality of arcuate shaped legs, with four legs being described by way of example only, even though only three legs 238 , 240 and 242 are shown in FIG. 8 .
[0065] Each leg 238 , 240 and 242 extends from one edge of the ring members 211 and 213 and/or the edge of the side flanges 216 and 218 in a generally axial direction with respect to the longitudinal axis through the aligned bores 222 and 224 in the housing 210 . Each leg 238 , 240 , and 242 defines a portion of a circle and has a cantilevered, bendable configuration with respect to the remainder of the housing 210 enabling each leg 238 , 240 and 242 to bend inward during coupling of the housing 210 to the second endform 184 , as described hereafter, and then to snap radially outward such that a portion of each leg 238 , 240 and 242 snaps into and rotatably, but axially non-movably, locks the housing 210 to the second endform 182 .
[0066] Each leg 238 , 240 and 242 includes a locking surface 244 in the form or a projection or hook extending radially from the axial extent of each leg 238 , 240 , and 242 . The axially forwardmost portion of each locking surface 244 has a ramp 246 to facilitate the radial inward bending movement of each leg 238 , 240 and 242 as describe hereafter.
[0067] The locking surfaces 244 snap into the annular recess 208 in the second endform 184 , as shown in FIG. 7 , to rotatably, but non-axially movably, couple the housing 210 to the second endform 184 .
[0068] As shown in FIG. 7 , the inner diameter 247 of each of the legs 238 , 240 and 242 is the same or just slightly larger than the outer diameter of the tip end portion 188 of the first endform 182 . This coaxially disposes the arms 238 , 240 , and 242 in line with the seal means in the housing 210 . In this manner, the housing 210 eliminates the need for a separate top hat typically employed in prior quick connectors to retain the seal means, such as a pair of O-rings 248 and an intervening, rigid annular spacer ring 249 , in the bore in the second endform 184 . The inner diameter 247 of the legs 138 , 240 and 242 also serves as a bearing surface for the tip end 188 of the endform 182 .
[0069] As shown in detail in FIGS. 5-11 , a retainer 250 forms part of the quick connector 180 and functions to releasibly latch the first endform 182 in the housing 210 . The retainer 250 is typically constructed as a one piece, unitary body formed of a molded plastic. The retainer 250 includes first and second side legs 252 and 254 which extend from an end wall 256 . A pair of side tabs 258 and 260 extend laterally outward at the connection point of the side legs 252 and 254 to the end wall 256 .
[0070] An opposite end of each side leg 252 and 254 carries a latch element 262 and 264 in the form of an outwardly extending hook-shaped latch projecting laterally outward from the outer surface of each side leg 252 and 254 , respectively. The latch elements 262 and 264 serve a first function of latching the retainer 250 in a preassembly, shipping position shown in FIG. 10 by bending inward during insertion of the retainer 250 through the first transverse bore 226 and then snapping laterally outward into the notches 230 and 232 in the side flanges 216 and 218 , respectively, of the housing 210 .
[0071] While the retainer 250 can slide downward within the notches 230 and 232 from the initial latched position shown in FIG. 10 , the latch elements 262 and 264 still remain captured within the notches 230 and 232 thereby preventing removal of the retainer 250 from the housing 210 .
[0072] A pair of inner arms 266 and 268 are disposed laterally inward of the side legs 252 and 254 , respectively. The arms 266 and 268 are interconnected by an end wall 270 which is spaced by a recess 272 from the end wall 256 . An opposed recess is also formed on an opposite edge of the end wall 270 and the end wall 256 . The end wall 270 is interconnected to the side legs 252 and 254 and/or the end wall 256 by webs 274 and 276 . An inner surface 278 formed by the arms 266 and 268 and the end wall 270 forms a portion of a circle. The diameter of the inner surface 278 between opposed portions of the arms 266 and 268 is the same or slightly larger than the outer diameter of the recess 192 in the first endform 182 .
[0073] The inner diameter of the inner surface 278 or the spacing between the arms 266 and 268 is smaller than the outer diameter of the tip end portion 188 of the first endform 182 . In this manner, if the retainer 250 is inadvertently moved from the preassembled, shipping position shown in FIG. 10 to the fully latched position shown in FIG. 11 and described hereafter, prior to insertion of the first endform 182 into the housing 210 , the inner arms 266 and 268 will block insertion of the tip end 188 of the first endform 182 past the retainer 250 into the housing 210 . Only when the retainer 250 is in the preassembled shipping position shown in FIG. 10 , with the ends 280 and 282 of the arms 266 and 268 not substantially entering the longitudinal through bore in the housing 210 , can the tip end 188 of the endform 182 be fully inserted through the housing 210 and into the bore portions 202 and 204 in the second endform 184 , shown in FIG. 7 wherein the tip end 188 is sealed by the seal elements 248 and 249 to the second endform 184 . At this time, the retainer 250 can be urged laterally through the housing 210 which initially causes the ends 280 and 282 of the arms 266 and 268 to initially flex outward about the outer diameter of the recess 192 and then close around the recess 192 to lock the retainer 250 in the surface engagement feature 186 or recess 192 of the first endform 182 and latch the first endform 182 in the housing 210 .
[0074] At this time, as shown in FIG. 11 , the latch elements 262 and 264 have moved laterally inward and then snapped back laterally outward along a lower surface of the side flanges 216 and 218 to latch the retainer 250 in the housing 210 in the fully latched position.
[0075] The ends 280 and 282 of the arms 266 and 268 , respectively, are provided with a length so as to extend into the bore 228 formed between the annular ring members 213 and 214 , as shown in FIG. 11 when the retainer 250 is in the fully latched position. This causes the arms 266 and 268 to uniquely increase the pullout force resistance provided by the retainer 250 to resist separation of the first endform 182 from the second endform 186 in the housing 210 due to the engagement of the ends of the arms 266 and 268 with the ring member 214 of the housing 210 .
[0076] Further, as shown in FIGS. 6, 9 and 11 , endform contact surfaces 284 and 286 are formed on the ends 280 and 282 of the arms 266 and 268 , respectively. Rather than an angled or flat, tapered surface, the surfaces 284 and 286 are formed as part of a spherical surface. The outer surface of the arms 266 and 268 are formed with an elliptical shape thereby making the length of the arms 266 and 268 longer so as to be disposed within the bore 228 formed between the ring members 213 and 214 when the retainer 250 is in the fully latched position shown in FIG. 11 .
[0077] The contact surfaces 284 and 286 will project into the longitudinal bore extending to the housing 210 depending upon the position of the retainer 250 in the preassembly, shipping position shown in FIG. 10 .
[0078] In use, the retainer 250 will initially be latched to the housing 210 in the shipping position shown in FIG. 10 . As shown in FIG. 7 , the tip end 188 of the first endform 182 is inserted through the bore 222 extending from one end of the housing 210 until the tip end 188 of the first endform 182 engages the contact surfaces 284 and 286 of the retainer 250 the insertion force applied to the first endform 182 forces the retainer 250 upwards in the orientation shown in FIG. 10 until the contact surfaces 284 and 286 clear the outer diameter of the tip end 188 of the first endform 182 thereby allowing the tip end 188 of the first endform 182 to clear the contact surfaces 284 and 286 and the entire inner legs 266 and 268 of the retainer 250 and pass into the bore in the second endform 184 until the tip end 188 sealingly engages the seal member 248 and 249 and the end of the tip end 188 seats within the bore portion 204 of the first endform 188 . At this time, the surface engagement feature 186 or groove 192 will be aligned with the ends 280 and 282 of the inner arms 266 and 268 , respectively, of the retainer 250 . The retainer 250 can then be urged from the preassembly, shipping position shown in FIG. 10 to the fully latched position shown in FIG. 11 . During such transverse movement, the arms 266 and 268 expand radially outward around the outer diameter of the recess 192 in the first endform 188 and then move back to the nominal position shown in FIG. 11 in which the arms 266 and 268 of the retainer 210 are fully seated in the recess 192 to latch the first endform 182 to the second endform 184 .
[0079] The housing 210 carrying the latched first endform 182 is now latchingly coupled to the second endform 184 . However, in the aspect described above, the housing 210 the first endform 182 of the second endform 184 and the housing 210 of the fluid quick connector may be rotated relative to each other to place the retainer 250 in a convenient location for manipulation.
[0080] During assembly of the fluid coupling employing the quick connector 180 , the seal members 248 and 249 are first inserted into the bore portion 204 of the second endform 184 through the open end 200 of the second endform 184 as shown in FIG. 7 . The housing 210 carrying the retainer 250 in the preassembled, shipping position shown in FIG. 10 is then urged through the open end of the second endform 184 . During such insertion, the legs 238 , 240 and 242 of the housing 210 bend radially inward through engagement of the ramp surface 246 on each leg 238 , 240 and 242 with a complementary ramp surface formed at the first end 200 of the second endform 184 to enable the first endform 182 is inserted a sufficient distance into the second endform until the projections 244 snap radially outward into the recess 208 in the first endform 184 as the legs 238 , 240 and 242 move radially outward to their nominal position as shown in FIGS. 7 and 8 .
[0081] The outermost ends of the latch arms 380 are disposed coaxially with the seal elements 330 and 332 since the inner diameter 383 of the latch arms 380 and the adjoining portion of the housing 351 is sized to be only slightly larger than the outer diameter of the tip end of the endform to be inserted through the housing 351 and into the bore 352 in the use element 354 . The inner diameter 383 of th latch arms 380 and the adjoining portion of the housing 351 forms a bearing surface for the endform. In addition, the close proximity of the inner diameter of the latch arms 380 and the adjoining portion of the housing 351 and the outer surface of the endform, after the endform is fully inserted into the joined housing 351 and use element 354 , prevents substantially radially inward movement of the projections or hooks 382 on the latch arms 380 so as to minimize inadvertent disengagement of the housing 351 from the use element 354 .
[0082] Referring now to FIGS. 12 and 13 , there is depicted another aspect of a quick connector 350 according to the present invention in which the quick connector 350 is configured for pre-mounting in the form of a stuffer pack in a bore 352 in a use element 354 , prior to receiving an endform, such as endform 13 on a tubular conduit 11 , in a sealed latched position to dispose the conduit 11 in fluid flow communication with the bore 352 in the use element 354 .
[0083] The quick connector 350 is constructed in essentially the same manner as the quick connector 100 described above in that it has an end configuration adapted for transversely receiving the retainer 360 which is substantially identical to the retainer 60 in FIGS. 1-4 . Further details concerning the end configuration of the quick connector 350 will not be described herein as such features are the same as the corresponding structure in the quick connector 100 shown in FIGS. 1-4 .
[0084] The remaining portion 360 of the top hat 358 has a diameter to slidably extend through the third stepped bore portion 24 in the housing 351 of the quick connector 350 .
[0085] In this aspect, the bore 352 in a use element 354 is provided with a stepped configuration having a first bore portion 370 extending from the outer end 372 of the use element 354 , an adjacent smaller, second diameter bore portion 374 , a third bore portion 376 and an optional fourth bore portion 378 of even smaller diameter both extending coaxially from the second bore portion 374 .
[0086] The second bore portion 374 is configured for premountingly receiving the seal means, such as one or more O-rings 331 and an intervening spacer 331 .
[0087] The housing 351 of the quick connector 350 is provided with at least one and preferably a plurality of circumferentially spaced legs or arms 380 , with three of the four equally spaced arms 380 being depicted in FIG. 12 . Each arm 380 is spaced by a slot from an adjacent arm 380 . Further, each arm 380 terminates in a radially outwardly extending hook or projection 382 . The projection 382 is releasably engagable with a latch receiver 384 formed as a plurality of coplanar recesses or as a continuous annular groove 384 in the bore 352 in the use element 354 between the first bore portion 370 and the second bore portion 374 .
[0088] As shown in FIG. 13 , after the seals 30 and the spacer 31 have been premounted in the second bore portion 374 , the quick connector housing 351 is inserted through the first bore portion 370 of the use element 354 . The arms 380 have sufficient flexibility so as to bend radially inward to allow the projections 382 to clear the end of smaller diameter first bore portion 370 . When the housing 351 has been inserted a sufficient distance into the bore 352 in the use element 354 , the projections 382 will snap radially outward into the latch receivers 384 latching the quick connector housing 351 to the use element 354 .
[0089] The retainer 360 can be then mounted in the quick connector housing 351 by transverse movement to the storage position shown in FIG. 10 or premounted in the quick connector housing 351 before the quick connector housing 351 is inserted into the bore 352 in the use element 354 , as described above.
[0090] After the quick connector housing 351 is mounted in the bore 352 and the retainer 60 is situated in the temporary storage position shown in FIG. 10 ,
[0091] The endform of a conduit can then be inserted through the open end of the quick connector housing 351 into full engagement with the seals 330 and 331 . Only when the endform has been fully inserted into engagement with the seals 330 and 331 can the retainer 60 be moved from the temporary storage position shown in FIG. 10 to the fully latched position shown in FIG. 11 .
[0092] Reverse movement of the retainer 360 back to the storage position shown in FIG. 4 or completely from the quick connector housing 351 will enable the endform to be separated from the quick connector 350 and the use element 354 .
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A fluid quick connector includes a retainer mounted in a housing which lockingly couples a first endform to the housing. Latch arms bendably extend from the housing for latching engagement with a second endform. An inner diameter of the latch arms are proximate the outer diameter of the first endform inserted through the housing to prevent substantial movement of the latch arms in a direction which would disengage the latch arms from the second endform. In another aspect, the retainer has inner arms which engage a recessed surface engagement feature in the first endform to lock the other endform to the housing. A portion of a spherical surface is formed on the ends of the inner arms to reduce the push in force required to insert the first endform through the housing and past the retainer.
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BACKGROUND OF THE INVENTION
This invention relates to a device for separating an automotive oil filter into its components for recycling, and further relates to the removal of engine waste oil from the filter for disposal in an environmentally safe manner.
Motor vehicles require periodic, regular replacement of the engine oil and replacement of the oil filter. A used oil filter has no further use on the motor vehicle and so it must be disposed of in some manner. The practice up to now has been to simply dispose of the filter along with the other refuse generated by a service station for ultimate disposal at a municipal landfill. Increasing concern over the environment, however, has drawn attention to the disposal of oil filters in two respects--recycling the metal parts and disposing the engine waste oil.
An ordinary automotive oil filter typically has a substantially cylindrical shape. The filter comprises a thin metal casing which forms the wall and one end of the cylinder, and a relatively thick metal plate on the other end. The base plate, which provides a rigid base to the filter, has a threaded central opening for attaching the filter to the motor vehicle. Inside the filter is a filter cartridge which consists of a cloth, paper or other soft synthetic filter material supported by two thin metal end plates and a thin metal central core.
The metal parts of an automotive oil filter are a valuable, recyclable resource. However, recycling processes require metals to be separated from other materials which would interfere with the recycling process or otherwise contaminate the end product. Due to the combination of different metals used to construct the filter, the synthetic filter material, and the engine waste oil trapped inside, an oil filter is not recyclable as a unit. The components must be separated from each other to have any value as a recyclable resource.
Regarding the problem of disposing engine waste oil, when an oil filter is removed from an automobile, waste oil is difficult to remove from the filter and so it remains trapped inside the filter. Over time some of the oil may seep out through the openings of the filter, thus raising the prospect of contamination of the landfill site and the groundwater below. Concern over the environment has led to efforts directed at recovering engine waste oil after it has been used and removed from the engine or crankcase of a motor vehicle for proper disposal or recycling. Some states are mandating by statute the recovery and recycling of engine waste oil and are restricting disposal of products containing engine waste oil, including oil filters. California and Wisconsin are examples of two states which now regulate the recovery, recycling and disposal of engine waste oil. For example, Section 159.15 of the Wisconsin Statutes mandates the establishment of engine waste oil collection facilities, and mandates the development of programs regarding the need for using recycled oil to maintain oil reserves and the need to minimize disposal of waste oil and products containing waste oil in ways harmful to the environment. The statute specifically requires businesses which sell automotive engine oil, and requires businesses which service and remove engine oil from motor vehicles, to maintain an engine waste oil collection facility for temporary storage of engine waste oil.
In California the State Legislation found that almost 100 million gallons of used automotive and industrial oil are generated each year in that state alone. The Legislature further found that, despite the fact that used oil is a valuable petroleum resource that can be recycled, significant quantities of used oil are wastefully or improperly disposed of by means which pollute the environment and endanger public health. For these reasons, California has mandated that used oil shall be collected and recycled to the maximum extent possible. See California Code, Public Resources, Sections 3460-3494.
SUMMARY OF THE INVENTION
The present invention provides an oil filter recycler apparatus for severing and separating an automotive oil filter into its principal components for recycling, and for removing engine waste oil for environmentally safe disposal.
Upon removal of a used filter from an automobile, a service station attendant places the filter on a rotatable turntable, which rotates the substantially cylindrical shaped filter about its axis. A retractable knife is adjusted up to and forced against the wall of the filter so as to protrude through the metal casing at a point approximately where the casing joins the metal base plate, and preferably in an area where a gap exists between the thick metal base plate of the filter and one of the metal end plates of the filter cartridge. By rotating the filter, the knife thus severs the casing along a line around the base of the filter. After the casing has been completely cut, the knife is released and retracted away from the filter. The knife is quickly and easily adjustable up to and away from the cutting position by a releasable ratchet pawl and threaded rod assembly.
The apparatus of the present invention has a means for automatically rotating the filter during the cutting process through the use of an electric motor and a gear drive assembly. Alternatively, a manual version allows the service attendant to manually rotate the filter, thus avoiding the need for a power source and avoiding the risk associated with the use of electrical devices near oil.
The apparatus of the present invention separates the metal casing, metal base plate and the inner filter cartridge of the filter by making a single cut around the base of the filter. The inner filter cartridge may be further separated by manually separating the two thin metal end plates, the metal central core and the filter material. The constituent parts may be sorted, rinsed of residual engine waste oil, and sent on for further processing as a reusable resource. Engine waste oil is fully removed from the filter and collected for proper disposal.
The principal objects of the invention are therefore to provide a device to sever the casing of an automotive oil filter; to separate for recycling the metal components of an oil filter, including the base plate, the casing, and the end plates and central core of the filter cartridge; and to remove for environmentally safe disposal the engine waste oil trapped in the oil filter.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings which set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings, which constitute part of this specification and include exemplary embodiments of the present invention, include the following:
FIG. 1 is a perspective view of the invention as a person is about to place an oil filter on it;
FIG. 2 is a vertical, exploded sectional view of an automotive oil filter which has been severed and separated into its' principal components;
FIG. 3 is a top view of a first embodiment of the invention, certain parts being shown as broken away for clarity, which has an electric motor drive assembly for automatically rotating the filter;
FIG. 4 is a cross-sectional view of the invention shown in FIG. 3 taken generally along line 4--4 in FIG. 3;
FIG. 5 is a side view of the knife assembly shown in the cutting position;
FIG. 6 is a top fragmentary view partially in section of the knife assembly shown in FIG. 5;
FIG. 7 is a view similar to FIG. 6, but showing the knife assembly in the retracted position;
FIG. 8 is a side view of a second embodiment of the invention which has a manually rotatable turntable for rotating the filter partially in section with portions broken away for clarity; and
FIG. 9 is a top view of the second embodiment of the invention shown in FIG. 8.
DETAILED DESCRIPTION
As shown in FIG. 2, a typical automotive oil filter 10 comprises essentially a thin metal casing or shell 12, a thick metal base plate 14, and a filter cartridge 18. The casing 12 forms the wall and one end of the substantially cylindrical shaped filter 10 and the circular base plate 14 forms the other end of the cylinder. The casing 12 and base plate 14 are crimped together. The base plate 14 has a threaded central opening 16 and a gasket 15 for attaching and sealing the filter 10 on an automobile. The filter cartridge 18 consists of a filter material 20 supported between upper and lower metal end plates, 22 and 24, respectively, and a metal central core 26. A narrow gap 28 exists between the lower end plate 24 of the filter cartridge 18 and the base plate 14 of the filter as shown in FIG. 4.
The oil filter recycler 30 comprises essentially a means for rotating the filter 10 about the axis of its' cylindrical shape and a knife means for severing or cutting the wall of the casing as the filter 10 is rotated. Referring to FIGS. 3 and 4, a first embodiment of the device 30 comprises a base frame 32 which supports a turntable 40 for rotating the filter 10. An upwardly extending shaft or protuberance 38 projecting out from the center of the turntable 40 fits into the threaded central opening 16 of the base plate 14 on the filter 10. The filter 10 is placed over the protuberance 38 so that the axis of the cylindrical shape of the filter is aligned with the axis of the circular turntable 40.
A means for automatically rotating the filter 10 is shown in FIGS. 3 and 4. In this embodiment 30, the turntable 40 and protuberance 38 are connected and rotate together. In this embodiment, the protuberance 38 is generally tapered and preferably has upwardly and inwardly inclined wedge blades 39 wedgingly engageable with the central opening 16 of the filter 10 to rotate it. FIG. 3 shows three such blades 39 which have the effect of digging into and locking against the edge of the central opening 16 when the filter 10 is rotated in one direction with respect to the turntable 40 (counterclockwise in FIG. 3), and the blades 39 have the effect of disengaging and slipping along the central opening 16 when the filter 10 is rotated in the opposite direction with respect to the turntable 40. Thus, when the turntable 40 is activated to automatically rotate the filter 10 to cut the casing 12, the wedge blades 39 essentially grab hold of and force rotation of the filter 10. After the cutting process is completed, a person may easily remove the now severed filter 10 by rotating it slightly in the opposite direction to release it from the blades 39. A slip disk 42 on the turntable 40 allows for rotation of the filter 10 relative to the turntable 40.
A drive assembly 70 automatically rotates the turntable 40 during the cutting process. The drive assembly 70 includes an electric motor 72 for turning a drive gear 74 and a chain 76 engaged with the drive gear 74 and engaged with gear teeth 78 around the periphery of the turntable 40. The turntable 40 and drive gear 74 are on the upper side of the base frame 32 and the motor 72 is below. A cover 77 over the drive assembly 70 protects the operator from pinch-points between the chain 76 and gears 74 and 78. The electric motor 72 operates off of an ordinary 110 volt AC power source.
The base frame 32 has a vertical flange 31 for supporting a knife assembly 50 in a position whereby a knife 58 is protrudable through the wall of the filter casing 12 at a point just slightly above where the casing 12 joins the base plate 14 of the filter, preferably in the gap 28 between the base plate 14 and the lower end plate 24 of the filter cartridge 18. As shown in FIGS. 5, 6 and 7, the knife assembly 50 includes the knife 58 which is radially adjustable toward and away from the axis of the filter 10, which corresponds to the center or axis of the turntable 40. The knife assembly 50 also includes a slidable knife holder 60, a rotatable threaded adjusting rod 52 on the holder 60, and a releasable ratchet pawl 62.
The ratchet pawl 62 is biased by spring 51 for engagement by its tooth 63 (FIG. 7) with the worm-gear threads of the adjusting rod 52 so that, in response to a lateral force applied to the end of the knife assembly 50, the knife holder 60 slides toward the casing 12 of the filter 10; and so that rotation of the threaded rod 52 in one direction slides the knife holder 60 toward the filter 10 with sufficient force to cause the knife 58 to protrude through the casing 12 of the filter 10; and so that rotation of the threaded rod 52 in the other direction slides the knife holder 60 away from the filter 10. The knife holder 60 is biased by spring 56 to automatically retract away from the filter 10 upon release of the ratchet pawl 62.
Upon placing a filter 10 on the turntable 40 of the device 30, a person may press against a knob 54 on the end of the knife assembly 50 to provide for a quick gross adjustment of the knife 58 u against the casing 12 of the filter 10. Rotation of the knob 54 forces the knife 58 through the casing 12. Actuation of the motor 72 causes the wedge blades 39 on the protuberance 38 to engage and rotate the filter 10, in turn causing the knife 58 to sever the casing 12 along a line adjacent to the base plate 14 of the filter. Pressing the ratchet pawl 62 releases it from the threaded rod 52 thereby retracting the knife 58 from the filter 10.
FIGS. 8 and 9 shows a manually rotatable embodiment of the invention 90. In this case, the turntable 92 is a freely rotatable disc slipped over a fixed protuberance 94 in the form of a shaft which tapers upwardly and inwardly to provide a wedging action. The filter 10 is again placed on the device 90 so that the gasket 15 on the base plate 14 rests flat on the turntable 92 and so that the shaft or protuberance 94 projects wedgingly into the central opening 16 of the filter 10. The protuberance 94 is fixed to the base frame 32 of the device 90 to simply align and maintain the filter 10 in proper position during the cutting process. The surface of the protuberance 94 on this device 90 is smooth rather than having blades. The filter 10 is rotated about its axis on the turntable 92 by a person grabbing the top of the filter 10 and rotating it by hand. The base frame 32 has a vertical riser 34 to provide a space for a container 36 beneath the device 90. Oil drain orifices 96 in the turntable 92 and in the base frame 32 allow oil dripping from the filter 10 to be collected in the container 36 below the frame. The knife assembly 50 is constructed and operates the same as stated above.
It is to be understood that the embodiments disclosed above are merely exemplary of the invention which may be embodied in various forms. For instance, the drawings show a rotatable circular knife 58, but a straight blade would also satisfactorily sever the casing 12 of the filter 10. The knife 58 is also adjustable along a linear path extending radially from the axis of the filter (or from the axis of the turntable), but an alternative construction may provide a knife assembly which swings the knife into and out of the cutting position. Also, the base frame 32 has a vertical riser 34 to provide an elevated platform for the turntable 40,92 so that oil from the filter 10 may drip into a container 36 below, but one may vary the specific construction of the base frame.
Therefore, specific structural and functional details disclosed above are not to be interpreted as limiting, but merely as a basis for the claims and for teaching one skilled in the art to variously employ the present invention in any appropriately detailed structure. Changes may be made in the details of construction, arrangement and operation of the invention without departing from the spirit of the invention, especially as defined in the following claims.
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An oil filter recycler for severing the casing of an automotive oil filter, for separating the filter into its components for recycling, and for removing engine waste oil for environmentally safe disposal, characterized by a turntable for rotating a cylindrically shaped filter about its' axis and a knife for severing the casing of the filter as it is rotated. The turntable is rotatable either manually or automatically. The knife is radially adjustable relative to the axis of the turntable. A releasable ratchet pawl spring biased for engagement with a rotatable threaded rod on a slidable knife holder provides for slidable, rotatable adjustment of the knife, and for quick release and retraction of the knife.
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TECHNICAL FIELD
[0001] This patent disclosure relates generally to high pressure valves and, more particularly, to a system and method for venting high pressure valves.
BACKGROUND
[0002] High-pressure fuel pump systems are used in a variety of motorized platforms, including those of trucks, buses, and automobiles, as well as off-road machines utilized in construction, mining, and agricultural fields. They are also utilized in marine as well as industrial applications, the latter including, by way of example, electric power generation and petroleum drilling rigs. Such pumps are generally mechanically driven via associated engines for delivering fuel under high pressure to fuel injectors and into individual cylinders of the engines through so-called common rail fuel systems.
[0003] Common rail fuel systems generally include fuel delivery components associated with a high-pressure variable delivery pumps. A variable delivery pump may be effective to deliver high-pressure fuel into a manifold that acts as a central accumulator for the high-pressure fuel prior to its delivery to individual injectors. The manifold thus dampens pressure fluctuations occurring from discreet high pressure pumping events. Typically, the fuel is sourced from a fuel tank by means of a low pressure fuel transfer pump to the variable delivery high-pressure fuel pump.
[0004] Apart from atmospheric emissions control purposes, the fuel is pressurized to facilitate the accurately timed and controlled delivery of discrete fuel amounts to the fuel injectors. As such, an electronic control system is generally employed to monitor and optimize system fuel pressure. The electronic control system operates the high-pressure pump as well as each of the electronically actuated fuel injectors to optimize fuel pressure and quantity, as well as timing of delivery, under a variety of engine operating conditions.
[0005] Normally, such systems include capabilities for managing fluid dynamics and pressurization of the fuel pump manifold and or rails. As an example, high pressure valves can be used to manage fluid flow and pressure control. However, life of the valve seat is such high pressure valves is often limited due to relative motion and the high contact stress between the valve body and valve seat. The combination of high stress and motion results in adhesive wear which ultimately results in valve leakage. Improvements in valve operation are needed to maintain operable life of the components and minimize leakage.
[0006] As an example, U.S. Pat. No. 5,012,785 (the '785 patent) describes a valve operatively mounted in an axially extending center bore of a high pressure pump rotor. The valve axially shifts between an open position in which a charge of fuel generated by the pump is transmitted as a pressure wave to a fuel injector nozzle and a closed position in which the pump charging chamber is sealed from the injection line and the injection line is vented to low pressure so that secondary pressure waves reflecting from the injector nozzle will be routed to the low pressure line for dissipation therein rather than rebounding from the delivery valve. Although the injection line of the '785 patent is vented, such venting does not address valve motion control and minimizing wear between the valve body and the valve seat. These and other shortcomings of the prior art are address by this disclosure.
SUMMARY
[0007] In one aspect, the disclosure describes a housing defining a valve chamber, wherein the valve chamber comprises a first end and a second end opposite the first end; a valve inlet disposed adjacent the first end of the valve chamber and in fluid communication therewith, wherein the valve chamber is configured to receive a flow of fluid from the valve inlet; a valve outlet in fluid communication with the valve chamber to receive a flow of fluid from the valve chamber; a valve seat fixedly disposed at the first end of the valve chamber; a valve body movably disposed within the valve chamber, the valve body comprising a valve head and a base portion; a retainer sealingly engaging the housing and defining a cavity between the base portion of the valve body and the retainer, wherein the retainer comprises one or more control orifices formed therein and configured to provide fluid communication to the cavity to regulate a position of the valve body between the first end and the second end of the valve chamber based on at least a pressure difference between the valve chamber and the cavity; and a spring member disposed between the retainer and the valve body, wherein the spring member is configured to bias the valve body towards the first end of the valve chamber, and wherein the valve head of the valve body is configured to abut against the valve seat to prevent a flow of fluid between the valve inlet and the valve chamber.
[0008] In another aspect, the disclosure describes a housing defining a valve chamber, wherein the valve chamber comprises a first end and a second end opposite the first end; a valve inlet disposed adjacent the first end of the valve chamber and in fluid communication therewith, wherein the valve inlet is in fluid communication with a fuel pump and the valve chamber is configured to receive a flow of fluid from the valve inlet; a valve outlet adjacent the second end of the valve chamber and in fluid communication therewith, wherein the valve outlet is in fluid communication with a fuel manifold and is configured to receive a flow of fluid from the valve chamber and direct the flow of fluid to the manifold; a valve seat fixedly disposed at the first end of the valve chamber; a valve body movably disposed within the valve chamber, the valve body comprising a valve head and a base portion; a retainer sealingly engaging the housing and defining a cavity between the base portion of the valve body and the retainer, wherein the retainer comprises one or more control orifices formed therein and configured to provide fluid communication to the cavity to regulate a position of the valve body between the first end and the second end of the valve chamber based on at least a pressure difference between the valve chamber and the cavity; and a spring member disposed between the retainer and the valve body, wherein the spring member is configured to bias the valve body towards the first end of the valve chamber, and wherein the valve head of the valve body is configured to abut against the valve seat to prevent a flow of fluid between the valve inlet and the valve chamber.
[0009] In yet another aspect, the disclosure describes a housing defining a valve chamber, wherein the valve chamber comprises a first end and a second end opposite the first end; a valve inlet disposed adjacent the first end of the valve chamber and in fluid communication therewith, wherein the valve chamber is configured to receive a flow of fluid from the valve inlet; a valve outlet in fluid communication with the valve chamber to receive a flow of fluid from the valve chamber; a valve seat fixedly disposed at the first end of the valve chamber; a valve body movably disposed within the valve chamber, the valve body comprising a valve head and a base portion, wherein the base portion defines a fluid chamber having a channel formed in an outer surface of the base portion; a retainer sealingly engaging the housing and defining a cavity between the base portion of the valve body and the retainer, wherein the retainer comprises a plurality of control orifices formed therein and configured to provide fluid communication to the cavity to regulate a position of the valve body between the first end and the second end of the valve chamber based on at least a pressure difference between the valve chamber and the cavity, and wherein a position of the valve body between the first end and the second end of the valve chamber controls an alignment of the channel formed in the valve body and one or more of the plurality of control orifices; and a spring member disposed between the retainer and the valve body, wherein the spring member is configured to bias the valve body towards the first end of the valve chamber, and wherein the valve head of the valve body is configured to abut against the valve seat to prevent a flow of fluid between the valve inlet and the valve chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a machine constructed in accordance with the aspects of the disclosure.
[0011] FIG. 2 is a schematic view of a fuel pump manifold and associated fuel rails that may be utilized within a fuel system in accordance with aspects of the disclosure.
[0012] FIG. 3 is a cross-sectional view of a portion of a fuel pump including a valve assembly in accordance with aspects of the present disclosure, where the valve assembly is shown in a closed position.
[0013] FIG. 4 is a cross-sectional view of the valve assembly of FIG. 3 , showing the valve assembly in an opened position.
[0014] FIG. 5 is a cross-sectional view of a portion of a fuel pump including a valve assembly in accordance with aspects of the present disclosure, where the valve assembly is shown in a closed position.
[0015] FIG. 6 is a cross-sectional view of the valve assembly of FIG. 5 , showing the valve assembly in an opened position.
[0016] FIG. 7 is a cross-sectional view of a portion of a fuel pump including a valve assembly in accordance with aspects of the present disclosure, where the valve assembly is shown in a closed position.
[0017] FIG. 8 is a cross-sectional view of the valve assembly of FIG. 7 , showing the valve assembly in an opened position.
[0018] FIG. 9 is a cross-sectional view of the valve assembly of FIG. 7 , showing the valve assembly in an opened position and venting a cavity to an environment.
DETAILED DESCRIPTION
[0019] Referring now to the drawings, and with specific reference to FIG. 1 , a machine 10 includes a machine body 12 supported on a conveyance 16 . In the illustrated embodiment, the machine 10 is shown as a mining truck, and the conveyance 16 is shown as wheels. However, the machine 10 could take a wide variety of forms, and the conveyance 16 could also vary substantially. For instance, the conveyance 16 could be tracks or possibly even a propeller in the case of a machine in the form of a seagoing vessel. The machine 10 includes a dump body 14 pivotally attached to the machine body 12 , and also an operator station 15 . One could expect a duty cycle for the machine 10 to include time periods of idling without movement such as when the machine 10 is waiting to receive a load, such as ore, in the dump body 14 , waiting to dump a load, and maybe even waiting to be refueled. Between these motionless idling periods, one might expect the machine 10 to be operating at full power carrying a heaving load in the dump body 14 may be up a steep grade at a mining site. During motionless idling, the engine powering the machine 10 might consume only miniscule amounts of fuel. When operating at full power carrying a heavy load up a steep grade, one might expect the machine 10 to consume relatively large quantities of fuel.
[0020] In certain aspects, the machine 10 may be powered by an engine that includes an intake manifold fluidly connected to a plurality engine cylinders. Referring now to FIG. 2 , a high-pressure fuel delivery system 30 for such an engine is shown schematically. From the pump manifold 20 , fuel may be directed into respective left and right fuel rails 32 and 34 , by way of respective left and right fuel pump lines or conduits 36 and 38 . The fuel travels into injectors 40 (only one of which is shown) by means of a plurality of injection lines 42 . The injection lines 42 extend from both the left and right rails 32 , 34 , into each of the injectors 40 . In the described embodiment, it may be appreciated that each of the rails 32 , 34 supplies fuel to a bank of eight cylinders, thus to a total of 16 cylinders of a V-16 cylinder engine in the disclosed embodiment, and by way of example only. Each of the fuel injectors 40 is adapted to inject pressurized fuel into an associated combustion chamber (not shown) under predetermined conditions of timing, fuel pressure, and fuel flow rate, in accordance with real-time engine conditions, as will be appreciated by those skilled in the art.
[0021] In the described embodiment, the plurality of fuel rails may in some arrangements be replaced by individual canisters or chambers for handling accumulated volumes of fuel prior to actual entry of the fuel into individual injectors. Such chambers or canisters may act as a plurality of fuel injection accumulators, each adapted for supplying pressurized fuel to at least one fuel injector. In such cases, such canisters, chambers, and/or accumulators would be considered equivalent to fuel rails by those skilled in the art, and are so treated herein.
[0022] With respect to the specific embodiment of the fuel rails 32 , 34 shown and described herein, mounting clamps 44 may be effective to secure the rails within the pump housing 19 of the disclosed embodiment. Alternatively, the structures of the pump manifold 20 and the fuel rails 32 , 34 , and even the fuel pump conduits 36 and 38 may be formed as an interior part of the housing 19 , or as separate manifold blocks, or even as individual components bolted to the housing 19 . FIG. 2 also schematically depicts fuel flow from the fuel tank 46 through the low pressure fuel transfer pump 48 , and into the high-pressure pump 18 . As will be discussed in further detail, the high-pressure pump 18 may include or may be in fluid communication with a valve assembly 100 to manage a flow of fluid such as fuel to the manifold.
[0023] FIG. 3 illustrates a cross-sectional view of the valve assembly 100 according to aspects of the present disclosure, where the valve assembly 100 is shown in a closed position. The valve assembly 100 may include a housing 102 having a valve inlet 104 and a valve outlet 106 formed therein. As shown, the valve assembly 100 may include a valve chamber 108 defined by a portion of the housing 102 . The valve chamber 108 may have a first end 110 and a second end 112 opposite the first end 110 . The valve chamber 108 may be in fluid communication with the valve inlet 104 and the valve outlet 106 . As shown in FIG. 3 , the valve inlet 104 may be disposed adjacent the first end 110 of the valve chamber 108 and the valve outlet 106 may be disposed along a length of the valve chamber 108 between the first end 110 and the second end 112 of the valve chamber 108 .
[0024] The valve body 114 may be moveably disposed in the valve chamber 108 . The valve body 114 may include a valve head 116 formed at a first end 118 of the valve body 114 opposite a second end 120 thereof. As shown, the valve head 116 may be oriented toward the first end 110 of the valve chamber 108 . The valve head 116 may be configured to abut a valve seat 122 formed in a portion of the housing 102 , for example, adjacent the valve inlet 104 at the first end 110 of the valve chamber 108 . As shown in FIG. 3 , the valve head 116 is in sealing engagement with the valve seat 122 such that the valve assembly 100 is in a closed or seated position. As shown in FIG. 4 , the valve head 116 is spaced (e.g., lifted) from the valve seat 122 such that the valve assembly 100 is in an opened position.
[0025] Returning to FIG. 3 , the valve body 114 may include a base portion 117 extending from the valve head 116 . As shown, the base portion 117 may terminate at a first shoulder 126 that extends beyond an outside diameter of the base portion 117 . As an example, a second shoulder 128 may be formed at a portion of the valve head 116 and may extend beyond an outside diameter of the first shoulder 126 .
[0026] A retainer 136 may be disposed adjacent the second end 112 of the valve chamber 108 and may sealingly engage a portion of the housing 102 . A portion of the retainer 136 may define at least a portion of the cavity 134 . As an example, the cavity 134 may be defined by the retainer 136 , a portion of the housing 102 , and the second end 120 of the valve body 114 .
[0027] The retainer 136 may include one or more control orifices 132 extending therethrough. As an example, the control orifices 132 may provide fluid communication between the cavity 134 and a portion of the valve chamber 108 . The control orifices 132 may be of varying size and shape. Further, the control orifices 132 may include one or multiple flow restriction means configured to controllably manipulate flow dynamics of the system. The control orifices 132 may include holes, channels (e.g., flutes), and other arrangement to control flow dynamics through the retainer 136 .
[0028] The retainer 136 may define at least a portion of a fluid chamber 140 such as a low pressure side of the valve assembly 100 . A fluid passage 142 may provide fluid communication between the fluid chamber and a cavity 144 formed between the retainer 136 and the housing 102 .
[0029] A spring member 138 may be disposed in the cavity 134 and may be configured to bias the valve body 114 toward the valve seat 122 . As shown, the spring member 138 is disposed between the retainer 136 and the valve body 114 (e.g., the second shoulder 128 ). As an example, the spring member 138 may be or include a coil spring. Other biasing elements may be used.
[0030] As shown in FIG. 3 , the valve head 116 is in sealing engagement with the valve seat 122 such that the valve assembly 100 is in a closed or seated position, thereby preventing a flow of the liquid fuel between the valve inlet 104 and the valve chamber 108 . As pressurized fluid flows through the valve inlet 104 , such as during actuation of a plunger or piston of an associated high-pressure pump (e.g., pump 18 ( FIG. 2 )), a force is exerted on the valve head 116 in opposition to the bias of the spring member 138 . As pressure builds at the valve inlet 104 , the forces on the valve head 116 exceed the bias force of the spring member 138 and the valve body 114 moves away from the valve seat 122 and compresses the spring member 138 . As an example, the pressure at the valve inlet 104 may be about 1800-2500 bar during a high pressure operation. Additionally, as the valve body 114 moves away from the valve seat 122 , the fluid in the cavity 134 is compressed, thereby providing an additional biasing force in opposition of the movement of the valve body 114 toward the cavity 134 . The fluid pressure in the cavity 134 mitigates pressure impulses that would normally cause the valve body 114 to compress the spring member 138 and even contact the retainer 136 at high velocities. The dimensions of the control orifices 132 , a cross-sectional area of the valve body 114 , and the stiffness of the spring member 138 may be configured so as to control a movement and/or position of the valve body 114 under various pressure conditions.
[0031] As shown in FIG. 4 , the valve head 116 is spaced (e.g., lifted) from the valve seat 122 such that the valve assembly 100 is in an opened position. As such, fluid may flow from the valve inlet 104 to the valve outlet 106 and on to a manifold such as a manifold 20 ( FIG. 2 ), for example. When pressure is reduced at the valve inlet 104 , the spring member 138 biases the valve body 114 toward the valve seat 122 . However, the bias force of the spring member 138 is controlled by a pressure change in the cavity 134 . For example, as the valve body 114 moves toward the valve seat 122 , a pressure is reduced in the cavity 134 causing an opposing force to the bias of the spring member 138 . The control orifices 132 allow fluid to back fill the cavity 134 is a controlled manner and such control orifices 132 may be configured along with the spring member 138 to provide a controlled motion of the valve body 114 .
[0032] As an illustrative example, as the linear motion of the valve body 114 changes the volume of the cavity 134 , a sudden motion of the valve body 114 is impeded by the flow dynamics of the cavity 134 . Therefore, the cavity 134 decreases the maximum impact velocity of both the strokes and return motions of the valve body 114 . As such, wear of the valve assembly 100 may be reduced and the life expectancy of the spring member 138 may be increased.
[0033] FIG. 5 illustrates a cross-sectional view of the valve assembly 200 according to aspects of the present disclosure, where the valve assembly 200 is shown in a closed position. The valve assembly 200 may include a housing 202 having a valve inlet 204 and a valve outlet 206 formed therein. As shown, the valve assembly 200 may include a valve chamber 208 defined by a portion of the housing 202 . The valve chamber 208 may have a first end 210 and a second end 212 opposite the first end 210 . The valve chamber 208 may be in fluid communication with the valve inlet 204 and the valve outlet 206 . As shown in FIG. 5 , the valve inlet 204 may be disposed adjacent the first end 210 of the valve chamber 208 and the valve outlet 206 may be disposed along a length of the valve chamber 208 between the first end 210 and the second end 212 of the valve chamber 208 .
[0034] The valve body 214 may be moveably disposed in the valve chamber 208 . The valve body 214 may include a valve head 216 formed at a first end 218 of the valve body 214 opposite a second end 220 thereof. As shown, the valve head 216 may be oriented toward the first end 210 of the valve chamber 208 . The valve head 216 may be configured to abut a valve seat 222 formed in a portion of the housing 202 , for example, adjacent the valve inlet 204 at the first end 210 of the valve chamber 208 . As shown in FIG. 5 , the valve head 216 is in sealing engagement with the valve seat 222 such that the valve assembly 200 is in a closed or seated position. As shown in FIG. 6 , the valve head 216 is spaced (e.g., lifted) from the valve seat 222 such that the valve assembly 200 is in an opened position.
[0035] Returning to FIG. 7 , the valve body 214 may include a base portion 217 extending from the valve head 216 . As shown, the base portion 217 may terminate at a first shoulder 226 that extends beyond an outside diameter of the base portion 217 . As an example, a second shoulder 228 may be formed at a portion of the valve head 216 and may extend beyond an outside diameter of the first shoulder 226 .
[0036] A retainer 236 may be disposed adjacent the second end 212 of the valve chamber 208 and may sealingly engage a portion of the housing 202 . A portion of the retainer 236 may define at least a portion of the cavity 234 . As an example, the cavity 234 may be defined by the retainer 236 , a portion of the housing 202 , and the second end 220 of the valve body 214 .
[0037] The retainer 236 may include one or more control orifices 232 extending therethrough. As an example, the control orifices 232 may provide fluid communication between the cavity 234 and a fluid chamber 240 such as a low pressure side of the valve assembly 200 . As a further example, the fluid chamber 240 may experience pressures on the order of about 4-5 bar. The control orifices 232 may be of varying size and shape. Further, the control orifices 232 may include one or multiple flow restriction means configured to controllably manipulate flow dynamics of the system. The control orifices 232 may include holes, channels (e.g., flutes), and other arrangement to control flow dynamics through the retainer 236 .
[0038] The retainer 236 may define at least a portion of the fluid chamber 240 such as a low pressure side of the valve assembly 200 . As a further example, the fluid chamber 240 may experience pressures on the order of about 4-5 bar. A fluid passage 242 may provide fluid communication between the fluid chamber and a cavity 244 formed between the retainer 236 and the housing 202 .
[0039] A spring member 238 may be disposed in the cavity 234 and may be configured to bias the valve body 214 toward the valve seat 222 . As shown, the spring member 238 is disposed between the retainer 236 and the valve body 214 (e.g., the second shoulder 228 ). As an example, the spring member 238 may be or include a coil spring. Other biasing elements may be used.
[0040] As shown in FIG. 5 , the valve head 216 is in sealing engagement with the valve seat 222 such that the valve assembly 200 is in a closed or seated position, thereby preventing a flow of the liquid fuel between the valve inlet 204 and the valve chamber 208 . As pressurized fluid flows through the valve inlet 204 , such as during actuation of a plunger or piston of an associated high-pressure pump (e.g., pump 18 ( FIG. 2 )), a force is exerted on the valve head 216 in opposition to the bias of the spring member 238 . As pressure builds at the valve inlet 204 , the forces on the valve head 216 exceed the bias force of the spring member 238 and the valve body 214 moves away from the valve seat 222 and compresses the spring member 238 . As an example, the pressure at the valve inlet 204 may be about 1800-2500 bar during a high pressure operation. Additionally, as the valve body 214 moves away from the valve seat 222 , the fluid in the cavity 234 is compressed, thereby providing an additional biasing force in opposition of the movement of the valve body 214 toward the cavity 234 . The fluid pressure in the cavity 234 mitigates pressure impulses that would normally cause the valve body 214 to compress the spring member 238 and even contact the retainer 236 at high velocities. The dimensions of the control orifices 232 , a cross-sectional area of the valve body 214 , and the stiffness of the spring member 238 may be configured so as to control a movement and/or position of the valve body 214 under various pressure conditions.
[0041] As shown in FIG. 6 , the valve head 216 is spaced (e.g., lifted) from the valve seat 222 such that the valve assembly 200 is in an opened position. As such, fluid may flow from the valve inlet 204 to the valve outlet 206 and on to a manifold such as manifold 20 ( FIG. 2 ), for example. When pressure is reduced at the valve inlet 204 , the spring member 238 biases the valve body 214 toward the valve seat 222 . However, the bias force of the spring member 238 is controlled by a pressure change in the cavity 234 . For example, as the valve body 214 moves toward the valve seat 222 , a pressure is reduced in the cavity 234 causing an opposing force to the bias of the spring member 238 . The control orifices 232 allow fluid to back fill the cavity 234 is a controlled manner and such control orifices 232 may be configured along with the spring member 238 to provide a controlled motion of the valve body 214 .
[0042] As an illustrative example, as the linear motion of the valve body 214 changes the volume of the cavity 234 , a sudden motion of the valve body 214 is impeded by the flow dynamics of the cavity 234 . Therefore, the cavity 234 decreases the maximum impact velocity of both the strokes and return motions of the valve body 214 . As such, wear of the valve assembly 200 may be reduced and the life expectancy of the spring member 238 may be increased.
[0043] FIG. 7 illustrates a cross-sectional view of the valve assembly 300 according to aspects of the present disclosure, where the valve assembly 300 is shown in a closed position. The valve assembly 300 may include a housing 302 having a valve inlet 304 and a valve outlet 306 formed therein. As shown, the valve assembly 300 may include a valve chamber 308 defined by a portion of the housing 302 . The valve chamber 308 may have a first end 310 and a second end 312 opposite the first end 310 . The valve chamber 308 may be in fluid communication with the valve inlet 304 and the valve outlet 306 . As shown in FIG. 7 , the valve inlet 304 may be disposed adjacent the first end 310 of the valve chamber 308 and the valve outlet 306 may be disposed along a length of the valve chamber 308 between the first end 310 and the second end 312 of the valve chamber 308 .
[0044] The valve body 314 may be moveably disposed in the valve chamber 308 . The valve body 314 may include a valve head 316 formed at a first end 318 of the valve body 314 opposite a second end 320 thereof. As shown, the valve head 316 may be oriented toward the first end 310 of the valve chamber 308 . The valve head 316 may be configured to abut a valve seat 322 formed in a portion of the housing 302 , for example, adjacent the valve inlet 304 at the first end 310 of the valve chamber 308 . As shown in FIG. 7 , the valve head 316 is in sealing engagement with the valve seat 322 such that the valve assembly 300 is in a closed or seated position. As shown in FIGS. 8 and 9 , the valve head 316 is spaced (e.g., lifted) from the valve seat 322 such that the valve assembly 300 is in an opened position.
[0045] Returning to FIG. 7 , the valve body 314 may include a base portion 317 extending from the valve head 316 . As shown, the base portion 317 may terminate at a first shoulder 326 that extends beyond an outside diameter of the base portion 317 . As an example, a second shoulder 328 may be formed at a portion of the valve head 316 and may extend beyond an outside diameter of the first shoulder 326 .
[0046] A retainer 336 may be disposed adjacent the second end 312 of the valve chamber 308 and may sealingly engage a portion of the housing 302 . A portion of the retainer 336 may define at least a portion of the cavity 334 . As an example, the cavity 334 may be defined by the retainer 336 , a portion of the housing 302 , and the second end 320 of the valve body 314 . The retainer 336 may also define at least a portion of the fluid chamber 340 such as a low pressure side of the valve assembly 300 . As a further example, the fluid chamber 340 may experience pressures on the order of about 4-5 bar.
[0047] The retainer 336 may include one or more control orifices 330 , 332 extending therethrough. As an example, a first control orifice 330 may provide fluid communication between the valve chamber 308 and the cavity 334 . As another example, a second control orifice 332 may provide fluid communication between the cavity 334 and an environment external to the valve assembly 300 . The control orifices 330 , 332 may be of varying size and shape. Further, the control orifices 330 , 332 may include one or multiple flow restriction means configured to controllably manipulate flow dynamics of the system. The control orifices 330 , 332 may include holes, channels (e.g., flutes), and other arrangement to control flow dynamics through the retainer 336 .
[0048] As shown in FIG. 7 , a fluid chamber 331 may be formed in the valve body 314 and may terminate in fluid communication with the cavity 334 . A channel 333 may be formed about at least a portion of the periphery of the valve body 314 and may be in fluid communication with the fluid chamber 331 . As the valve body 314 moves from the first end 310 of the valve chamber 308 toward the second end 312 of the valve chamber 308 the channel 333 may align with the first control orifice 330 and/or the second control orifice 332 to provide fluid communication with the cavity 334 .
[0049] A spring member 338 may be disposed in the cavity 334 and may be configured to bias the valve body 314 toward the valve seat 322 . As shown, the spring member 338 is disposed between the retainer 336 and the valve body 314 (e.g., the second shoulder 328 ). As an example, the spring member 338 may be or include a coil spring. Other biasing elements may be used.
[0050] As shown in FIG. 7 , the valve head 316 is in sealing engagement with the valve seat 322 such that the valve assembly 300 is in a closed or seated position, thereby preventing a flow of the liquid fuel between the valve inlet 304 and the valve chamber 308 . As pressurized fluid flows through the valve inlet 304 , such as during actuation of a plunger or piston of an associated high-pressure pump (e.g., pump 18 ( FIG. 2 )), a force is exerted on the valve head 316 in opposition to the bias of the spring member 338 . As pressure builds at the valve inlet 304 , the forces on the valve head 316 exceed the bias force of the spring member 338 and the valve body 314 moves away from the valve seat 322 and compresses the spring member 338 . As an example, the pressure at the valve inlet 304 may be about 1800-2500 bar during a high pressure operation. Additionally, as the valve body 314 moves away from the valve seat 322 , the fluid in the cavity 334 is compressed, thereby providing an additional biasing force in opposition of the movement of the valve body 314 toward the cavity 334 . The fluid pressure in the cavity 334 mitigates pressure impulses that would normally cause the valve body 314 to compress the spring member 338 and even contact the retainer 336 at high velocities. The dimensions of the control orifices 332 , a cross-sectional area of the valve body 314 , and the stiffness of the spring member 338 may be configured so as to control a movement and/or position of the valve body 314 under various pressure conditions.
[0051] As shown in FIG. 8 , the valve head 316 is spaced (e.g., lifted) from the valve seat 322 such that the valve assembly 300 is in an opened position. As such, fluid may flow from the valve inlet 304 to the valve outlet 306 and on to a manifold such as manifold 20 ( FIG. 2 ), for example. When pressure is reduced at the valve inlet 304 , the spring member 338 biases the valve body 314 toward the valve seat 322 . However, the bias force of the spring member 338 is controlled by a pressure change in the cavity 334 . For example, as the valve body 314 moves toward the valve seat 322 , a pressure is reduced in the cavity 334 causing an opposing force to the bias of the spring member 338 . In certain aspects, the first control orifice 330 facilitates fluid communication between the valve chamber 308 and the cavity 334 when the channel 333 is aligned with at least a portion of the first control orifice 330 .
[0052] As shown in FIG. 9 , pressure at the valve inlet 304 continues to cause the valve head 316 to lift further from the valve seat 322 such that the spring member 338 compresses further. As such, fluid may flow from the valve inlet 304 to the valve outlet 306 and on to a manifold such as manifold 20 ( FIG. 2 ), for example. When pressure is reduced at the valve inlet 304 , the spring member 338 biases the valve body 314 toward the valve seat 322 . However, the bias force of the spring member 338 is controlled by a pressure change in the cavity 334 . For example, as the valve body 314 moves toward the valve seat 322 , a pressure is reduced in the cavity 334 causing an opposing force to the bias of the spring member 338 . In certain aspects, the second control orifice 332 facilitates fluid communication between the cavity 334 and an environment external the valve assembly 300 when the channel 333 is aligned with at least a portion of the second control orifice 332 . During such alignment, fluid may flow from the environment through the second control orifice 332 and into the cavity 334 to increase and/or equalize a pressure therein. Such flow may allow the valve body 314 to move toward the seat 322 in an accelerated manner until the fluid communication between the channel 333 and the second control orifice 332 is ceased, such as shown in FIGS. 7 and 8 .
[0053] As an illustrative example, as the linear motion of the valve body 314 changes the volume of the cavity 334 , a sudden motion of the valve body 314 is impeded by the flow dynamics of the cavity 334 . Therefore, the cavity 334 decreases the maximum impact velocity of both the strokes and return motions of the valve body 314 . As such, wear of the valve assembly 300 may be reduced and the life expectancy of the spring member 338 may be increased.
INDUSTRIAL APPLICABILITY
[0054] The disclosed valve assemblies 100 , 200 , 300 may find potential utility for use with fuel pumps in internal combustion engines, and particularly to such engines utilizing high-pressure fuel systems, including compression ignition engines, such as diesel engines.
[0055] In general, technology disclosed herein may have industrial applicability in a variety of settings such as in a variety of diesel engine settings in which space requirements are particularly limited. The valve assemblies 100 , 200 , 300 may be effective to improve fuel pressure modulation of associated engines by reducing fuel pressure variability associated with divergent placements of control valve, sensor and relief valve units. Industrial applicability of such compact fuel pump units extends to virtually all motorized transport platforms, including automobiles, buses, trucks, tractors, industrial work machines and most off-road machines utilized in agriculture, mining, and construction.
[0056] The high pressure pump unit features disclosed herein may be particularly beneficial to wheel loaders and other earth moving, construction, mining or material handling vehicles that may utilize compact fuel pump systems within such fuel pump housings. Such pump unit features may also be particularly beneficial to the previously mentioned marine and industrial applications including petroleum, drilling, and electrical.
[0057] It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.
[0058] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
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A valve assembly for a fuel pump is disclosed. In certain aspect, the valve assembly includes a housing defining a valve chamber, a valve inlet in fluid communication with the valve chamber, a valve outlet in fluid communication with the valve chamber, a valve seat; a valve body movably disposed within the valve chamber, a retainer sealingly engaging the housing and defining a cavity between the base portion of the valve body and the retainer, wherein the retainer comprises one or more control orifices formed therein and configured to provide fluid communication to the cavity to regulate a position of the valve body based on at least a pressure difference between the valve chamber and the cavity, and a spring member disposed between the retainer and the valve body, wherein the spring member is configured to bias the valve body.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/409,697, filed Mar. 1, 2012, which is a continuation of U.S. patent application Ser. No. 13/037,162, filed Feb. 28, 2011, which is a continuation of U.S. patent application Ser. No. 12/183,949, filed Jul. 31, 2008, which claims the benefit of priority under 35 U.S.C. §119(e) to both U.S. Provisional Application 60/963,183, filed Aug. 3, 2007; and U.S. Provisional Application No. 60/994,011, filed Sep. 17, 2007, the entireties of which are incorporated herein by reference and are to be considered part of this specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the use of thermostatic HVAC controls that are connected to a computer network as a part of a system for offering peak demand reduction to electric utilities. More specifically, the present invention pertains to use of communicating thermostat combined with a computer network to verify that demand reduction has occurred.
[0004] 2. Background
[0005] Climate control systems such as heating and cooling systems for buildings (heating, ventilation and cooling, or HVAC systems) have been controlled for decades by thermostats. At the most basic level, a thermostat includes a means to allow a user to set a desired temperature, a means to sense actual temperature, and a means to signal the heating and/or cooling devices to turn on or off in order to try to change the actual temperature to equal the desired temperature. The most basic versions of thermostats use components such as a coiled bi-metallic spring to measure actual temperature and a mercury switch that opens or completes a circuit when the spring coils or uncoils with temperature changes. More recently, electronic digital thermostats have become prevalent. These thermostats use solid-state devices such as thermistors or thermal diodes to measure temperature, and microprocessor-based circuitry to control the switch and to store and operate based upon user-determined protocols for temperature vs. time.
[0006] These programmable thermostats generally offer a very restrictive user interface, limited by the cost of the devices, the limited real estate of the small wall-mounted boxes, and the inability to take into account more than two variables: the desired temperature set by the user, and the ambient temperature sensed by the thermostat. Users can generally only set one series of commands per day, and to change one parameter (e.g., to change the late-night temperature) the user often has to cycle through several other parameters by repeatedly pressing one or two buttons.
[0007] As both the cost of energy and the demand for electricity have increased, utilities supplying electricity increasingly face unpleasant choices. The demand for electricity is not smooth over time. In so-called “summer peaking” locations, on the hottest days of the year, peak loads may be twice as high as average loads. During such peak load periods (generally in the late afternoon), air conditioning can be the largest single element of demand.
[0008] Utilities and their customers generally see reductions of supply (brownouts and blackouts) as an unacceptable outcome. But their other options can be almost as distasteful. In the long term, they can build additional generating capacity, but that approach is very expensive given the fact that such capacity may be needed for only a few hours a year. And this option is of course unavailable in the short term. When confronted with an immediate potential shortfall, a utility may have reserve capacity it can choose to bring online. But because utilities are assumed to try to operate as efficiently as possible, the reserve capacity is likely to be the least efficient and most expensive and/or more polluting plants to operate. Alternatively, the utility may seek to purchase additional power on the open market. But the spot market for electricity, which cannot efficiently be stored, is extremely volatile, which means that spot prices during peak events may be as much as 10× the average price.
[0009] More recently, many utilities have begun to enter into agreements with certain customers to reduce demand, as opposed to increasing supply. In essence, these customers agree to reduce usage during a few critical periods in exchange for incentives from the utility. Those incentives may take the form of a fixed contract payment in exchange for the right to cut the amount of power supplied at specified times, or a reduced overall price per kilowatt-hour, or a rebate each time power is reduced, or some other method.
[0010] The bulk of these peak demand reduction (PDR) contracts have been entered into with large commercial and industrial customers. This bias is in large part due to the fact that transaction costs are much lower today for a single contract with a factory that can offer demand reduction of 50 megawatts than they would be for the equivalent from residential customers—it could take 25,000 or more homes to equal that reduction if these homes went without air conditioning.
[0011] But residential air conditioning is the largest single component of peak demand in California, and is a large percentage in many other places. There are numerous reasons why it would be economically advantageous to deploy PDR in the residential market. Whereas cutting energy consumption at a large factory could require shutting down or curtailing production, which has direct economic costs, cutting consumption for a couple of hours in residences is likely to have no economic cost, and may only result in minor discomfort—or none at all if no one is at home at the time.
[0012] Residential PDR has been attempted. But there have been numerous command and control issues with these implementations. The standard approach to residential PDR has been to attach a radio-controlled switch to the control circuitry located outside the dwelling. These switches are designed to receive a signal from a transmitter that signals the compressor to shut off during a PDR call.
[0013] There are a number of technical complications with this approach. There is some evidence that “hard cycling” the compressor in this manner can damage the air conditioning system. There are also serious issues resulting from the fact that the communication system is unidirectional. When utilities contract for PDR, they expect verification of compliance. One-way pagers allow the utility to send a signal that will shut of the NC, but the pager cannot confirm to the utility that the NC unit has in fact been shut off. If a consumer tampers with the system so that the NC can be used anyway, the utility will not be able to detect it, absent additional verification systems.
[0014] One way in which some utilities are seeking to address this issue is to combine the pager-controlled thermostat with so-called advanced metering infrastructure (AMI). This approach relies on the deployment of “smart meters”—electric meters that are more sophisticated than the traditional meter with its mechanical odometer mechanism for logging only cumulative energy use. Smart meters generally include a means for communicating instantaneous readings. That communication may in the form of a signal sent over the power lines themselves, or a wireless communication over a data network arranged by the utility. These meters allow utilities to accomplish a number of goals, including offering pricing that varies by time of day in order to encourage customers to move consumption away from peak demand hours. These smart meters can cost hundreds of dollars, however, and require both a “truck roll”—a visit from a trained service person—and most likely the scheduling of an appointment with the occupants, because swapping the meter will require turning off power to the house.
[0015] If the utility installs a smart meter at each house that contracts to participate in a PDR program, it may be possible to verify that the NC is in fact switched off. But this approach requires two separate pieces of hardware, two separate communications systems, and the ability to match them for verification purposes.
[0016] It would be desirable to have a system that could both implement and verify residential peak demand reduction with reduced expenses.
SUMMARY OF THE INVENTION
[0017] At least one embodiment of the invention that includes system for predicting the rate of change in temperature inside a structure comprising at least one thermostat located inside the structure and controlling an HVAC system in said structure; at least one remote processor that is in communication with said thermostat; at least one database for storing data reported by said thermostat; at least one processor that compares outside temperature at at least location and at least one point in time to information reported to said remote processor from said thermostat, and wherein said processor uses the relationship between the inside temperature and the outside temperature over time to derive a first prediction for the rate of change in inside temperature assuming that the operating status of the HVAC system is “on”; and said processor uses the relationship between the inside temperature and the outside temperature over time to derive a second prediction for the rate of change in inside temperature assuming that the operating status of the HVAC system is “off”; and said processor compares at least one of the first prediction and the second prediction to the actual inside temperature recorded inside the structure to determine whether the actual inside temperature is closer to the first prediction or the second prediction.
[0018] In one embodiment, the invention comprises a thermostat attached to an HVAC system, a local network connecting the thermostat to a larger network such as the Internet, one or more additional thermostats attached to the network and to other HVAC systems, and a server in bi-directional communication with the thermostats. The server logs the ambient temperature sensed by each thermostat vs. time and the signals sent by the thermostats to the HVAC systems to which they are attached. The server preferably also logs outside temperature and humidity data for the geographic locations for the buildings served by the connected HVAC systems. Such information is widely available from various sources that publish detailed weather information based on geographic areas such as by ZIP code. The server also stores other data affecting the load upon the system, such as specific model of HVAC system, occupancy, building characteristics, etc. Some of this data may be supplied by the individual users of the system, while other data may come from commercial sources such as the electric and other utilities who supply energy to those users.
[0019] By using these multiple data streams to compare the performance of one system versus another, and one system versus the same system at other times, the server is able to estimate the effective thermal mass of the structure, and thereby predict the expected thermal performance of a given structure in response to changes in outside temperature. Thus, for example, if the air conditioning is shut off on a hot afternoon, given a known outside temperature, it will be possible to predict how quickly the temperature in the house should rise. If the actual temperature change is significantly different from the predicted rate of change, or does not change at all, it is possible to infer that the air conditioning has not, in fact been shut off.
[0020] This and other advantages of the present invention are explained in the detailed description and claims that make reference to the accompanying diagrams and flowcharts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows an example of an overall environment in which an embodiment of the invention may be used.
[0022] FIG. 2 shows a high-level illustration of the architecture of a network showing the relationship between the major elements of one embodiment of the subject invention.
[0023] FIG. 3 shows an embodiment of the website to be used as part of the subject invention.
[0024] FIG. 4 shows a high-level schematic of the thermostat used as part of the subject invention.
[0025] FIG. 5 shows one embodiment of the database structure used as part of the subject invention
[0026] FIGS. 6A and 6B show a graphical representation of the manner in which the subject invention may be used to verify that a demand reduction event has occurred.
[0027] FIG. 7 is a flow chart illustrating the steps involved in generating a demand reduction event for a given subscriber.
[0028] FIG. 8 is a flow chart illustrating the steps involved in confirming that a demand reduction event has taken place.
[0029] FIG. 9 is a representation of the movement of messages and information between the components of the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] FIG. 1 shows an example of an overall environment 100 in which an embodiment of the invention may be used. The environment 100 includes an interactive communication network 102 with computers 104 connected thereto. Also connected to network 102 are one or more server computers 106 , which store information and make the information available to computers 104 . The network 102 allows communication between and among the computers 104 and 106 .
[0031] Presently preferred network 102 comprises a collection of interconnected public and/or private networks that are linked to together by a set of standard protocols to form a distributed network. While network 102 is intended to refer to what is now commonly referred to as the Internet, it is also intended to encompass variations which may be made in the future, including changes additions to existing standard protocols.
[0032] When a user of the subject invention wishes to access information on network 102 , the buyer initiates connection from his computer 104 . For example, the user invokes a browser, which executes on computer 104 . The browser, in turn, establishes a communication link with network 102 . Once connected to network 102 , the user can direct the browser to access information on server 106 .
[0033] One popular part of the Internet is the World Wide Web. The World Wide Web contains a large number of computers 104 and servers 106 , which store HyperText Markup Language (HTML) documents capable of displaying graphical and textual information. HTML is a standard coding convention and set of codes for attaching presentation and linking attributes to informational content within documents.
[0034] The servers 106 that provide offerings on the World Wide Web are typically called websites. A website is often defined by an Internet address that has an associated electronic page. Generally, an electronic page is a document that organizes the presentation of text graphical images, audio and video.
[0035] In addition to the Internet, the network 102 can comprise a wide variety of interactive communication media. For example, network 102 can include local area networks, interactive television networks, telephone networks, wireless data systems, two-way cable systems, and the like.
[0036] In one embodiment, computers 104 and servers 106 are conventional computers that are equipped with communications hardware such as modem or a network interface card. The computers include processors such as those sold by Intel and AMD. Other processors may also be used, including general-purpose processors, multi-chip processors, embedded processors and the like.
[0037] Computers 104 can also be handheld and wireless devices such as personal digital assistants (PDAs), cellular telephones and other devices capable of accessing the network.
[0038] Computers 104 utilize a browser configured to interact with the World Wide Web. Such browsers may include Microsoft Explorer, Mozilla, Firefox, Opera or Safari. They may also include browsers used on handheld and wireless devices.
[0039] The storage medium may comprise any method of storing information. It may comprise random access memory (RAM), electronically erasable programmable read only memory (EEPROM), read only memory (ROM), hard disk, floppy disk, CD-ROM, optical memory, or other method of storing data.
[0040] Computers 104 and 106 may use an operating system such as Microsoft Windows, Apple Mac OS, Linux, Unix or the like.
[0041] Computers 106 may include a range of devices that provide information, sound, graphics and text, and may use a variety of operating systems and software optimized for distribution of content via networks.
[0042] FIG. 2 illustrates in further detail the architecture of the specific components connected to network 102 showing the relationship between the major elements of one embodiment of the subject invention. Attached to the network are thermostats 108 and computers 104 of various users. Connected to thermostats 108 are HVAC units 110 . The HVAC units may be conventional air conditioners, heat pumps, or other devices for transferring heat into or out of a building. Each user is connected to the servers 106 a via wired or wireless connection such as Ethernet or a wireless protocol such as IEEE 802.11, a gateway 110 that connects the computer and thermostat to the Internet via a broadband connection such as a digital subscriber line (DSL) or other form of broadband connection to the World Wide Web. In one embodiment, electric utility server 106 a and demand reduction service server 106 b are in communication with the network 102 . Servers 106 a and 106 b contain the content to be served as web pages and viewed by computers 104 , as well as databases containing information used by the servers. Also connected to the servers 106 a via the Internet are computers located at one or more electrical utilities 106 b.
[0043] In the currently preferred embodiment, the website 200 includes a number of components accessible to the user, as shown in FIG. 3 . Those components may include a means to store temperature settings 202 , a means to enter information about the user's home 204 , a means to enter the user's electricity bills 206 , means to calculate energy savings that could result from various thermostat-setting strategies 208 , and means to enable and choose between various arrangements 210 for demand reduction with their electric utility provider as intermediated by the demand reduction service provider.
[0044] FIG. 4 shows a high-level block diagram of thermostat 108 used as part of the subject invention. Thermostat 108 includes temperature sensing means 252 , which may be a thermistor, thermal diode or other means commonly used in the design of electronic thermostats. It includes a microprocessor 254 , memory 256 , a display 258 , a power source 260 , a relay 262 , which turns the HVAC system on and off in response to a signal from the microprocessor, and contacts by which the relay is connected to the wires that lead to the HVAC system. To allow the thermostat to communicate bi-directionally with the computer network, the thermostat also includes means 264 to connect the thermostat to a local computer or to a wireless network. Such means could be in the form of Ethernet, wireless protocols such as IEEE 802.11, IEEE 802.15.4, Bluetooth, or other wireless protocols. (Other components as needed) The thermostat 250 may also include controls 266 allowing users to change settings directly at the thermostat, but such controls are not necessary to allow the thermostat to function.
[0045] The data used to generate the content delivered in the form of the website is stored on one or more servers 106 within one or more databases. As shown in FIG. 5 , the overall database structure 300 may include temperature database 400 , thermostat settings database 500 , energy bill database 600 , HVAC hardware database 700 , weather database 800 , user database 900 , transaction database 1000 , product and service database 1100 and such other databases as may be needed to support these and additional features.
[0046] The website will allow users of connected thermostats 250 to create personal accounts. Each user's account will store information in database 900 , which tracks various attributes relative to users of the site. Such attributes may include the make and model of the specific HVAC equipment in the user's home; the age and square footage of the home, the solar orientation of the home, the location of the thermostat in the home, the user's preferred temperature settings, whether the user is a participant in a demand reduction program, etc.
[0047] As shown in FIG. 3 , the website 200 will permit thermostat users to perform through the web browser substantially all of the programming functions traditionally performed directly at the physical thermostat, such as temperature set points, the time at which the thermostat should be at each set point, etc. Preferably the website will also allow users to accomplish more advanced tasks such as allow users to program in vacation settings for times when the HVAC system may be turned off or run at more economical settings, and set macros that will allow changing the settings of the temperature for all periods with a single gesture such as a mouse click.
[0048] In addition to using the system to allow better signaling and control of the HVAC system, which relies primarily on communication running from the server to the thermostat, the bi-directional communication will also allow the thermostat 108 to regularly measure and send to the server information about the temperature in the building. By comparing outside temperature, inside temperature, thermostat settings, cycling behavior of the HVAC system, and other variables, the system will be capable of numerous diagnostic and controlling functions beyond those of a standard thermostat.
[0049] For example, FIG. 6 a shows a graph of inside temperature, outside temperature and HVAC activity for a 24 hour period. When outside temperature 302 increases, inside temperature 304 follows, but with some delay because of the thermal mass of the building, unless the air conditioning 306 operates to counteract this effect. When the air conditioning turns on, the inside temperature stays constant (or rises at a much lower rate) despite the rising outside temperature. In this example, frequent and heavy use of the air conditioning results in only a very slight temperature increase inside o the house of 4 degrees, from 72 to 76 degrees, despite the increase in outside temperature from 80 to 100 degrees.
[0050] FIG. 6 b shows a graph of the same house on the same day, but assumes that the air conditioning is turned off from noon to 7 PM. As expected, the inside temperature 304 a rises with increasing outside temperatures 302 for most of that period, reaching 88 degrees at 7 PM.
[0051] Because server 106 a logs the temperature readings from inside each house (whether once per minute or over some other interval), as well as the timing and duration of air conditioning cycles, database 300 will contain a history of the thermal performance of each house. That performance data will allow the server 106 a to calculate an effective thermal mass for each such structure—that is, the speed with the temperature inside a given building will change in response to changes in outside temperature. Because the server will also log these inputs against other inputs including time of day, humidity, etc. the server will be able to predict, at any given time on any given day, the rate at which inside temperature should change for given inside and outside temperatures.
[0052] As shown in FIG. 3 , website 200 will allow the users to opt 210 into a plan that offers incentives such as cash or rebates in exchange for reduced air conditioning use during peak load periods.
[0053] FIG. 7 shows the steps followed in order to initiate air conditioner shutoff. When a summer peak demand situation occurs, the utility will transmit an email 402 or other signal to server 106 a requesting a reduction in load. Server 106 a will determine 404 if the user's house is served by the utility seeking reduction; determine 406 if a given user has agreed to reduce peak demand; and determine 408 if a reduction of consumption by the user is required or desirable in order to achieve the reduction in demand requested by the utility. The server will transmit 410 a signal to the user's thermostat 108 signaling the thermostat to shut off the air conditioner 110 .
[0054] FIG. 8 shows the steps followed in order to verify that the air conditioner has in fact been shut off. Server 106 a will receive and monitor 502 the temperature readings sent by the user's thermostat 108 . The server then calculates 504 the temperature reading to be expected for that thermostat given inputs such as current and recent outside temperature, recent inside temperature readings, the calculated thermal mass of the structure, temperature readings in other houses, etc. The server will compare 506 the predicted reading with the actual reading. If the server determines that the temperature inside the house is rising at the rate predicted if the air conditioning is shut off, then the server confirms 508 that the air conditioning has been shut off. If the temperature reading from the thermostat shows no increase, or significantly less increase than predicted by the model, then the server concludes 510 that the air conditioning was not switched off, and that no contribution to the demand response request was made.
[0055] For example, assume that on at 3 PM on date Y utility X wishes to trigger a demand reduction event. A server at utility X transmits a message to the server at demand reduction service provider Z requesting W megawatts of demand reduction. Demand reduction service provider server determines that it will turn off the air conditioner at house A in order to achieve the required demand reduction. At the time the event is triggered, the inside temperature as reported by the thermostat in house A is 72 degrees F. The outside temperature near house A is 96 degrees Fahrenheit. The inside temperature at House B, which is not part of the demand reduction program, but is both connected to the demand reduction service server and located geographically proximate to House A, is 74 F. Because the A/C in house A has been turned off, the temperature inside House A begins to rise, so that at 4 PM it has increased to 79 F. Because the server is aware of the outside temperature, which remains at 96 F., and of the rate of temperature rise inside house A on previous days on which temperatures have been at or near 96 F., and the temperature in house B, which has risen only to 75 F. because the air conditioning in house B continues to operate normally, the server is able to confirm with a high degree of certainty that the A/C in house A has indeed been shut off.
[0056] In contrast, if the HVAC system at house A has been tampered with, so that a demand reduction signal from the server does not actually result in shutting off the A/C in house A, when the server compares the rate of temperature change at house A against the other data points, the server will receive data inconsistent with the rate of increase predicted. As a result, it will conclude that the A/C has not been shut off in house A as expected, and will not credit house A with the financial credit that would be associated with demand reduction compliance, or may trigger a business process that could result in termination of house A's participation in the demand reduction program.
[0057] FIG. 9 illustrates the movement of signals and information between the components of the subject invention to trigger and verify a demand reduction response. In step 602 the electric utility server 106 b transmits a message to demand reduction service server 106 a requesting a demand reduction of a specified duration and size. Demand reduction service server 106 a uses database 300 to determine which subscribers should be included in the demand reduction event. For each included subscriber, the server then sends a signal 604 to the subscriber's thermostat instructing it (a) to shut down at the appropriate time or (b) to allow the temperature as measured by the thermostat to increase to a certain temperature at the specified time, depending upon the agreement between the homeowner and the demand reduction aggregator. The server then receives 606 temperature signals from the subscriber's thermostat. At the conclusion of the demand reduction event, the server transmits a signal 608 to the thermostat permitting the thermostat to signal its attached HVAC system to resume cooling, if the system has been shut off, or to reduce the target temperature to its pre-demand reduction setting, if the target temperature was merely increased. After determining the total number of subscribers actually participating in the DR event, the server then calculates the total demand reduction achieved and sends a message 610 to the electric utility confirming such reduction.
[0058] Additional steps may be included in the process. For example, if the subscriber has previously requested that notice be provided when a peak demand reduction event occurs, the server will also send an alert, which may be in the form of an email message or an update to the personalized web page for that user, or both. If the server determines that a given home has (or has not) complied with the terms of its demand reduction agreement, the server will send a message to the subscriber confirming that fact.
[0059] It should also be noted that in some climate zones, peak demand events occur during extreme cold weather rather than (or in addition to) during hot weather. The same process as discussed above could be employed to reduce demand by shutting off electric heaters and monitoring the rate at which temperatures fall.
[0060] It should also be noted that the peak demand reduction service can be performed directly by a power utility, so that the functions of server 106 a can be combined with the functions of server 106 b.
[0061] The system installed in a subscriber's home may optionally include additional temperature sensors at different locations within the building. These additional sensors may we connected to the rest of the system via a wireless system such as 802.11 or 802.15.4, or may be connected via wires. Additional temperature and/or humidity sensors may allow increased accuracy of the system, which can in turn increase user comfort, energy savings or both.
[0062] While particular embodiments of the present invention have been shown and described, it is apparent that changes and modifications may be made without departing from the invention in its broader aspects and, therefore, the invention may carried out in other ways without departing from the true spirit and scope. These and other equivalents are intended to be covered by the following claims:
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The invention comprises systems and methods for estimating the rate of change in temperature inside a structure. At least one thermostat located is inside the structure and is used to control an climate control system in the structure. At least one remote processor is in communication with said thermostat and at least one database stores data reported by the thermostat. At least one processor compares the outside temperature at at least one location and at least one point in time to information reported to the remote processor from the thermostat. The processor uses the relationship between the inside temperature and the outside temperature to determine whether the climate control system is “on” or “off”.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to systems for measuring turbine exhaust gas temperatures and more particularly to a method and sensors for accurately measuring deviations in the exhaust gas temperature profile of a turbine.
[0002] Turbines, including gas, steam and other forms of turbomachinery, include a stator structure and a rotor structure. The stator is a fixed structure around which the rotor rotates. The stator and rotor each generally includes one or more sets of blades offset from one another and extending into an annular flow path between the stator and the rotor. In a gas turbine, for example, a set of stator compressor blades and a set of rotor compressor blades act together to compress air entering the flow path. Fuel is injected into the flow path beyond the compressor blades. Mixing nozzles in the flow path act to mix the fuel and compressed air in a premixing stage. That mixture is then ignited in a combustor stage. The product of combustion is an expanded gas that passes through the flow path of the turbine to contact a set of stator turbine blades and a set of rotor turbine blades. The expanded gas moving in the flow path acts to move the rotor turbine blades, causing their rotation. Spent combustion products exit the turbine as exhaust gas directed to the atmosphere by an exhaust duct.
[0003] An important operating and control parameter associated with efficient turbine operation is the temperature of the exhaust gas. Typically, the exhaust gas is measured using a plurality of thermocouples spaced equidistant around the circumference of the exhaust duct. The mean exhaust temperature calculated from the retrieved thermocouple measurements is used to monitor and control turbine operation. In addition, deviations in temperature readings between individual thermocouples are monitored for undesirable operating conditions and events. Relatively small deviations may be evidence of operating inefficiencies placing uneven stress in localized areas of the turbine, thereby reducing service life of one or more components. Large temperature deviations may be evidence of serious abnormalities requiring immediate attention.
[0004] Statistical evidence gathered from thermocouple outputs over many hours of turbine operation has generally been used to establish failure trends. It has been determined that such statistical trending has been a useful diagnostic tool for incipient failure detection. Measured temperature deviations have been used to detect anomalies including, but not limited to, fuel nozzle defects, combustor stage liner cracking, turbine flame out, fuel/air premixing flashback, and/or structural leakage. All such anomalies influence the rates at which fuel and/or air are introduced into the turbine and so their detection is of great importance.
[0005] Difficulties arise in such monitoring and diagnostic techniques resulting from a masking of the abnormalities that the thermocouples are designed to detect. Specifically, the thermocouples are ordinarily laid out circumferentially around the exhaust duct in pre-determined patterns defined by the number, location, and spacing of the combustor elements and the stator and rotor blades. These difficulties can often be traced to a phenomenon known as aliasing. In general terms, aliasing occurs when sampling intervals are insufficient to distinguish between events taking place at different frequencies. That is, a sampling rate may be sufficient to detect events at one frequency but insufficient to detect events occurring at a higher frequency. Of greater concern, normal high frequency events may appear as low frequency signals, thereby masking anomalous low-frequency events.
[0006] In the context of a turbine exhaust duct, aliasing occurs when normally occurring exhaust temperature patterns include high-frequency signals that appear as low-frequency signals. The limit at which this occurs is a function of the number of discrete thermocouples deployed about the turbine exhaust duct. That is, the number of thermocouples in the array on the duct is insufficient to resolve all of the spatial frequencies present in the exhaust pattern established by the noted turbine components. The high spatial frequency content of the exhaust pattern is therefore incorrectly represented (aliased) as lower spatial frequency content. The aliased signal is an ambiguous one potentially representing two or more spatial frequency patterns including anomalies that may be of interest. Significant anomalies may therefore go undetected. One solution would be to deploy many more thermocouples. Such a solution is not practical, however.
[0007] The aliasing phenomenon is well known in the signal-processing field, less so in the field of turbomachinery. Nevertheless, the problem can clearly be seen through several simple equations for N number of thermocouples spaced equidistant from one another about the perimeter of an exhaust duct. The location of that thermocouple, n, with respect to the center of the exhaust duct is defined by the azimuthal angle en in the relationship set out in Equation (1):
⊖ n =2 πn/N Eq. (1)
[0008] For what is effectively a periodic sampling of a sinusoidal signal, the signal to be analyzed, identified generally by the function x(ε), can be resolved and simplified into generic Equation (2), in which the amplitude of the signal is A, and k is its spatial frequency:
x (⊖))= A cos(k⊖)) Eq. (2)
[0009] When sampled at each of the N discrete locations the result is;
x ( n )= A cos(2 πkn/N ) Eq. (3)
[0010] For two such spatially periodic components of differing frequencies, k 1 and k 2 , and described by the functions x 1 (⊖) and x 2 (⊖), we get the two sets of sampled measurements x 1 (n) and x 2 (n), where:
x 1 ( n )= A cos(2 πk 1 n/N ) Eq. (4)
[0011] and
x 2 ( n )= A cos(2 πk 2 n/N ) Eq. (5)
[0012] when each of the differing signals is sampled at identical locations on the exhaust duct. It can be shown by substitution that the two sets of sampled measurements, x 1 (n) and x 2 (n), are identical when the relationship
k 1 −k 2 =mN Eq. (6)
[0013] is satisfied for some m= . . . , −2, −1, 0, 1, 2, . . . , etc. (i.e., any integer). In this circumstance, the two signals are indistinguishable when observed via the array of N thermocouples.
[0014] An example illustrates this point. In a gas turbine having 14 combustor cans and 27 thermocouples spaced about the exhaust duct, the exhaust pattern will contain features indicating the presence of the 14 combustor cans. However, since the sampling spread is not adequate, the features will not be accurately represented. The spatial frequencies of the fundamental (14 per revolution) and harmonics (28, 42, . . . , per revolution) exceed the Nyquist limit of 27/2=13.5 beyond which the signal cannot be uniquely represented. For the fundamental with k 1 =14 we have from Equation (6) k 2 =−13 with m =1. That is, the signal from the 14 combustor cans is aliased in the observable range ±13.5 per revolution, as a signal out of phase and with a spatial frequency of 13 per revolution. Interpretation of this aliased signal would be confusing.
[0015] For the first harmonic we have from Equation (6) k 1 =28 and k 2 =1 for m=1. That is, the signal is observed as one with a spatial frequency of 1 per revolution. This signal would likely be sufficiently strong to obscure any real discrete defect about the turbine annulus that would also be characterized by a fundamental spatial frequency of 1 per revolution.
[0016] It can be seen that signal aliasing will occur using conventional discrete thermocouple systems. As a result, significant events such as thermal distortions and the like may be masked by normal exhaust temperature patterns and remain undetected by the thermocouples of the exhaust duct. Accordingly, there is a need for a technique to describe the exhaust gas temperature profile and deviations associated therewith. That technique can be used to identify normal pattern spatial frequencies that may mask anomalies that should be detected. There is thus a need for a mechanism to eliminate or minimize the aliasing of the spatial frequencies of the normal temperature pattern. There is also a need for a sensing arrangement that resolves aliasing and thereby provides an accurate temperature profile in regard to the entirety of the turbine structure.
SUMMARY OF THE INVENTION
[0017] The above-mentioned needs are met by the present invention, which provides a methodology and set of sensor types suitable for improved turbine exhaust gas temperature measurements. The method includes limiting the bandwidth of the spectral character of an exhaust gas temperature profile of a turbine having an exhaust gas duct. It includes the steps of first determining the spatial frequencies of a gas turbine exhaust temperature pattern and then establishing a spatial frequency limit. The method further includes the step of defining a filter function to filter out those of the spatial frequencies greater than the spatial frequency limit and then applying to the turbine exhaust duct a temperature sensor system that generates the filter function.
[0018] The sensor arrangement to achieve improved exhaust gas measurements provides the appropriate filter function. One such arrangement is a sensor with a plurality of distributed gradient thermocouples affixable to the turbine exhaust duct, wherein each of the distributed gradient thermocouples is formed of two or more materials of differing thermoelectric coefficients, and wherein the sensor defines a filter function for filtering out aliased signals of a standard exhaust gas temperature pattern.
[0019] The present invention and its advantages over the prior art will become apparent upon reading the following detailed description and the appended claims with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0020] The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the concluding part of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
[0021] [0021]FIG. 1 is a simplified cross-sectional view of the hot gas path of a gas turbine.
[0022] [0022]FIG. 2 is a simplified end view of a turbine exhaust duct of having the thermocouple gradient set of the present invention coupled thereto.
[0023] [0023]FIG. 3 is a simplified representation of a gradient thermocouple of the present invention.
[0024] [0024]FIG. 4 is a graph of the spectral power density of the fundamental and harmonic thermal frequencies as measured using the discrete thermocouples.
[0025] [0025]FIG. 5 is a graph of an exemplar amplitude response of the filter function associated with the thermocouple gradient of the present invention in relation to spatial response frequency.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 presents a simple view of a portion of a turbine engine 10 . Among other things, the turbine engine 10 includes a compressor (not shown) that provides pressurized air to a combustor section 11 where the pressurized air is mixed with fuel from fuel inlet 12 and ignited for generating hot combustion gases. These gases flow downstream to a turbine 13 , along with cooling air from a plurality of circumferentially spaced turbine stator nozzles 14 . The turbine 13 includes a plurality of circumferentially spaced apart blades, including exemplar turbine blade 15 , extending radially outwardly from a wheel that is fastened to a shaft 16 for rotation about the centerline axis of the turbine engine 10 . The hot combustion gases expand against the turbine blade 15 causing the wheel to rotate as they pass to an exhaust duct 17 . This gas expansion in turn rotates the shaft 16 that is connected to the compressor and may also be connected to load equipment such as an electric generator or a propeller.
[0027] Of course, depending upon the specific dimensions and duties of the turbine engine 10 , there may be a plurality of the various components shown. For the purpose of the description of the spectral analysis technique of the present invention, certain aspects of the operation of the turbine engine 10 will be given detailed attention. Specifically, the components of fluid flow through the turbine engine 10 , including combustor flow 18 , cooling air flow 19 , and exhaust flow 20 , will be considered in this example analysis.
[0028] Using conventional mass conservation and isenthalpic mixing equations, each stream tube associated with the turbine engine 10 can be represented in simple one-dimensional terms, assuming mass is conserved along that pathway, by the following two equations:
m exhaust (⊖)= m combustor ( E ))+ m cool (⊖)= m turbine (⊖)) Eq. (7)
m turbine inlet (⊖) h turbine inlet (⊖)= m combustor (⊖) h combustor (⊖)+ m cool (⊖) h cool (⊖) Eq. (8)
[0029] where mass flows are per unit time and unit area of annular flowpath through the turbine 10 . ⊖ is the azimuthal angle around the turbine 10 , h combustor (⊖) is the enthalpy of the exit pattern from the combustor 11 , m cool (⊖) is the periodic cooling flow from stator blades of the turbine 10 , and h cool is the enthalpy of discharge coolant from the compressor 12 . It is to be noted that h combustor (φ) can be resolved into its components by the simple equation
h combustor (⊖)= h combustor +Δh combustor (⊖) Eq. (9)
[0030] where h combustor is the spatial mean combustor exhaust enthalpy and Δh combustor (⊖) describes the spatial enthalpy variations caused by combustor features including, but not limited to, such features as can, swirlers, and the like.
[0031] It is known that the polytropic flow pattern through the turbine engine 10 is caused by the plurality of various components within the flow pathway. The enthalpy associated with that flow may be characterized by Equation (10), in which p is the pressure associated with the particular flow component identified by subscript:
h exhaust (ε))= h turbine inlet (ε)*( p exhaust /p combustor ) y−1/y Eq. (10)
[0032] For the purpose of the present invention, the solution for h exhaust (⊖)) is of interest in resolving the spatial spectrum of the exhaust temperature pattern. By combining and manipulating Equations (8) and (9) and assuming m cool (⊖)/m combustor is much less than unity, it can be determined that
h turtbne (⊖)/ h combustor =1 +Δh combustor (⊖)/ h combustor −( h combustor −h cool )/ h combustor *m cool (⊖)/ m combustor −m cool (Ε)Δ h combustor (⊖))/ m combustor h combustor +higher order terms Eq. (11)
[0033] Thermal pattern and cooling variations can then be characterized pursuant to the functions f cool (⊖) and f pattern (⊖), where f cool (⊖) defines the spatial variation caused by nozzle cooling and unit amplitude of that flow. That is, the spatial frequency associated with the number of cooling nozzles, their spacing, and the like. The function f pattern (⊖) defines the spatial variation caused by combustor flow and unit amplitude of that flow. That is, the spatial frequency associated with the number of combustor cans, their spacing, and the like. Using these general functions to characterize the circumferential variations in the gas flows, it can be seen that,
m cool (e)/m combustor =( m cool m combustor )(1 +f cool (⊖) Eq. (12)
[0034] and
Δ h combustor (⊖)/ h combustor =(Δ h combustor /h combustor ) f pattern (⊖) Eq. (13)
[0035] Taking into account Equations (10) to (13), Equation (14) that follows represents a model of the present invention for the turbine exhaust gas temperature profile:
h exhaust({circle over (-)})=( p exhaust/ p combustor) y−1/y [ 1 -(( h combustor- h cool)/ h combustor) ( m cool/ m combustor)+( 1 - m cool/ m combustor)
[0036] Equation (14) provides a set of terms correlating to the components of the turbine engine 10 that affect the temperature pattern of the exhaust flow 20 out of the turbine exhaust duct 17 . Table 1 summarizes the terms of Equation (14) and the turbine components that define specific spatial frequencies of the exhaust duct thermal pattern.
TABLE 1 Spatial Term Order Frequencies 1 1 0 (h combustor - h cool )/h combustor m cool /m combustor 0 (1 - m cool /m combustor ) * f pattern Δh combustor /h combustor n cans , 2n cans , 3n cans , . . . ((h combustor - h cool )/h combustor ) * f cool m cool /m combustor n nozzles , 2n nozzles , 3n nozzles , . . . f cool f pattern m cool Δh combustor / n nozzles ± n cans , n nozzles ± m combustor h combustor 2n cans , n nozzles ± 3n cans , . . .
[0037] The first term in Table 1 is associated with the mean combustor exhaust temperature. The second term is associated with the mean cooling effect of the airflow from the stator nozzles. The third term is the amplitude of the spectral temperature signal with respect to the spatial frequency associated with the flow from the combustor cans relative to the centerline of the turbine, and its higher harmonics. The fourth term is the amplitude of the spectral temperature signal with respect to the spatial frequency associated with flow from the stator nozzles relative to the centerline of the turbine, and its higher harmonics. The final term represents side bands that result from the non-linearity produced by the mixing of the fluid flow streams from the combustor cans and the nozzles. The spectrum is illustrated in FIG. 4 for a machine with 14 combustor cans and 48 nozzles. With 27 thermocouples, all high frequency content above the Nyquist limit of 13.5 is aliased and greatly confuses interpretation of the measured spectrum.
[0038] The method developed in the present invention to characterize the spectral frequency as a function of the effects of the combustor cans, the cooling nozzles, and their associated components, can be used to identify effective temperature sensors. Specifically, a distributed gradient thermocouple system 30 of the present invention is shown in simplified form in FIG. 2. The system 30 includes a plurality of spaced gradient thermocouples 31 having coupling leads 32 for transmission of an electrical signal to analysis equipment (not shown). The thermocouples 31 are preferably spaced about the turbine exhaust duct 17 in a manner similar to that used in the prior discrete thermocouple arrangement. It is to be noted that the gradient thermocouples 31 may be separated from one another around the perimeter of the exhaust duct 17 or they may overlap in one or more locations, in accordance with the desired filter function. The number of thermocouples 31 used is dependent upon the particular turbine characteristics and specifically spatial frequencies to be detected. Further, the gradient thermocouple system 30 is one among other options to address the aliasing problem. Another is a resistance thermometer to be described.
[0039] An important aspect of the distributed gradient thermocouple system 30 of the present invention is the make-up of the gradient thermocouples 31 shown in FIG. 3. They are formed as composites of materials having differing thermoelectric coefficients. Each of the gradient thermocouples 31 is formed of a mixture of two or more such materials. Further, each is formed with a varying ratio of the mixture of materials along the length of the thermocouple 31 . That is, for example, material “A” may be the composition of one of the coupling leads 32 . The end 33 of the thermocouple wire that joins to it is 100% material A. The second coupling 32 is formed of material B and the end of the other thermocouple wire joined to it is 100% material B. Along the thermocouple wire towards end 34 , the first thermocouple wire has gradually increasing amounts of material B added to the base material A and the second thermocouple wire has gradually increasing amounts of material A added to the base material B. At end 34 , both thermocouple wires are arranged to have identical compositions, nominally 50% each of materials A and B. Of course, a variety of materials of different thermoelectric coefficients may be employed in a variety of ratios to provide thermocouples 31 with selectable outputs producing the desired filter function along the thermocouple length. Standard thermocouple materials with appropriate continuously variable solubility in each other, such that a smooth variation of thermoelectric coefficient is obtained, are to be employed.
[0040] This arrangement of materials of differing thermoelectric coefficients provides a sensor with the desired characteristics. Differential temperature changes along the length of each gradient thermocouple 31 produce differential contributions to the electromotive force, EAB, sensed at the junction with leads 32 . The differential contributions, dEAB, for the -example of two materials A and B, is proportional to the difference between the thermoelectric coefficients for each of the materials at the composition of materials existing at that point along the thermocouple wire. This can be characterized by Equation (15), in which “a” is the local thermoelectric coefficient of the material, “x” is a specific location along the length of the thermocouple, “L” is the length of the gradient thermocouple, “T” is the local temperature, and subscripts “a” and “b” refer to the two thermocouple wires:
E AB =∫[α a ( x )−α b ( x )]( dT ( x )/ dx ) dx Eq. (15)
[0041] Assume for purposes of one example that there is a gradient in material composition between ends 33 and 34 so that the following gradient in differential thermoelectric coefficient is produced:
α a ( x )−α b ( x )=(α a (0)−α b (0))(1 −x/L ) Eq. (16)
[0042] Since the thermocouple wires are 100% materials A and B at end 33 where x=0, we have α a (0)=α A and α b (0)=α B or, α a (x)−α b (x)=α AB (1−x/L), where Δα AB =α A −α B . Substituting Equation (16) into Equation (15) and expanding by parts results in Equation (17):
E AB =Δα AB * (1/ L )∫ T ( x )− T (0) dx Eq. (17)
[0043] Equation (17) clearly indicates that each of the gradient thermocouples 31 responds to the spatially averaged temperature differential experienced along its entire length L. It is to be noted that extension wires 32 and/or cold junctions may be added to the thermocouples 31 to produce average temperature values in relation to a cold-junction temperature, if one is to be measured.
[0044] The array of gradient thermocouples 31 of the system 30 provides a filtering system that acts to suppress the amplitude of higher frequency signals associated with the harmonics of the turbine's standard components. This may be understood as follows. Consider a gas turbine exhaust temperature pattern described by the 2-r periodic function T(θ); T(θ)−T(θ+2π), where E is the azimuthal angle around the turbine. An exhaust pattern sensor having a spatial filter function F(θ) yields a measured temperature M(θ). T(θ), F(θ), and M(θ) are related to one another through the convolution M(θ)=∫F(θ−φ)T(φ)dφ. Invoking the convolution property of the Fourier transform, M(n)=F(n)T(n), where n is the spatial frequency and M, F, and T are Fourier transforms of M, F, and T, respectively.
[0045] For the gradient thermocouple of the present invention as shown in FIG. 2, whose action is expressed by Equation (17), the filter function is F(θ)=0 for |0|>π/n thermocouples , and F(θ)=n thermocouples /2π for |θ═≦π/n thermocouples . The standard Fourier transform for the filter function associated with the distributed gradient thermocouple system of the present invention is presented in Equation (18) in which n is the spatial frequency, revolutions −1 :
F ( n )= n thermocouples /Trn *sin( πn/n thermocouples ) Eq. (18)
[0046] Satisfactory results are obtained in the case when n thermocouples is chosen to equal the number of combustor cans. Note that this is a significantly smaller number of thermocouples then in the existing art discussed. The resulting filter spectrum is shown in FIG. 5. Note that the Nyquist limit is now n thermocouples /2. Observe that from Equation (18) and from FIG. 5 that the dominant signals, the fundamental and harmonics of the combustor can spectrum, are totally rejected in this arrangement. The remaining high frequency content associated with the cooled nozzles is significantly reduced in amplitude. For example, for a turbine 10 with 48 nozzles, 14 combustor cans, and 14 thermocouples 31 , the signal amplitude of the typical pattern is reduced by a factor of |F(η=48)|=(14/48*π)*sin(48*π/14)=0.09. All of the expected high frequency content is therefore significantly attenuated and when aliased to frequencies below the Nyquist limit, it no longer obscures the low frequency signals produced by genuine, discrete combustor defects.
[0047] Alternative filter functions may be developed by those skilled in this field. The objective of the present invention is to provide a method and at least one proposed system for recognizing the spectral patterns associated with typical turbine structures and providing a filter mechanism for masking high frequency fundamental and harmonic that can otherwise mask defects to be detected and to do so without significantly increasing the number of measuring devices. The gradient thermocouple system 30 of FIG. 2 is one such system. Manipulation of the ratios of the differing materials and their associated thermoelectric coefficients may be used to tailor specific filter characteristics of the gradient thermocouple system 30 .
[0048] An alternative effective filter function may be provided using a resistance thermometer. A resistance thermometer system may be deployed around the turbine exhaust duct 17 in the same manner as described for the gradient thermocouple system 30 shown in FIG. 2. Instead of being formed of two or more materials of differing thermoelectric coefficients, each resistance thermometer of the system is a wire or a wound wire package. The resistance thermometer has a resistivity ρ at any one point x along its length L between a first end A and a second end B that is dependent upon the temperature according to ρp(x)=ρ 0 +β(T(x)−T 0 ), where ρ 0 is the resistivity at reference temperature T 0 and β is the temperature coefficient of the resistivity. Equation (19) describes the resistance across the resistance thermometer of constant cross sectional area A. As a result, the resistance thermometer provides an alternative filter function that markedly reduces the strength of the turbine's typical spectral pattern.
R AB =ρ 0 ( L/A )+( β/A )*∫ T ( x )− T 0 dx Eq. (19)
[0049] More complex filter functions may be obtained by manipulation of cross sectional area and other features of the resistance thermometer.
[0050] The foregoing has described a method for characterizing the spectral pattern of a turbine exhaust duct temperature. Additionally, it has described two sensor types each designed to introduce a filter function into the temperature measurement analysis to limit the spectral frequency bandwidth. In that way, relatively small-scale structural anomalies observable from deviations in the turbine exhaust gas temperature profile will not be masked by aliased signals associated with normally occurring exhaust gas temperature patterns. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A method for characterizing the parameters of a normally occurring turbine exhaust gas temperature profile is provided. From that characterization the characteristics of a filter function to eliminate or significantly reduce the strength of aliased signals from that normally occurring pattern are established. Sensors to provide filtering functions for that purpose include a distributed gradient thermocouple system and a resistance thermometer system. Examples of such sensor systems are disclosed. The method and related sensors improve the detection limits associated with exhaust gas temperature profiles used to monitor, diagnose, and control gas turbines.
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BACKGROUND AND SUMMARY OF THE INVENTION
1. Technical Background
The present invention relates generally to medical devices, and more particularly to a vascular filter and delivery system.
2. Discussion
Vascular filters may be used for a variety of therapeutic applications, including implantable vena cava filters for capturing thrombus, or for distal protection during a vascular procedure.
The present invention relates to a filter system including a vascular filter that can be placed inside a body passage or cavity, such as a blood vessel, through a catheter consisting of a tubular basic body with a distal end, a proximal end and a lumen extending in between the ends. The vascular filter can be received in a compressed state inside the lumen, and the catheter is provided with an ejection device which can be used to eject the vascular filter from the distal end of the catheter. The filter may be implanted either permanently or temporarily.
Vascular filters are often made of an elastic or so-called "memory" material. Prior to actually positioning the vascular filter according to the known technique inside the blood vessel, the filter is arranged in a compressed state in the catheter. By means of an ejection member, the filter may be pushed from the open distal tip of the catheter into the blood vessel.
Many prior vascular filters expand from the compressed state inside the catheter lumen to an enlarged or deployed state, when released or deployed at the desired site for treatment. Some vascular filters tend to resiliently expand to that deployed state, which facilitates ejection from the catheter. Also, this resilient outward pressing may resist longitudinal movement from the desired site or compressive external forces.
It is also possible, however, that the resilient expansion by a filter may cause it to push off in a resilient manner against the distal end of the catheter. This possible longitudinal pushing or jumping tendency may cause a vascular filter to rest in some location other than the desired site. Consequently, accurate positioning of the filter inside the blood vessel may require some measure of skill.
Accordingly, it is desirable to provide a vascular filter capable of being more easily positioned accurately, and which tends to proceed smoothly and predictably during deployment.
One embodiment of the present invention is therefore to provide a vascular filter for use with a catheter to introduce the filter, wherein a brake is provided. The brake acts between the filter and catheter which may tend to control ejection by means of engaging the lumen. This engagement may of course be frictional, and the brake may be provided on the filter or the catheter, or may consist of cooperating components on both filter and catheter.
With a vascular filter and catheter system according to the present invention, an accelerating force exerted by the vascular filter on the distal tip of the catheter can be resisted or even negated by the brake. The brake preferably frictionally opposes the movement of the filter out of the catheter. Consequently any expansive accelerating force exerted during ejection of the filter is controlled, at least any particular expanisive force which may cause an unexpected longitudinal advance in relation to the distal tip of the catheter.
The brake may have any of a number of embodiments, as will be discussed in the detailed explanation below which are given by way of example. For example, the brake may have been biased, or the brakes may form a unit with the filter, or may act in unison with additional brakes.
These and various other objects, advantages and features of the invention will become apparent from the following description and claims, when considered in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an external perspective view of a vascular filter and catheter system, arranged according to the principles of the present invention and in a position of use;
FIGS. 2 and 3 are partial perspective views of a vascular filter and catheter system according to one embodiment of the present invention, showing operation of a braking system;
FIG. 4 is a perspective view of a vascular filter, showing another embodiment of the present invention;
FIG. 5 is a partial perspective view of a vascular filter and catheter system arranged according to the principles of the present invention, after the filter has been ejected from the catheter;
FIG. 6 is a perspective view of a vascular filter, according to another embodiment of the present invention; and
FIG. 7 is a partial perspective view of the vascular filter and catheter system of FIG. 6, after the filter has been ejected from the catheter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiments of the present invention is merely illustrative in nature, and as such does not limit in any way the present invention, its application, or uses. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention.
Referring to the drawings, in FIG. 1 a vascular filter 1 according to the present invention has been illustrated. In the situation illustrated, the vascular filter 1 has just been introduced into a blood vessel 2 by means of a catheter 3, which is substantially hollow. In the distal tip 4 of the catheter 3, at least one vascular filter was initially arranged in a compressed state. As an alternative (not illustrated), it is also possible that the filter is pushed along the entire length of the catheter from its proximal end to its distal end, after the catheter distal end has been advanced to the desired position. Preferably the filter is packed, in a compressed state, in transport packaging forming a covering. The vascular filter may be ejected from the distal tip 4 of the catheter 3 by means of a pushing wire 5 and introduced into the blood vessel. Due to release from the radially compressive force imposed by the lumen at the distal tip 4 of the catheter 3, the vascular filter 1 will tend to expand resiliently to obtain an expanded shape.
The vascular filter illustrated here comprises a number of ribs 6 extending in an axial direction in relation to the blood vessel 2 and along the internal wall hereof. These ribs 6 form an elongated body member. On either side of the ribs 6, filters 7 have been arranged each forming a grid shape. Liquid inside the blood vessel can pass through in an unimpeded fashion, but thrombus will tend to be intercepted by one of the two filters 7.
An advantage of this configuration is that it provides two chances at intercepting thrombus moving inside the blood vessel. In addition, due to the configuration of the ribs 6 which extend along the internal wall of the blood vessel 2, there should be no free ends of ribs which might stick into the internal wall of the blood vessel 2. The configuration of the vena cava filter according to the present invention illustrated is consequently designed so as to minimize any distress or damage to the blood vessel inside of which it has been arranged. As filters 7 have been arranged on either side of the ribs 6, and consequently a symmetrical shape has been obtained, there is no difference in the performance of the filter regarding the direction from which this vascular filter 1 has been placed inside the blood vessel 2.
As has been illustrated here clearly, the grid shape of each of the filters 7 is such that each of the ribs 6 is connected with a number of the components of these filters. Furthermore, each of the ribs 6 is connected with both filters 7 on either side. Due to this configuration, an added safety feature is that one of the ribs 6 or a component of one of the filters 7 may even break without a part of the filter 1 separating as a consequence.
In addition, tipping over or misalignment of either filter is less likely due to the more or less tubular shape into which the ribs 6 have been arranged, so that positioning of the vascular filter 1 inside the blood vessel 2 can take place with unprecedented stability and reliability.
The vascular filter 1 is preferably made of a very resilient material, like nitinol. Following ejection from the distal tip 4 of the catheter 3, filter 1 can expand and will be wedged against the internal wall 8 of the blood vessel 2.
In accordance with embodiment of the present invention shown in FIG. 1, two projections 9 form a resilient brake, arranged close to the proximal end of the vascular filter 1. These resilient projections 9 serve in particular to control ejection of the proximal section of the filter 1.
The projections 9 push against the inside of the catheter lumen close to the distal end of the catheter 3. The proximal filter 7 may tend to exert a force on the distal edge of the catheter 3 during ejection of the filter 1. In this way the projections 9 slow down the rate of expansion, and thus control the expansive force of the filter 7. Thus, accuracy when positioning a vascular filter according to the present invention may be improved.
In the embodiment shown in FIGS. 2 and 3, the projections 9 have been biased and extend in an outward radial direction in relation to the proximal end section of the filter 1, so that they push against the internal wall of the catheter 3, before escaping from the catheter themselves. These outwardly directed projections 9 consequently cause a braking force on the internal wall of the catheter 3, which is also directed outwards, so that control of the ejection of the filter 1 is effected.
The projections 9 form a unit with the filter 1, in the sense that each of the projections 9 has been made of material from the filter 1 located in between closely arranged cuts 10. The strips of material from the cuts 10 have subsequently been biased.
The filter 1 shown in the Figures has been made of a cylindrical unit. As an alternative, the filter may have been made from a plate-like unit or from an assembly of rib-like elements. Other options are possible as well. The filter may have been made of a resilient material, such as nitinol, which expands into the filter 1 with the shape illustrated here, following ejection of the cylindrical body 1'. As an alternative or as an addition, different types of memory materials, or other shape-memory metals, may be used.
The projections 9 are positioned radially opposite each other near to the proximal end of the filter 1, so that as a consequence a more uniformly distributed force is exerted on the internal wall of the catheter 3. To this end also, more than two projections 9 may be employed. In FIG. 2, the action of the projections 9, which push from the proximal end of the filter 1 against the internal wall of the distal end 4 of the catheter 3, has been illustrated schematically. As has already been mentioned before, this braking effect is preferably present especially during the release and expansion of the proximal filter 7 of the vena cava filter 1 according to the present invention. The projections 9 tend to slow down the ejection speed of the vascular filter 1, which is caused by elements of the proximal filter 7 pushing off against the extreme edge of the catheter 3 at the distal end hereof.
FIG. 3 shows the situation illustrated in FIG. 2 during a slightly later stage, and it is clear that the projections 9 pushed against the internal wall of the catheter 3 with a certain force. This situation is evidenced by confirming that the projections 9 protrude more than the internal dimensions of the catheter 3, in the state illustrated in FIG. 3. The compression of the projections 9 illustrated in 2 consequently ensures that a braking force is exerted on the internal wall of the catheter 3, which tends to control expansion of the proximal filter 7.
In the embodiment of the vascular filter 1 according to the present invention illustrated in FIG. 4, the brake is formed as a single loop 11. The loop 11 is resilient in the sense that it has a tendency to expand from the state drawn with continuous lines, in the direction indicated by arrow A, into the state drawn with dotted lines. In FIG. 4, the loop 11 has been illustrated in a state which corresponds to transportation inside the catheter 3 to the desired position. In contrast, the state of the loop 11 indicated with dotted lines corresponds to the relaxed situation, in which the vascular filter 1 has been ejected into the blood vessel. This last situation has been illustrated in greater detail in FIG. 5, in which the vascular filter 1 and the proximal filter 7 with its loop 11 have expanded in a controlled manner.
It should be noted that by the time that the bending points 12 of the loop 11 pass the extreme distal edge of the catheter 3, the majority of the vascular filter, and in particular proximal filter 7, will have already secured itself against the wall of the blood vessel. Any longitudinal force due to expansion of the loop 11, after the bending points 12 have been ejected beyond the distal tip of the catheter 3, is consequently cushioned by the proximal filter 7 being stabilized inside the blood vessel 2.
One advantage of the embodiment of a vascular filter according to the present invention illustrated in the FIGS. 4 and 5 is that the loop 11 may be used to later remove the vascular filter 1. Loop 11 can thus serve as a target for a hook-shaped extraction element, in order to remove the vascular filter 1. The hook-shaped extraction body (not shown) may engage the loop 11, and pull the entire vascular filter 1 back into a catheter enveloping the extraction element.
After reading the above, many possible embodiments which may be used to control the ejection speed during expansion of certain components, other embodiments and features will occur to one of ordinary skill in the field. All of these are to be considered as falling within the scope of the attached claims. It is for instance possible to use a vascular filter which has a different shape than the one described above. It is also possible to use a more conventional vascular filter without the double filter-function. The vascular filter also does not need to comprise ribs extending in an axial direction in relation to the blood vessel.
Also, one or more removal members may be added at the distal end of the vascular filter, which may have been embodied in the shape of a hook or a loop. Such a removal member can be gabbed from the other side or the distal side such that removal of the filter is possible.
It should be understood that an unlimited number of configurations for the present invention could be realized. The foregoing discussion describes merely exemplary embodiments illustrating the principles of the present invention, the scope of which is recited in the following claims. Those skilled in the art will readily recognize from the description, claims, and drawings that numerous changes and modifications can be made without departing from the spirit and scope of the invention.
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The present invention relates to a vascular filter which can be placed inside a body cavity, such as a blood vessel. A catheter may be used to deliver the filter, and consists of a tubular basic body with a distal end, a proximal end and a lumen extending between the ends. The vascular filter may be received in a compressed state inside the catheter lumen. The catheter may include an ejection device, which can be used to eject the vascular filter from the distal end of the catheter. Some portion of the vascular filter may tend to push off in a resilient manner against the distal end of the catheter, and the filter preferably includes a brake for acting on the catheter lumen, which tends to slow and control ejection from the catheter.
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This is a continuation-in-part of application Ser. No. 700,191, filed June 28, 1976 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an improved magnetic record member for use in magnetic recording devices such as a magnetic disc and a magnetic drum and a process for manufacturing same.
A magnetic recording device basically consists of magnetic heads for recording and reproducing (referred to simply as "head" hereinafter) and magnetic record members.
In general, recording and reproducing systems for the magnetic recording device may be classified into two types. In one system, upon the initiation of operation, a head is brought into contact with the surface of a magnetic record member and then, the record member is rotated at a given speed in a manner to provide a spacing between the head and the magnetic record member surface, thereby enabling the recording and reproducing operations. According to this system, upon completion of operation, rotation of the record member is stopped in a state where the head and record member are maintained in frictional contact with each other as is the case with the starting of operation.
In another system, after a magnetic record member is rotated at a given speed beforehand, a head is suddenly urged against the record member surface to provide a spacing due to an air layer created between the head and the record member so as to perform the recording and reproducing operations. As a result, the latter system brings the head and record member into frictional contact with each other when the head is urged against the record member surface.
Such frictional contact tends to harm the head and the magnetic record member so that satisfactory recording and reproducing operations become impossible. In addition, there is a case where the head unexpectedly contacts the record member surface so that the head and record member may both be damaged. Also, even if the head and record members are not damaged, a load is increasingly imposed on a spring for supporting the head as the contacting frequency of the head and record member is increased. For this reason, the spacing between the head and the recording surface of the member is varied. Besides these, a magnetic metal thin film medium used as the record member is possibly subjected to a high temperature and high humidity environment so that the record member surfaces experiences corrosion. This affects the magnetic characteristics of the member, and as a result, deteriorates the recording and reproducing characteristics thereof. Consequently, this requires the provision of a protective film or an over-layer on the surface of the magnetic metal thin film medium serving as one magnetic memory medium of the magnetic recording device.
The following characteristics must be required for the aforesaid protective film.
(1) A protective film medium should withstand an unexpected or inadvertent contact of a head with a magnetic record member during recording and reproducing operations (resistance to head-crushing).
(2) The load imposed on a spring should be small, which is caused by a frictional force for supporting the head exerted by frictional contact of the head with the record member at a plurality of contacting cycles (lubricity).
(3) Even due to such frictional contacts at a plurality of contacting cycles, the protective film medium should be maintained in a state which is free of damage and peeling (anti-abrasion characteristic).
(4) Even at high temperature and high humidity conditions, the protective film medium should protect the magnetic metal thin film medium so as to insure desired recording and reproducing characteristics (resistance to environmental conditions).
(5) The protective film medium should not impair the magnetic characteristics of a metal substrate including the magnetic memory medium.
U.S. Pat. No. 3,466,156 teaches the use of a polymer film and a wax lubricant film as a protective film formed by coating polyamide resins and ceresin wax. However, the use of this protective film has several disadvantages. In other words, the polymer film and the wax lubricant (film) are easily flaked off by frictional contact of a head against a magnetic record member at a plurality of contacting cycles. In this manner, this protective film fails to meet the characteristics (2) and (3).
Moreover, it is known that SiO 2 is coated using a spattering process on a magnetic record member as a protective film. However, the film formed by spattering SiO 2 fails to meet the characteristics (1) and (2). Also, a successful attempt to meet the characteristics (1) to (5) is known in the technique for coating glass through a spattering process as a protective film. However, the use of the spattering process unavoidably brings about the difficulty in the manufacture on a mass production basis, and hence, the cost increase in the manufacture. Also, there is another disadvantage in that the size increase in the magnetic record member is accompanied with that of the target for spattering. For this reason, technical difficulty is encountered, with an unavoidable increase in the total cost of the apparatus.
It is an object of the present invention to provide a magnetic record member and a process for manufacturing the same free of the aforesaid shortcomings in the prior art magnetic record members.
BRIEF DESCRIPTION OF THE INVENTION
The present magnetic record member comprises an alloy disc, a non-magnetic alloy layer coated on the alloy disc and polished to a mirror surface, a magnetic metal thin film medium coated on the polished non-magnetic alloy layer and a polysilicate film coated on the magnetic metal thin film medium.
The present manufacturing process for the magnetic record member comprises the steps of: forming a film of a non-magnetic alloy on the surface of an alloy disc; polishing the non-magnetic alloy layer thus formed to a mirror surface; forming a magnetic metal thin film medium on the surface of the highly polished non-magnetic alloy layer; applying a solution of tetrahydroxy silane derived by hydrolysis of tetraalkoxy silane onto said film medium; baking the disc after having thus prepared the composite layers at a temperature of more than 100° C. in such a manner that variation in the magnetic property of the thin film medium will not adversely affect the recording and reproducing characteristics of the magnetic record member; and forming a polysilicate film on the thin film medium.
Also, the present magnetic record member comprises a mirror-polished alloy disc, a magnetic metal thin film medium coated directly on the alloy disc and a polysilicate film medium coated on the magnetic metal thin film is thus provided.
The present manufacturing process for the last described magnetic record member comprises the steps of: forming a magnetic metal thin film medium directly on the surface of the alloy disc polished to a mirror surface; applying a solution of tetrahydroxy silane derived by hydrolysis of tetraalcoxy silane onto said thin film medium; baking the disc after having thus prepared the layer at a temperature greater than 100° C. in such a manner that the variation in the magnetic property of the thin film medium will not give adverse effects on the recording and reproducing characteristics of the magnetic record member; and forming a polysilicate film on the thin film medium.
BRIEF DESCRIPTION OF THE FIGURE
The objects and other features of the present invention will be described more in detail in conjunction with the accompanying drawing which shows an end view of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the drawing, a magnetic record member 5 of the present invention comprises an alloy disc 1, a non-magnetic alloy layer 2 coated on the surface of the alloy disc 1, a magnetic metal thin film medium 3 coated on the highly polished surface or mirror surface of the non-magnetic alloy layer 2 and a protective film 4 made of polysilicate and formed on the thin film medium 3.
The present record member 5 is manufactured by the steps of: plating a non-magnetic alloy on the surface of the alloy disc 1; forming a magnetic metal thin film medium on the polished surface of the thus formed alloy layer 2 by a plating process; applying a solution of tetrahydroxy silane derived by hydrolysis of tetraalkoxy silane on the surface of the thin film medium 3; baking the disc after having thus prepared the composite layers at a temperature greater than 100° C. in a manner that variation in the magnetic property of the thin film medium 3 will not adversely effect the recording and reproducing characteristics of the magnetic record member; and thereby forming the polysilicate film 4, which is a polymer of tetrahydroxy silane, on the surface of the thin film medium 3.
The alloy disc 1 must be finished to a slightly topographic surface (no more than 50 μm (50 microns) in the circumferential direction and no more than 10 μm (10 microns) in the radial direction of the disc.
This is because an increase in topograph leads to a failure of a head to satisfactorily float or fly above the magnetic record member surface upon recording or reproducing with the result of variation in spacing of the head from the record member. This varies the recording and reproducing characteristics of the record member, either in cases where the head makes contact with the record member surface or in cases where the head is spaced from the member surface.
The surface of the non-magnetic alloy layer 2 plated on the surface of the alloy disc 1 is highly polished to a surface roughness less than 0.04 μm by mechanical polishing. It is to be noted that if a metal which may be polished to a mirror surface is used as the alloy disc 1, the alloy layer 2 is unnecessary. The thin film medium 3 adaptable for high density recording is placed on the surface of the alloy layer 2. The protective film 4 made of polysilicate protects the medium 3 from experiencing any frictional contact and chemical attack caused by prevailing temperature and humidity. The protective film 4 may be readily formed by applying a solution of tetrahydroxy silane derived by hydrolysis of tetraalkoxy silane onto the medium 3 which is rotated with the disc 1 and the layer 2, followed by drying and baking processes.
The higher the flying height of the head (i.e., the spacing between the head and the protective film surface, upon recording and reproducing of the magnetic record member), the more stable will be the record member against head-crushing. However, for the sake of recording and reproducing of the record member, a smaller spacing (spacing between the head and the surface of the record member, upon recording and reproducing) is more advantageous. For this reason, it is essential to minimize the thickness of the protective film 4. In this respect, a thickness of the order of 0.1 μm is preferable, considering the strength of the protective film 4. The range of the thickness of the protective film 4 can be taken up to 0.3 μm because the thickness exceeding the aforesaid limit of 0.3 μm causes cracking in the protective film due to stress created upon polymerization of tetrahydroxy silane. As will be described hereinafter, it is indispensable to bake the protective film 4 on the magnetic record member at a temperature more than 100° C., while the upper limit of the baking temperature depends on a thermally changing temperature of characteristics of the film medium 3. With the medium 3, uniformity of a coercive force is lost at temperatures over 300° C., thereby impairing the recording and reproducing characteristics of the record member. For this reason, the range of the baking temperatures must be set from 150° C. to 300° C. Temperatures higher than 250° C. cause magnetization in the non-magnetic alloy layer 2, resulting in a decrease in the reproduced output. However, temperatures above 250° C. will not vitally affect the above mentioned characteristics of the magnetic record member. Also, temperatures exceeding 350° C., however, cause cracking in the record member due to a difference in thermal expansion coefficients between the alloy disc 1 and the alloy layer 2.
An amorphous inorganic material having a structure approximating that of SiO 2 glass is coated on the surface of the record member 5 as the protective film 4. The amorphous material as used herein is a kind of an inorganic high molecular compound of a net structural formula shown below in which each Si-O bond consisting of covalent bonds and Si-OH . . . O bonds consisting of hydrogen bonds are linked together three-dimensionally (this material will be referred to as polysilicate, hereafter): ##STR1##
The solid lines represent the covalent bonds while the broken lines represent the hydrogen bonds in the above net structural formula.
The above mentioned polysilicate is produced by a dehydrating-condensation-polymerization of tetrahydroxy silane derived by hydrolysis of tetraalkoxy silane. The starting material for tetrahydroxy silane, i.e., tetraalkoxy silane is given in the formula of Si(OR) 4 , wherein R represents an alkyl radical, i.e., any one of methyl, ethyl, propyl and butyl radicals.
The tetraalkoxy silane is soluble in a low grade alcohol and is readily hydrolized by carboxylic acid to give the tetrahydroxy silane. This tetrahydroxy silane is highly activated so that it is difficult to isolate this from others, and is relatively highly stable in alcohol, particularly in methyl alcohol, ethyl alcohol, propyl alcohol or butyl alcohol. Upon application of an alcohol solution of tetrahydroxy silane to the surface of the magnetic metal medium 3 and upon evaporation of a solvent thereof, the polymer of the three dimensional net structural formula, i.e., polysilicate is formed as the film 4 on the surface of the medium 3 by the dehydrating condensation-polymerization of the silane radicals Si-OH as follows: ##STR2##
In this case, unreacted silanol-radical Si-OH remains in polysilicate, thereby enhancing the adsorption and occlusion effects thereof, and the unreacted silanol radical may be reduced in amount by baking the polysilicate at a high temperature. Thus, the density of the polysilicate will be further increased. As a result, polysilicate with strong covalent bonds of Si-O may be obtained rather than with weak hydrogen bonds of a silanol radical so that the hard protective film 4 may be produced. It is desirable from the viewpoint of hardness required for the film 4 that the polysilicate is heated at temperatures greater than 100° C. On the other hand, in order to obtain a surface characteristic with a lower frictional coefficient brought about by the adsorption and occlusion effects of water or oil due to the unreacted silanol radical, it is desirable to heat the polysilicate at temperatures less than 750° C. at which level the unreacted silanol radical disappears. The infrared-adsorption-spectrum analysis of this unreacted silanol radical reveals that an adsorption-spectrum of the silanol radical Si-OH appears at a frequency of 3400 cm -1 , and suggests that the unreacted silanol radical is contained in the polysilicate. However, in the case where the polysilicate is baked at temperatures greater than 750° C., the infrared adsorption spectrum of the silanol radical Si-OH disappears.
As will be described later, the prior art protective film consisting of SiO 2 film prepared by the spattering process has a tendency to readily cause head-crushing compared with the protective film 4 consisting of polysilicate prepared through the process of the invention, and has a degraded surface characteristic.
In contrast thereto, in the protective film 4 formed through the present process, the unreacted silanol radical confirmed by the infrared-adsorption-spectrum analysis is included. So, film 4 has an improved surface characteristic with a smaller frictional coefficient due to the adsorption and occlusion of water or oil into the silanol radical remaining in the film. For this reason, resistance to head-crushing, anti-abrasion property and lubricity for the magnetic record member 5 are consequently improved by using the film 4. Since an adsorbing force of water or oil into the silanol radical is so great that even if the record member 5 is heated to 200° C., there results no change in its resistance to head-crushing as well as in the anti-abrasion property.
A polysilicate produced by a dehydrating-condensation-polymerization of tetrahydroxy silane involves the following reaction:
Si(OH).sub.4 →SiO.sub.2 +2H.sub.2 O
however, this reaction does not proceed to the righthand direction completely, permitting unreacted Si(OH) 4 to remain as silanol radicals. More specifically, the weight ratio n of water produced due to said reaction is represented by equation (1) where α is the reaction rate and M is the molecular weight. ##EQU1## Also, the Si(OH) 4 -conversion weight ratio m of silanol radicals in non-volatile material is expressed: ##EQU2## In this case, because of the relationship of M H .sbsb.2 O =18, M Si (OH).sbsb.4 =96 and M SiO .sbsb.2 =60, equation (3) is obtained: ##EQU3## To measure the weight change of polysilicate film with respect to the baking temperatures, the experimental data shown in Table A was obtained.
Table (A)______________________________________BakingTemperatures n × 100 m × 100(degrees centigrade) (weight percent) (weight percent)______________________________________350 35 10200 30 29100 21 56750 37 2______________________________________
Table (A) shows that the polysilicate film baked at the temperature of 750° C. contains a mere 2% silanol radicals coinciding with the above mentioned analysis of the infrared absorption spectrum of the unreacted silanol radical.
Because of the above mentioned hardness of polysilicate and because of the absorption and occulsion effects of silanol radicals, the baking temperatures of a magnetic record member should be selected within the range of 100° C. to 750° C. Consequently, the Si(OH) 4 -converted weight percent of silanol radicals must lie in a range of 2% to about 56%. From the standpoint of practical use, however, the baking temperatures of said record member should be selected in a range of 100° C. to 350° C. It follows therefore that the Si(OH) 4 -converted weight percent of silanol radicals is in the range of about 10% to 56%.
The following examples illustrate the features of the processes for manufacturing the present magnetic record member 5, and descriptions therefor will be given in comparison with prior art examples.
PRIOR ART EXAMPLE 1
A disc-type aluminum alloy substrate was finished to a surface having a slight topograph using turning and heat-flattening processes. The topograph in this case should be less than 50 μm in the circumferential direction and 10 μm in the radial direction. Then a nickel-phosphorus (Ni-P) non-magnetic alloy was plated on the aluminum alloy substrate to about 50 micron-thickness. The Ni-P-plated film was then finished to a mirror surface having a surface roughness of less than 0.04 μm and a thickness of about 30 μm using a mechanical polishing process. Next, a cobalt-nickel-phosphorus (Co-Ni-P) magnetic metal alloy was plated as a magnetic memory medium on the surface of the Ni-P plated film to about 0.05 micron thickness. SiO 2 was then coated on the surface of the Co-Ni-P magnetic alloy film as a protective film to a thickness of about 0.1 microns using a spattering process. Thus, a magnetic record member was obtained for a magnetic disc device.
PRIOR ART EXAMPLE 2
A Ni-P non-magnetic alloy was plated on the surface of a disc-type aluminum alloy in a manner similar to that adopted in the prior art Example 1. Then, a cobalt-nickel-phosphorus (Co-Ni-P) alloy was plated on the surface of the (Ni-P) non-magnetic alloy layer. Borosilicate glass of a composition shown below was then coated as a protective film on the surface of the Co-Ni-P alloy layer thus plated to 0.1 millimeter thickness with the use of the spattering process, thereby providing a magnetic record member serving as a magnetic disc device:
______________________________________ SiO.sub.2 50.2% BaO 25.1% B.sub.2 O.sub.3 13.0% Al.sub.2 O.sub.3 10.7% As.sub.2 O.sub.3 0.4%______________________________________
EXAMPLES OF THE PRESENT INVENTION
EXAMPLE 1
A disc-type aluminum alloy was finished to obtain a surface having a slight topograph by turning and heat-flattening processes so that an alloy disc 1 of desired finish may be made. Then, a nickel-phosphorus (Ni-P) non-magnetic alloy was plated on the aluminum alloy surface to form a non-magnetic alloy layer 2 having about 50 micron-thickness. The surface of the Ni-P-plated film was polished to form a mirror finish surface, i.e., to obtain a surface roughness less than 0.04 μm and of about 30 micron-thickness using a mechanical polishing process. Then, a cobalt-nickel phosphorus (Co-Ni-P) magnetic metal alloy was plated thereon to provide a magnetic metal thin film medium 3 having about 0.05 micron-thickness. Next, a solution of a composition shown below was thoroughly mixed and filtered through a filtering film to remove precipitated SiO 2 or dust. The solution was applied onto the surface of the Co-Ni-P magnetic metal alloy layer through a spin coating process. More particularly, the disc-type aluminum alloy substrate on which the Ni-P and the Co-Ni-P film were plated in this order, was rotated at a speed greater than 200 r.p.m. (revolutions per minute) in a horizontal plane, while said solution having the above mentioned composition was being discharged from its reservoir to the disc surface. The discharged solution was thus spread over the disc surface toward its outer periphery due to the centrifugal force. When a solvent (ethyl and butyl alcohols) of the solution discharged on the disc surface was evaporated, a polysilicate film was formed on the disc surface as the protective film 4. The disc having the protective film 4 of polysilicate of 0.1 micron-thickness was then placed at a room temperature (about 25° C.) for a while so as to evaporate the solvent of ethyl and butyl alcohols remaining in the polysilicate film. In this manner, a protective film was formed on the disc surface for the magnetic disc device.
COMPOSITION (referred to above)
Ethyl alcohol solution including tetrahydroxy silane of eleven weight percent . . . twenty weight percent n-butyl alcohol . . . eighty weight percent.
EXAMPLE 2
In a similar process to Example 1 of the present invention, a Ni-P film and a Co-Ni-P film were plated in this order on an aluminum alloy disc surface. Then, a polysilicate film was formed to 0.1 micron-thickness on the disc surface using the spin coating process. The disc having the polysilicate film was then baked in an electric furnace at a temperature of 100° C. for eight hours.
EXAMPLE 3
After a polysilicate film was prepared on the disc surface similarly to Example 2 of the present invention, the disc was baked in an electric furnace at a temperature of 150° C. for five hours.
EXAMPLE 4
A polysilicate film was formed on the disc surface according to a similar process to Example 2 of the present invention, and then, the disc was baked in the electric furnace at a temperature of 200° C. for three hours.
EXAMPLE 5
Similar to Example 2 of the present invention, a polysilicate film was formed on the disc surface and then, the disc was baked in the electric furnace at a temperature of 250° C. for three hours.
EXAMPLE 6
Likewise, a polysilicate film was formed on the disc surface in a process similar to Example 2 of the present invention, and next, the disc was baked in the electric furnace at a temperature of 300° C. for one hour.
EXAMPLE 7
Similar to Example 2 of the present invention, a polysilicate film was formed on the disc surface, and next, the disc was baked in the electric furnace at a temperature of 350° C. for one hour.
EXAMPLE 8
According to a process similar to Example 1 of the present invention, a Ni-P film and a Co-Ni-P film were plated in this order on an aluminum alloy disc surface. Then, a Ni-P non-magnetic alloy film of 0.4 micron-thickness was formed by the plating on the disc surface, and after this, a polysilicate film was formed thereon to 0.1 micron-thickness by means of the spin coating process. Finally, the disc was baked in an electric furnace at a temperature of 200° C. for three hours.
As has been described previously, film thickness of polysilicate of more than 0.3 μm cannot be adopted because of cracking in the film.
As a result, as described in Example 8 of the present invention, the Ni-P non-magnetic alloy was plated on the surface of the Co-Ni-P magnetic film to a thickness of 0.4 microns. Then, polysilicate was applied onto the surface of the Ni-P non-magnetic alloy layer to a thickness of 0.1 micron so as to form a protective film of a total of 0.5 micron-thickness, i.e., the total thickness of the aforesaid Ni-P non-magnetic alloy layer and the polysilicate film formed on the surface of the Co-Ni-P magnetic metal thin film.
Operation tests were given to the respective magnetic discs made according to the prior art Examples 1 and 2 and Examples 1 to 8 of the present invention by repeating the start and stop operations during the recording and reproducing states in which each head is brought into frictional contact with the magnetic disc surface whenever the above mentioned start and stop operations are performed. In these tests, the following observations were measured:
(1) frequencies of the occurrence of head-crushing during the repeated operation tests.
(2) variation in the reproduced output through the head due to a plurality of frictionally contacting cycles of the head and magnetic disc, and
(3) observation of the protective film-peeling due to a plurality of frictional contact cycles of the head against the magnetic disc.
In addition, measurements were made of each magnetic disc produced according to the prior art Examples 1 and 2 and the present Examples 1 to 8 so as to check the following:
(4) variation in both reproduced output through the head and surface condition of the protective film, and
(5) uniformity of the reproduced output. Table 1 shows the above mentioned test results.
Table 1__________________________________________________________________________ characteristics Prior art Ex- (2) (4) amples and Ex- (1) vari (g) en- (5) amples of the head- ation peeled viron- vari- present in- crush- in out- area mental action in vention ing put (ratio) test output__________________________________________________________________________ prior art once per 10% 5% no <30% Example 1 100 change cycles noticed prior art Example 2 none none none " "PRESENT Example 1 " " 10% -- <30%INVENTION Example 2 " " none no " change noticed Example 3 " " " " " Example 4 " " " " " Example 5 " " " " " Example 6 " " " " " Example 7 " " " " > 30% Example 8 " " " " <30%__________________________________________________________________________
DESCRIPTION OF TEST RESULTS
Regarding characteristic (1), thirty thousand frictional contact tests of the heads against the magnetic discs given in all of the Examples were performed. In the course of the tests, flakes of the protective film were removed from the magnetic disc surface which caused head-crushing, and then, the tests were continued for another track of the same disc surface. However, since the magnetic disc completed by the prior art Example 1 caused head-crushing frequently, the tests were withheld after one thousand frictional contact tests. As a result, it was found that the head of the magnetic disc in the prior art Example 1 bit the disc surface, and continuous recording and reproducing operations became impossible at one hundred repeated frictional contact tests of the head against the magnetic disc.
In contrast thereto, in the cases of the prior art Example 2 and Examples 1 to 8 of the present invention, there occurred no biting of the head into the magnetic disc surface to an extent where the Co-Ni-P magnetic metal thin film medium was reached. Therefore, the recording and reproducing operations were continued normally.
Concerning the characteristic (2), a reproduced output voltage through an amplifier was observed with an oscilloscope during flying or floating movement of the head placed above the magnetic disc. Then, the comparison of an initial output with an output after thirty-thousand repeated frictional contacts tests of the head against the magnetic disc was performed. The test results revealed that the magnetic discs produced according to the prior art Example 2 and the present Examples 1 to 8 are free of any decrease in output within an accurate range of measurements. In contrast, the disc obtained by the prior art Example 1 caused head-crushing with the result that the frictional contact tests of the head against the magnetic disc were interrupted before reaching an intended 30,000 cycles. In other words, the aforesaid operation tests were repeated to 1,000 cycles with the result of ten percent output decrease.
As regards the characteristic (3), the frictional contact test of the head against the magnetic disc was repeated to 30,000 cycles. Next, head traces on a track on the magnetic disc surface were observed with a microscope for the measurement of peeled area of the magnetic disc surface, but no peeling was observed on the magnetic disc surface prepared by the prior art Example 2 and the present Examples 2 to 8.
On the other hand, the magnetic disc obtained in the present invention, Example 1, had a peeled area equal to ten percent of the head contacting area on its track. However, in the case of the prior art Example 1, the frictional contact test could not be carried out up to 30,000 cycles due to head-crushing so that the test was stopped at 1,000 cycles. The resultant peeled area was found to be about 5% of the head contacting area on its track.
As for the characteristic (4), the environmental test was carried out as follows: The environmental test consisting of two cycles of test performed at a temperature of 65° C. and at a relative humidity of 90% for four hours and of one cycle at a temperature of -40° C. (minus forty degrees Centigrade) for three hours was repeated ten times. The test results revealed no change in magnetic disc surfaces prepared according to the prior art Example 1 and the present invention, Examples 2 to 8.
It is to be noted that the environmental test was not performed for the magnetic disc prepared in the present invention, Example 1, because the disc is subjected to heating to 65° C.
For the characteristic (5), variation in reproduced output (ratio of the difference between the maximum and the minimum head-reproducing outputs obtained from the same track to the maximum output thereof) was checked. As a result, variation in the reproduced output more than thirty percent was not found in the magnetic discs of the prior art Examples 1, 2 and Examples 1 to 6 of the present invention while variation in the reproduced output over thirty percent was found in the magnetic discs of the present invention, Example 7. This is due to the fact that the baking of the magnetic disc at a high temperature caused the lack of uniformity in characteristics of the magnetic record member.
As is apparent from the foregoing, the magnetic discs having protective films of SiO 2 formed by the spattering process as in the prior art examples are not suitable for the magnetic record member requiring high reliability.
It was found that magnetic discs having the protective films of polysilicate given in the present examples would have high reliability within a baking temperature range of 100° C. to 300° C. as well as excellent recording and reproducing characteristics.
In addition, magnetic discs having the protective films prepared by the glass-spattering process used in the prior art Example 2 can provide sufficiently high reliability as well as excellent recording and reproducing characteristics. However, the manufacturing yield of the conventional discs per unit hour is 1/10th that of the present magnetic discs having the polysilicate protective films produced on a mass-production basis. Also, the spattering process is accompanied with the use of a complicated vacuum system which requires the expenditure of much time and effort, and is accompanied with the use of a costly spattering apparatus for preparing a protective film on a large size magnetic disc.
On the other hand, the polysilicate films may be formed at a low cost in such a simple manner that an alcohol solution of tetrahydroxy silane may be applied to the base disc surface using the above mentioned spin coating method, alcohol in the alcohol solution may be evaporated, and the thus obtained discs may be baked in the atmosphere. For this reason, the protective films consisting of polysilicate are excellent in characteristics required for the protective films and mass-producibility, and advantageous in manufacturing cost and freedom of size restriction on a magnetic record member.
In the aforesaid respective Examples of the present invention, the aluminum alloy disc, the Ni-P alloy layer, and the Co-Ni-P were used as the alloy disc 1, the non-magnetic alloy layer 2 and the magnetic metal thin film medium 3, respectively, with the result that the baking temperature of the protective film 4 was restricted to a temperature no greater than 300° C. However, it is apparent that by a combination use of an alloy disc having less thermal change, a non-magnetic alloy layer and a magnetic thin film medium, such a temperature restriction can be removed.
In the above mentioned present Examples, in place of the aluminum alloy disc prepared for the disc 1, a titanium alloy may be used, which is allowed to be polished to a surface. Consequently, the non-magnetic alloy layer 2 can be omitted. Next, a magnetic metal thin film medium may be formed on the thus prepared alloy disc by the plating process, and then, a protective film of polysilicate may be formed thereon.
Moreover, in the present invention, Example 8, the Ni-P non-magnetic alloy was plated on the aluminum alloy disc surface, and then the Co-Ni-P magnetic metal thin film medium was plated on the Ni-P non-magnetic alloy polished to a desired surface finish. The Ni-P non-magnetic alloy was then plated thereon followed by the coating of a polysilicate film. Although the protective film was coated on the surface of the Co-Ni-P magnetic metal thin film medium, it is possible to form a protective film of a thickness greater than 0.3 microns by forming the polysilicate coating on the surface of the Ni-P non-magnetic alloy. More particularly, a polysilicate film of more than 0.3 micron-thickness can not be formed because of cracking, while the Ni-P non-magnetic alloy may be plated to the uniform thickness of several tens of microns. In addition, even in the case of Example 1 of the present invention in which the polysilicate film can not be sufficiently hardened, the Ni-P non-magnetic alloy and the polysilicate may be plated in this order on the surface of the Co-Ni-P magnetic metal thin film medium so as to protect the Co-Ni-P magnetic metal medium. More specifically, if a part of the polysilicate film is peeled off, the Ni-P non-magnetic alloy protects the above mentioned thin film medium. Namely, the use of the Ni-P non-magnetic alloy alone may not adequately protect the Co-Ni-P magnetic metal thin film medium because of head-crushing caused by the Ni-P non-magnetic alloy layer. However, the Ni-P non-magnetic alloy has a close relationship with the Co-Ni-P magnetic metal thin film medium in composition and position in the periodic table. For this reason, the former may be firmly plated on the surface of the latter. Thus, if the polysilicate film which reluctantly causes head-crushing is coated on the surface of the Ni-P magnetic alloy layer, the Co-Ni-P magnetic metal thin film medium may be well protected thereby, even if a part of the polysilicate film is peeled off.
Although the present invention has been described above in conjunction with a number of Examples, various modifications and alternatives may be made within the scope of the present invention and the scope of the invention is defined by the claims and not by the Examples recited hereinabove.
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The thin film magnetic medium of a magnetic disc, and the read/record head employed with the disc are both protected from abusive use and physical damage as well as chemical damage (including damage due to heat and/or humidity) by a polysilicate layer, formed upon the magnetic medium. Inexpensive methods of forming the protective film (which methods lend themselves to mass production) are described. These methods are a small fraction of the cost of present day techniques.
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FIELD OF INVENTION
This invention relates to magnetic knife sheaths. More specifically, the invention allows for easy transport and protection of knives in a relatively small magnetic sheath. The sheath has two magnetically charged faces that attract each other, protecting and holding the knife blade securely between them.
BACKGROUND OF THE INVENTION
Professional chefs frequently carry their knives from place to place. During transport it is necessary to protect the knife blades, both to keep the blade sharp and to prevent accidentally cutting oneself. In addition, individuals at home frequently use some sort of sheath to protect and secure kitchen knives.
In order to transport their knives, professional chefs typically use a lightweight, hard plastic sheath that holds the knife blade. The plastic sheath is shaped like a long and very narrow taco shell. The bottom side is sealed. The other three sides have very narrow slots. The knife blade must be forced into the narrow slot, between the plastic faces. The knife blade is held in place simply by the narrowness and tightness of the plastic slot.
The plastic sheath has several disadvantages. A knife blade is not immobilized between the plastic faces. The knife blade can move against the bottom of the plastic sheath, dulling the knife blade.
In addition, the plastic sheaths are solid and inflexible. They cannot be opened. Therefore, the plastic sheaths cannot be cleaned or sterilized. Chefs are often tired at the end of a long night of work, and frequently place their knives into the plastic sheaths without thoroughly cleaning the knife blade first. Because the plastic sheaths cannot be opened or cleaned, particles of food from the dirty knife blade may remain inside the plastic sheath. The invention makes it possible to open and clean the knife sheath.
Furthermore, because the plastic sheath cannot be opened, chefs may cut their hands when placing the knife blade into the plastic sheath. Placing the knife blade in the plastic sheath involves holding the plastic sheath in one hand and the knife in the other. The chef then lines up the knife blade with the very narrow slot in the plastic sheath, and pushes the knife blade into the plastic sheath. If the chef misaligns the knife blade and the slot in the plastic sheath, the knife blade may be pushed into the palm of the hand that is holding the plastic sheath. The knives are very sharp and will frequently cut the chef's hand. It is much easier and safer to place a knife blade into the invention because the invention may be opened.
Individuals at home also wish to protect and secure their knifes. The magnetic knife holders most commonly used in the home involve a large magnet, which is attached to a wall or cabinet. Alternatively, knives are frequently placed in some sort of wooden block, or some other solid material that holds the knives as a group on a countertop. These various types of knife holders take up a lot of space on a wall or cabinet. In addition, they are difficult to clean. None of the prior inventions provide a lightweight, compact means for securing and protecting knife blades.
BRIEF SUMMARY OF THE INVENTION
The present invention involves a devise for securing knives comprising two magnetically charged faces moveably attached to each other by a magnet support with a central hinge, wherein, when in the closed position, the magnetically charged faces cover all, or a part of, the knife blade, thereby securing and protecting the knife blade
OBJECTS AND ADVANTAGES
Several of the objects and advantages of the present invention are described below.
One object of the invention is to provide an inexpensive, lightweight, small and moveable means for securing and protecting knife blades.
It is a further object to immobilize knife blades during transport and storage to prevent dulling the knife blade.
It is still a further object to allow the knife sheath to be cleaned and sterilized.
It is still a further object to permit the knife sheath to be opened and closed.
It is still a further object to prevent or reduce accidents by making it easier to place the knife into the sheath.
Further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 1 A and 1 B show the invention in the open position, looking down from directly above, and also show end-on sectional views of the invention.
FIG. 2 is a perspective view of the invention in the closed position with a knife blade, drawn in phantom outline, secured between the magnetically charged faces.
FIG. 3 is a perspective view of the invention in the open position.
FIGS. 4, 4 A and 4 B are perspective views of the invention in the closed position showing differently sized tabs on the magnet supports to facilitate opening the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, there are two magnetically charged faces 10 . The magnetically charged faces 10 are preferably made from lightweight magnets. Each magnet 10 is either secured between magnet support 12 and interior face 12 B (as shown in FIG. 1 ), or attached directly to a magnet support 12 without an interior face 12 B (as shown in FIG. 3 ). The inventor currently prefers making the magnet support 12 and interior face 12 B from flexible vinyl. However, the magnet support 12 and interior face 12 B may also be made of a wide variety of materials that may be repeatedly bent without breaking, for example, high-density polymers, rubber, or leather. In the preferred embodiment, the magnet support 12 will have a design printed directly on the flexible vinyl, high-density polymer, rubber, leather or other flexible material. Alternatively, the magnet support 12 may have no design, or may have a design that is laminated to the exterior surface of the magnet support.
The magnetically charged face 10 is placed adjacent to magnet support 12 . FIG. 1 shows that two magnetically charged faces 10 are sealed between magnet support 12 and interior face 12 B. Magnet support 12 and interior face 12 B are preferably made out of the same material. In the embodiment shown in FIG. 1, each magnetically charged face 10 is sealed on all four sides between magnet support 12 and interior face 12 B. The seal between magnet support 12 and interior face 12 B is preferable created through the application of heat, but the seal may also be created by adhesive or sealant. The seal should be susceptible to washing and sterilizing, thus permitting the entire invention to be cleaned and sterilized.
In another embodiment, shown in FIG. 3, the invention does not contain an interior face 12 B. Instead, each magnetically charged face 10 adheres to magnet support 12 by virtue of either the application of adhesive, such as urethane, acrylic, epoxy glue, or other adhesive, or the application of heat to form a thermal bond. The adhesive or thermal bonding should be susceptible to washing and sterilizing, thus permitting the entire invention to be cleaned and sterilized.
In the embodiments shown by FIG. 1 and FIG. 3, the two magnetically charged faces are placed in such a manner that when the invention is in the closed position, as shown in FIG. 2, the magnetically charged faces 10 are magnetically attracted to each other. The magnetic attraction of the magnetically charged faces will securely hold the knife blade, as shown in FIG. 2 .
The invention contains a flexible portion, living hinge, or central hinge 12 A located between the magnetically charged faces 10 . FIG. 4, FIG. 4 A and FIG. 4B indicate the location of the central hinge by dashed lines. The central hinge 12 A is sufficiently flexible to allow hinge-like motion so that the invention may be repeatedly opened and closed. FIG. 1 and FIG. 3 show the invention in the open position. The central hinge 12 A allows the magnet support 12 to move from the open position to the closed position shown in FIG. 2 .
When in the closed position, one magnetically charged face 10 lines up with the other magnetically charged face 10 ; that is, the magnetically charged faces 10 are essentially opposite to each other, and form a mirror image of each other. The magnetically charged faces 10 are aligned on the magnet support 12 so that when central hinge 12 A is in the closed position (see FIG. 2) the magnetic poles of magnetically charged faces 10 are magnetically attracted to each other. This magnetic attraction causes the central hinge 12 A to remain in the closed position, thereby holding and securing the knife blade 18 in place. The inventor currently prefers to make the central hinge 12 A out of the same material used for the magnet support 12 , with the same cross-sectional thickness. Alternatively, the central hinge 12 A may be a living hinge, or may be made by scoring, or by a mechanical hinge.
The size and shape of the magnetically charged faces 10 , the magnet support 12 and the interior face 12 B can be varied as needed to match the different sizes of different knife blades. Typically, the entire knife blade will be completely covered by the magnetically charged faces 10 , the magnet support 12 , or the interior face 12 B. However, it is not absolutely necessary to have the entire knife blade covered by the magnetically charged faces 10 , the magnet support 12 , or the interior face 12 B. Some knife blades, for example, large or curved knife blades, may be secured and protected by the invention as long as the sharp edge of the blade is covered by the magnetically charged faces 10 , the magnet support 12 , or the interior face 12 B.
FIGS. 4, 4 A and 4 B shows additional embodiments of the invention. FIG. 4 shows an embodiment in which one edge of the magnet support 12 extends beyond the other edge of the magnet support 12 to form a tab 14 . The size and shape of tab 14 can be varied. For example, tab 14 may extend the entire length of magnet support 12 , as shown in FIG. 4 . Alternatively, the tab 14 may be shorter than the length of magnet support 12 to form a tab 14 A, as shown in FIG. 4 A. Another alternative is to place the tab 14 B along the short edge of magnet support 12 , as shown in FIG. 4 B.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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The invention is a magnetic knife sheath that permits easy transport and protection of knives in a relatively small sheath. The sheath has two magnetically charged faces that attract each other, protecting and holding the knife blade securely between them.
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TECHNICAL FIELD
A framing system for supporting panels for use as walls, partitions, office landscaping, displays such as at shows, seminars, meetings, exhibits, trade shows and the like, and in particular to a framing system which is compact for storage and delivery but which is easily set up without tools.
BACKGROUND
In the past, panels for trade shows were either one large piece, which was cumbersome to store and deliver, or were made up of fold-up units using complicated arrangements of cables and hinges for set-up, or which used modular units requiring different types of pin connectors and which had to be disassembled to change panels.
There are also a very large number of different framing systems known using framing members of various cross-sectional shapes and various types of corner brackets. .The following U.S. patents show known framing systems: Des. 253,552, U.S. Pat. Nos. 3,783,543, 4,195,681, 2,201,577, 2,666,508, 2,784,813, 2,447,347, 3,648,393, 3,709,533, 3,124,858, 2,504,700 and 2,923,351.
It is an object of the present invention to provide a framing system that can be delivered in a small size and can be easily set up without tools.
It is another object to provide a framing system wherein the edges of the supported panels do not have to be finished because they are hidden by and protected by a finished framing member.
It is a further object to provide a framing system using a framing member of different lengths but of identical cross-sectional shape and using joiner strips of different lengths but of identical cross-sectional shape and which can provide a very large variety of different framing arrangements by simply varying the lengths of the framing members and of the joiner strips.
It is another object to provide a framing system in which the panels can be easily hingedly connected together to vary their angular relationship.
It is a further object to provide a framing system in which a wide variety of different types of panels can be connected to the frames, on one or both sides, and in a variety of different ways and which panels can be removed and replaced after the frame system has been set up, without having to disassemble it in any way.
It is another object to provide a framing system in which an electrical cord can be included in the frame members and electrical outlets can be provided on the frame members where desired.
BRIEF SUMMARY OF THE INVENTION
A framing system including a framing apparatus, method and framing member. The framing member is substantially H-shaped in cross-section providing an inner U-shaped channel (facing or opening radially inwardly of the frame toward the supported panel) and an outer U-shaped channel facing or opening radially outwardly away from the frame.
The framing apparatus includes specific frames and also includes a group of frames assembled together by a joiner strip. For frames arranged vertically one above the above, a horizontally oriented joiner strip is simply placed, part in each of the adjacent, facing outer channels. For frames arranged horizontally side-by-side a vertically oriented joiner strip is also placed, part in each of the adjacent, facing outer channels, however, in addition, in order to hold the two frames together, the joiner strip is held to each frame by an upper hinged connector and a lower clip, each of which fits into the upper and lower hollow ends, respectively, of the joiner strip. The joiner strip is preferably a tubular member of rectangular cross-section. In one embodiment, the joiner strip is made of two separate, smaller joiner strips hinged together, whereby the adjacent connected frames (and their panels) can be positioned at an angle to each other on the floor, which not only helps stabilize the frames but also provides more display area in a given space.
The method includes the method of easily setting up the framing apparatus without tools.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood by reference to the following detailed description thereof, when read in conjunction with the attached drawings, wherein like reference numerals refer to like elements and wherein:
FIG. 1 is a front, perspective view of a set-up framing system according to the present invention;
FIG. 2 is a top view of the system shown in FIG. 1;
FIG. 3 is a cross-sectional, perspective view through the framing member according to the present invention;
FIG. 4 is a partial cross-sectional, perspective, exploded view, taken along line 4--4 in FIG. 1, showing two frames assembled together by a horizontal joiner strip;
FIG. 5 is a partial cross-sectional view showing two frames connected to the bottom of a joiner strip;
FIG. 6 is a partial cross-sectional view showing two frames connected to the top of a joiner strip;
FIG. 7 is a partial cross-sectional view showing two frames connected to the top of a hinged joiner strip;
FIG. 8 is an enlarged partial cross-sectional front view of one corner of a frame;
FIG. 9 is an enlarged cross-sectional end view of one corner of a frame, taken along line 9--9 of FIG. 8;
FIG. 10 is a front, partial cross-sectional view showing one embodiment of the present invention of a cross-strip added to the frame; and
FIG. 11 is a partial cross-sectional side view showing how an item connects to the cross-strip of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawings, FIGS. 1 and 2 show a framing apparatus 10 set up and free standing and including two full size frames 12 and 14, two half size frames 16 and 18, a different removable panel 20, 22, 24 and 26 on each of the frames 12, 14, 16 and 18, respectively, a pair of vertical hinged joiner strips 28 and 30, and a horizontal joiner strip 32. The framing apparatus 10 can be easily and quickly set from the individual pieces and without tools. The opposite sides of the frames 12, 14, 16 and 18 can also be provided with panels if those sides are also to be in view. The frames can be of any desired size, however, in one preferred embodiment frame 12 is about seven feet high, four feet wide and 23/4 inches thick. Any desired number and arrangement and size of frames can be used. FIGS. 1 and 2 also show a finishing strip 35, which will be described in more detail below.
The panels can be attached to the frames by any suitable means (as described in more detail below), but preferably by a series of spaced-apart Velcro or other self-adhering strips 34, only three of which are shown in FIG. 1. In this way, the panels can be easily removed and replaced with different panels. The panels can be made of any desired material, such as glass, plexiglas, press-board, wood, etc., however, the presently preferred material is plywood covered with another material such as cloth, carpet, or a Formica laminate. The paneled frames can be used as walls or partitions, or they can be used in exhibits with display material hung therefrom or with the panel being the display. The panels can be transparent or translucent and can be front or rear lighted.
FIG. 2 is a top view of the framing apparatus 10 of FIG. 1 showing the frames 12, 14, 16 and the hinged joiner strips 28 and 30. FIG. 2 also shows three electrical outlets 36, two female and one male, in the top of frame 12. The joiner strips 28 and 30 will be described in more detail below.
FIG. 3 shows the cross-sectional shape of a framing member 40 according to the present invention. Each of the frames 12, 14, 16 and 18 are made of four framing members identical in cross-section to framing member 40. The framing member 40 is substantially H-shaped in cross-section with two parallel legs 42 and 44 connected by a transverse web 46, forming an outer U-shaped channel 48 and an inner U-shaped channel 50. The outer channel 48 is deeper than the inner channel 50 and faces or opens outwardly away from the frame (such as frame 12) and the inner channel 50 faces or opens inwardly into the inside of the frame (such as frame 12).
The outer edges 52 and 54 of the legs 42 and 44, respectively, (the edges adjacent the outer channel 48) include outwardly extending flanges 56 and 58. The flanges 56 and 58 provide protection for the edges of the panels (such as panel 20 in FIG. 1); the panel edges are covered or hidden by these flanges so that such edges need not be finished, and the flanges provide a neat, straight, appearance for the edge of the paneled frames.
The inner edges 60 and 62 of the legs 42 and 44, respectively, (the edges adjacent the inner channel 50) include inwardly extending flanges 64 and 66. The purpose for the flanges 64 and 66 will be described below with respect to FIGS. 8 and 9.
The ends of each of the four framing members used to form each frame (such as frame 12) are mitered and are connected by angle brackets as will be described below with reference to FIGS. 8 and 9. FIG. 3 also shows a Velcro strip 34 adhesively attached to the framing member 40.
FIG. 4 is a cross-sectional, exploded, view through the assembled portion of frames 16 and 18 of FIG. 1. FIG. 4 shows a bottom frame member 70 of the frame 16, a top frame member 72 of the frame 18, and the horizontal joiner strip 32. The joiner strip 32 is preferably a tube of rectangular cross-section that forms a slip-fit into the open channels 74 and 76, respectively, of the frame members 70 and 72. Preferably, the width of the joiner strip 32 is greater than twice the depth of the open channels 74 and 76, so as to space the frames 16 and 18 apart a small distance, such as about 1/4 to 1/2 inch. Alternatively, the frames 16 and 18 can be allowed to be in abutting contact with each other. The joiner strips do not have to be attached or connected to either frame, since the slip fit is sufficient to maintain the frames 16 and 18 in proper vertical alignment and with sufficient stability.
While FIG. 4 shows how vertically adjacent frames in a framing apparatus are assembled, FIGS. 5 and 6 show how horizontally adjacent frames 80 and 82 are connected by means of a vertical joiner strip 84. FIG. 5 shows a clip 86 screwed to a web 88 of a bottom frame member 90 of the frame 80. A clip 92 is similarly attached to the frame 82. FIG. 6 shows a hinged connector 94 screwed to a web 96 of a top frame member 98 of the frame 80, and another hinged connector 100 is similarly connected to the frame 82. The hinged connector 94 includes a fixed member 102 and a movable finger 104 hingedly connected to the fixed member. The bottom end of the joiner strip 84 is placed on the clips 86 and 92 with the movable fingers of the hinged connected raised (to the position shown in dotted lines in FIG. 6). The fingers are then lowered over the top end of the joiner strip 84, thus securely holding the frames 80 and 82 together.
FIG. 7 is an enlarged cross-sectional view showing how the two frames 12 and 14 of FIG. 1 are connected at their tops to the hinged joiner strip 28. FIG. 7 shows a pair of hinged connectors 110 and 112 (each identical to the hinged connectors 94 and 100 of FIG. 6) connected to webs 114 and 116, respectively, of the top frame member 118 and 120, respectively, of the frames 12 and 14. As shown in FIG. 7, the hinged joiner strip comprises a pair of identical, separate, tubular members 122 and 124 connected by a hinge 126. The bottom end of the joiner strip 28 is held in clips (not shown) identical to those shown in FIG. 5.
By simply reversing the hinged joiner strip 28, the two frames 12 and 14 can be made to move at an angle to each in the opposite direction from that shown in FIG. 1. It is to be noted that can be easily and quickly done without the use of tools.
FIGS. 8 and 9 show how the ends of two adjacent framing members (such as left side member 130 and bottom frame member 132 of frame 12 of FIG. 1) are connected to form a frame corner. All of the four corners of each frame are identically constructed and thus only one need be shown. The ends of the frame members 130 and 132 are mitered to form a mitered joint or corner. An L-shaped angle bracket 134 is inserted with one leg in each of the inner channels 136 and 138 of the frame members 130 and 132, respectively. An L-shaped spacer element 140 is also preferably positioned in the channels along with the angle bracket 134 and toward the outside of the frame from the angle bracket. The angle bracket is provided with two internally screw threaded holes 142 in each leg, and a set screw 144 is then screwed down against the spacer element forcing the spacer element and the angle bracket apart thus wedging them tightly in place in the inner channels and thus tightly forming the mitered corner. The set screws have polygonal openings for receiving a mating Allen wrench. The spacer elements help to spread the force of the set screw, however, they can be omitted if desired.
FIGS. 10 and 11 show another embodiment of the present invention wherein a cross strip 150 is added to a frame 152. The cross strip can be located anywhere desired in the frame. The cross strip 150 includes a slot 154 in the front side thereof. This provides another way of hanging items to the frame 152, and in particular, heavy items. FIG. 11 shows a heavy article 162 having a rear bracket 164 that fits into and hangs from the slot 154. The frame 152 can have a panel 166 thereon with a corresponding slot 168 through which the bracket 164 extends. While only one slot 154 is shown, it is preferred that the cross strip 150 have such a slot 154 in each of its outwardly facing sides (and a corresponding slot in each panel).
The cross strip 150 is preferably supported by brackets 170 identical to brackets 134 except for a cut out or notch 172 on each side of one leg (the horizontal leg) to accommodate the flanges 64 and 66 (see FIG. 3). The vertical leg of the brackets 170 are attached using set screws as with the angle bracket 134 of FIG. 8. An L-shaped spacer element is not used here, however, a straight spacer element can be used under the vertical leg of the bracket 170. The horizontal leg of the lower bracket is screwed, by machine screws, directly to the cross strip 150. The horizontal leg of the upper bracket 170 need have no screw connection to the cross strip.
An electrical conduit 174 provides electrical conductors from the frame members into the cross strip to allow an electrical outlet 176.
For those open channels of a frame (such as the left edge of frame 12 in FIG. 1) which form an end of a frame apparatus and thus do not have need for a joiner strip therein, a finishing strip 35 (see FIG. 1) is preferably placed therein to form a smooth finished end surface. The finishing strip 35 has a depth equal to that of the outer channel and is held in place in the same manner as are the vertical joiner strips 28 and 30. Finishing strips need not be placed in the outer channel on the top of the frame, and in fact, this open channel can be suitably used to hold brackets for supporting lighting fixtures and the like.
In a preferred embodiment of the present invention, the framing member 40 is made of extruded aluminum. The flanges 56 and 58 each have a width of about 1/2 inch. The flanges 64 and 66 each have a width of about 0.375 inch. The channels 48 and 50 have a width of about a 13/4 inch. The height of the member 40 is about 1.9 inch. The thickness of the walls are about 0.125 inch. The depth of the outer channel 48 is about 1.25 inches. The depth of the inner channel 46 is about 0.28 inch. The ends of the framing members 40 are mitered at 45°. The angle bracket 134 is prepared from a 4 inch by 2 inch by 3/16 inch aluminum strip. Each leg of the L-shaped bracket is 2 inches by 2 inches.
While the presently preferred embodiment uses an extruded aluminum frame member 40, other materials can be used including plastic, which would be less expensive and lighter weight. Also, the frame member does not have to be of one-piece construction but can be made of separate parts joined together by welding, screws, etc.
The flanges 56 and 58 can be omitted, if desired, although then the panels edges themselves should preferably be finished. The flanges 64 and 66 can be omitted, with a different angle bracket connection being made, such as by simply screwing the angle brackets 134 directly to the web 46.
The panels (such as 20 in FIG. 1) can be connected to the frame 12 in any desired way, the preferred being a series of spaced-apart Velcro strips attached to the frame and also attached at mating locations on the back of the panel.
If a series of frames is to be placed in a long line, then transverse leg extensions can be attached to the bottom of the frames for better support. Also, and alternatively, the vertical joiner strips, such as 84 in FIGS. 5 and 6, can extend above the top of the frames for attachment to the ceiling, for example, or for attaching lights or other fixtures thereto.
The horizontal joiner tube 32 in FIG. 4 is simply a means for assemblying two frames together (holding them in their desired location and orientation) that are located one on top of the other. No connection means are required. However, for frames that are side by side, they should be physically connected (held together) as by the connecting means including, in FIGS. 5 and 6, for example, the vertical joiner strip 84, the clips 86 and 92 and the hinged connectors 94 and 100.
The joiner strips are preferably tubular and slip fit in the outer channels, however, they can have other constructions and shapes, if desired, and other means for connecting them to the frames can be used. Other ways of providing a hinged joiner strip can also be used, as will be understood by one skilled in the art. The inner and outer channels and the joiner strips can have other than rectangular cross-sections. The frames preferably use four framing members and are preferably mitered at 45°; however, other numbers of framing members and other angles of miter can be used. The actual depths and the relative depths of the channels can be varied from the preferred ones described above, as desired.
If the floor on which the frames are to rest is not level, leveler legs can be attached to the bottom of the frames.
For use of the framing system of this invention in office landscaping, it may be desirable to make the framing member 40 larger and heavier.
The invention has been described in detail with particular reference to the preferred embodiments thereof, but it will be understood that variations and modifications can be affected within the spirit and scope of the invention as described hereinafter and as defined in the appended claims.
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A framing system including a framing apparatus (10) comprising a series of self supporting frames (12, 14, 16 and 18) held together by joiner strips (28 and 30) and supporting decorative panels (20, 22, 24 and 26); the apparatus (10) can be used as walls, partitions, or for displays at exhibits and trade shows. The framing apparatus can be easily and quickly set up without tools, and the panels are easily removable and replaceable even after the system is set up. The frames can include electrical outlets (36) and cross strips (150) with a slot (154) for supporting heavy articles to be hung on the frames. A framing method and framing member are also enclosed.
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BACKGROUND OF THE INVENTION
The present invention broadly relates to generated spiral bevel gears and pertains, more specifically, to a new and improved duplex or double-cut method of manufacturing a generated spiral-toothed bevel gear, particularly the pinion of a bevel-gear or hypoid-gear drive, on a gear-cutting machine.
In its more particular aspects, the present invention specifically relates to a new and improved duplex method of manufacturing a generated spiral-toothed bevel gear on a gear-cutting machine by cutting concave and convex tooth flanks or surfaces by means of cutter heads rotating about respective cutter-head axes and provided with cutters comprising outer and inner blade edges, respectively, whereby there is generated an approximate contact-line tooth bearing or crowning with conjugating tooth flanks of a mating or meshing gear, in that the cutter radii of the outer and inner blade edges and therewith the respective centers of rotation of the cutter heads as well as the center of rotation, i.e. the generating drum axis, of a generating gear are altered in relation to settings or values for manufacturing the mating or meshing gear such that the connecting lines of the centers of rotation of each cutter head and of the generating gear form a parallelogram for the conjugate gear tooth flanks or surfaces of gear and pinion.
The basis for all realized or existing types of bevel-gear tooth systems is the exact toothing or gear-tooth forming with congruent generating gears for generating the pinion and the crown gear, so that pinion and crown gear in the process of meshing fulfil the basic requirement of a gear tooth system in every rolling contact position. Permanent line contact prevails between the meshing or engaged flanks or surfaces. In other words, the crown-gear flank or surface is an exact conjugation of the pinion flank or surface, so that the exact toothing can also be designated as conjugate gear toothing, meaning that the gear ratio is essentially constant during the tooth engagement cycle.
In order to produce congruent generating gears, there is required a geometrical and kinematical adaptation of the gear-cutting machines for the pinion and crown gear. The most significant value or magnitude is thereby the proportional or parallel profile of the tooth depth. There is no connection between the form or profile of the flank line and the position of the generating gears and the congruence of the generating gear flanks, respectively. The manufacture of mating conjugate gear wheels depends solely on the arrangement between the generating drum, the cutter head and the gear blank of the pinion and crown-gear cutting machine.
Exact gear toothings are unsuitable for real or practical use because, for example, oblateness under load conditions, assembly tolerances in the gear box, shaft bearing or mounting systems, toothed-wheel rims and teeth etc., can lead to considerable trouble and malfunction during operation. Therefore, practical toothings comprise flank crowning in order to achieve a localized tooth bearing. There are particularly known elevational tooth bearing, lengthwise crowning and generation crowning as well as higher-order generation-dependent corrections. For instance, elevational tooth bearing is generated by cutter sphericity, while lengthwise crowning is generated by different cutter radii or by inclining the cutter head spindle as disclosed, for example, in Swiss Pat. No. 417,284, published Jan. 31, 1967 of the present assignee, Oerlikon-Buhrle AG, located in Zurich, Switzerland. Generation crowning is generated by kinematic effect. In most cases, there is used a combination of such flank or tooth surface corrections in the manufacturing process of bevel gears with proportional as well as parallel tooth depths. However, localized tooth bearing leads to a basically undesired rotational or kinematic error which depends on the size of the crowning correction.
Known partial generating methods or continuous generating methods for manufacturing spiral-toothed bevel gears having proportional or parallel tooth depths thus relate to gear-cutting machine corrections which ensure the running capability or ability of toothings and, furthermore, make use of the expensive mechanisms to simultaneously optimize the contact behavior as well as to improve the kinamatic conditions during the machining process. It is thereby intended to provide an ideal gearing of wheels which under any possible load ensures a perfect transmission of rotation, i.e. without kinematical error, and possesses a defined tooth bearing or tooth contact displacement behavior dependent solely upon the offset of axes.
In a Technical Memorandum prepared by Faydor L. Litvin et al for the 1985 Off-Highway and Power Plant Congress and Exposition sponsored by the Society of Automotive Engineers, Milwaukee, Wis., Sept. 9-12, 1985, entitled "Generated Spiral Bevel Gears: Optimal Machine-Tool Settings and Tooth Contact Analysis", SAE Technical Paper Series 851573, NASA Technical Memorandum 87075, a method for deriving optimal machine settings for manufacturing generated spiral bevel gears with proportional tooth depths was made known for the first time and according to which a bearing contact or contact-line crowning can be generated without kinematic errors. The suggested corrective measures for improved bearing contact are based on an alteration of the cutter radius and on an imagined parallel and equal displacement of the center of rotation of the generating gear and of the cutter-head axis when the tooth flanks of the pinion are generated in relation to the associated tooth flanks of the mating gear.
However, a variable cutter radius requires a cutter head with continuously adjustable or variable cutters, in order to exactly adjust the required radius of the inner and outer blade edges by distances in the range of approximately 1 mm to 10 mm. This has a negative effect with respect to precision and rigidity. Such cutter heads, in most cases equipped with a reduced number of cutters, have been hitherto fabricated only for laboratory tests or then commercially available cutter heads were specially modified for such laboratory tests. Furthermore, the contact-line crowning or tooth bearing which is a spatial curve requires different machine settings for generating the thrust flanks and the tension flanks and, therefore, precludes the cutting of both tooth flanks at the pinion with one cutter head in one pass or operation and, in other words, precludes the single-cut method or the double-flank cutting method. However, the actually required duplex or double-cut method, in which adjacent flanks, i.e. a thrust flank and a tension flank, are separately cut by respective cutter heads, renders possible highly optimized bevel gear drives, particularly with respect to quiet running and mechanical strength. Moreover, the duplex or double-cut method is at present the only known method for generating correct or pure contact-line crowning or localized tooth bearing.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved duplex method of manufacturing a generated spiral-toothed bevel gear of a bevel-gear or hypoid-gear drive and which method does not exhibit the aforementioned drawbacks and shortcomings of the prior art.
Another and more specific object of the present invention aims at providing a new and improved duplex or double-cut method of manufacturing a generated spiral-toothed bevel gear and by means of which the aforesaid known method developed by Litvin et al for the manufacture of a pinion of a bevel gearing pair is improved such that the known method can be practically and economically carried out.
Now in order to implement these and still further objects of the present invention which will become more readily apparent as the description proceeds, the new and improved duplex method of manufacturing a generated spiral-toothed bevel gear is manifested, among other things, by the features that the alteration of the cutter radii of respective outer and inner blade edges is accomplished by inclining the cutter-head axes in that the cutter-head axes are inclined in a direction remote or away from main contact points located at the blade edges of the cutters, whereby the points of intersection of the cutter-head axes with normals at the aforesaid main contact points constitute the altered centers of rotation of the cutter heads.
The advantages achieved by the inventive method are essentially seen in the fact that commercially available cutter heads can now be used for the manufacture of bevel gears with proportional as well as with parallel gear depths.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings, there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 schematically shows the constructive conception of the contact-line crowning or localized tooth bearing in accordance with the method developed by Litvin et al;
FIG. 1a shows a fragmentary sectional view through a crown-wheel tooth space and a pinion tooth;
FIG. 2a shows a tooth contact analysis of the contact-line crowning or localized tooth bearing in an ease-off illustration;
FIG. 2b shows a tooth contact analysis of the contact-line crowning with the illustration of a localized tooth bearing;
FIG. 2c shows a tooth contact analysis of the contact-line crowning with the illustration of rotation transfer;
FIG. 3 schematically shows a first side view, partially in section, of two cutter heads in a mutual position in the process of cutting tooth flanks or surfaces; and
FIG. 4 schematically shows a second side view, partially in section, of two cutter heads in a mutual position in the process of cutting tooth flanks or surfaces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the construction for performing the inventive duplex method of manufacturing a generated spiral bevel gear of a bevel-gear or hypoid-gear drive has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of this invention.
Turning attention now specifically to FIG. 1 of the drawings, the constructive conception of the contact-line crowning or localized tooth bearing according to Litvin et al schematically illustrated therein shows a generating gear 10 comprising a center of rotation 11 which, for example, is located at an imagined generating drum axle, and a flank line 12 having a main contact point 14 and a respective spiral angle β.
A center of rotation C1 represents a cutter-head axis. The connecting line from this center of rotation C1 to the main contact point 14 constitutes a cutter radius R1 of an imagined cutter head for generating a crown gear, for instance, the cutter radius of the inner blade edges for generating convex flank lines 16 of the crown gear (FIG. 1a).
For generating a pure contact-line crowning or localized tooth bearing, Litvin et al propose altering the cutter radius and thereby the center of rotation of a cutter head for generating an associated pinion, whereby now likewise the center of rotation of the generating gear is to be altered in the same direction.
With reference to FIG. 1, there are thus provided the following new settings, for example, for the generation of concave flank lines 17 of the pinion to be generated with the outer blade edges of a cutter head.
A new cutter-head radius R2 is now longer by a displacement ΔR and the cutter head now rotates about a center of rotation C2. By an equal displacement in the same direction, the center of rotation 11 of the generating gear 10 is now located at a new center of rotation 21. The connecting lines of the centers of rotation 11, 21, C1 and C2 form a parallelogram. If this parallelogram is moved about the two centers of rotation 11 and 21, the arrow heads of the cutter radii R1 and R2 define a line or curve 15 of equal generating or pressure angles, without any flank or tooth surface correction. This is apparent from further centers of rotation C1', C2' and respective cutter radii R1' and R2'. The line or curve 15 forms in the tooth contact analysis the "path of contact" which leads to substantially zero kinematic errors within the area of the flank.
FIGS. 2a, 2b and 2c show in three illustrations the results of tooth contact analysis of the tension sides of a toothing comprising contact-line crowning or tooth bearing according to Litvin et al, whereby:
according to FIG. 2a, an ease-off illustration shows a flank surface 16 of the crown gear and a flank surface 17 of the associated pinion;
according to FIG. 2b, a tooth bearing or localized tooth contact shows the flank surface 16 of the crown gear with the regions designated K for head, F for heel and Z for toe, as well as a "path of contact" 18 with the flank surface 17 of the associated pinion; and
according to FIG. 2c, a rotation transfer shows respective rotational or kinematic errors 19 in multiple meshing.
According to the ease-off illustration in FIG. 2a, the flank surface 17 of the pinion is twisted relative to the flank surface 16 of the associated crown wheel by two diagonally opposite maximum air-gap values 22 and 23 of, for example, approximately 0.15 mm and 0.2 mm respectively. In the central area or region of the flank the contact lines possess a constant length in the tooth bearing depicted in FIG. 2b and which is given by the constant contact-line crowning. There is thus a "bias-in" tooth bearing. Kinematic errors do not occur in the potential flank area or region. Only during entry of the tip edge and upon exit at the transfer line there can occur minor kinematic errors 19. Exact transfer of rotation or movement thus takes place during multiple meshing.
If there is used a gear-cutting machine with a generating drum, the centers of rotation 11 and 21 must be located on the generating drum axis. Since this generating drum axis cannot be displaced or altered from 11 to 21, only the cutter radius changes from R1 to R2 in FIG. 1. In order to achieve a relative alteration of position of the pinion with respect to the generating drum and the cutter head, the pinion and the cutter head are correspondingly re-set at the gear-cutting machine and in addition there also result new blade-edge angles at the respective cutters of the cutter head. This is disclosed in prior art literature of Litvin et al and is therefore not further discussed hereinbelow. Furthermore, to generate the other pinion flanks with the convex flanks 27 depicted in FIG. 1a, the cutter radius is shortened by a predetermined amount in relation to the respective cutter radius for generating the concave flanks 26 of the crown gear. The centers of rotation 11 and C1 are then to be correspondingly altered in the same direction.
According to the inventive method there is now suggested that the change or alteration of cutter radii for generating the convex and concave tooth flanks for the pinion is not achieved by corresponding measures at the cutter head, but by inclination of the cutter-head axis in a predetermined direction and by a predetermined amount.
In FIGS. 3 and 4 there is illustrated in simplified manner the influence of the aforesaid inclination of the cutter-head axis upon the cutter radius.
In FIG. 3, two cutter heads 30 and 31 are arranged opposite to one another such that a main contact point 32 is mutually located at an outer blade edge 33 and at an inner blade edge 34. Axes 36 and 37 of the cutter heads 30 and 31, respectively, thereby intersect one another. The two cutter head axes 36 and 37 are likewise intersected by a common normal 35 relative to the blade edges 33 and 34 and located at the main contact point 32. These points of intersection are suitably designated by reference numerals 38 and 39.
In FIG. 4, two cutter heads 50 and 51 are arranged opposite to one another such that a main contact point 52 is mutually located at an outer blade edge 53 and an inner blade edge 54. Axes 56 and 57 of the cutter heads 50 and 51, respectively, thereby intersect each other. The two cutter heads 50 and 51 are likewise intersected by a common normal 55 relative to the blade edges 53 and 54 and located at the main contact point 52. These points of intersection are suitably designated by reference numerals 58 and 59.
The cutter head 30 (FIG. 3) and the cutter head 50 (FIG. 4) are identical in this exemplary embodiment and serve to cut the tooth spaces of a not particularly illustrated crown wheel. In other words, the outer blade edges 33 cut the concave tooth flanks and the inner blade edges 54 cut the convex tooth flanks.
The convex tooth flanks of a not particularly illustrated pinion are cut by the inner blade edges 34 of the cutter head 31, while the concave tooth flanks of the aforesaid pinion are cut by the outer blade edges 53 of the cutter head 51.
The inclination of the cutter heads 31 and 51 according to the inventive duplex or double-cut method of manufacturing the aforesaid pinion is accomplished in the following manner:
The normal 55 depicted in FIG. 4 and extending between the main contact point 52 and the point of intersection 58 corresponds to an effective or actual cutter radius 60 of the inner blade edges 54 of the cutter head 50 for generating the convex tooth flanks of the aforesaid crown wheel. The normal 55 extending between the main contact point 52 and the other point of intersection 59 corresponds with an effective or actual cutter radius 61 of the outer blade edges 53 of the cutter head 51 for generating the concave tooth flanks of the pinion. The distance between the points of intersection 58 and 59 is designated in FIG. 4 by reference character ΔR.
The illustration in FIG. 4 corresponds with that in FIG. 1 with respect to the tooth flanks and to the cutter radii of the two cutter heads 50 and 51, i.e. the cutter radii 60 and R1 are shorter than respective cutter radii 61 and R2, whereby this difference in the embodiment depicted in FIG. 4 is achieved by an inclination of the cutter-head axis 57 in the direction of the arrow 45 and thus in a direction away or remote from the main contact point 52. The points of intersection 58 and 59 now correspond with the centers of rotation C1 and C2 depicted in FIG. 1 and form the centers of rotation of the cutter heads 50 and 51.
In analogous manner there results in FIG. 3 an effective or actual cutter radius 40 for the outer blade edges 33 of the cutter head 30 for generating the concave tooth flanks of the crown wheel and an effective or actual cutter radius 41 for the inner blade edges 34 of the cutter head 31 for generating the convex tooth flanks of the pinion, whereby in correct manner the cutter radius 41 is shorter than the cutter radius 40 and the points of intersection 38 and 39 form the centers of rotation for the cutter heads 30 and 31. Quite unexpectedly, this is however achieved by an inclination of the cutter-head axis 37 in the same direction as in FIG. 4, i.e. in a direction away or remote from the main contact point 32.
By virtue of this inclination of the cutter head axes 37 and 57 for the purpose of altering or changing the cutter radii of the cutter heads 31 and 51 of the pinion in connection with the relative alteration or change of position of the pinion with respect to the center of rotation 11 of the generating gear 10, a contact-line crowning or localized tooth bearing can now be generated or produced by commercially available cutter heads, so that the inventive method can be practically and economically utilized.
Crown wheels can be generally fabricated by the known single-cut method. Pinions are processed, for instance according to the duplex or double-cut method, in the first place by an entering knife cutter and an outer or external cutter for producing the concave tooth flanks. Subsequently, the machine is reset or readjusted and the convex tooth flanks are processed by a cutter head which is only equipped with inner or internal blade edges.
In the case of automatically readjustable gear-cutting machines it is also possible to roughen the tooth spaces by a fully equipped cutter head in a first machine setting. The machine then automatically readjusts and smoothes, for example, the convex flanks. The machine again readjusts thereafter in order to smooth the concave tooth flanks. In this manner, pinions can be economically cut by one cutter head and in accordance with the inventive duplex or double-cut method which, in fact, relates to the tooth flank smoothing.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY,
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For manufacturing a pinion of a pair of mating bevel gears having contact-line tooth bearing or crowning in accordance with the method developed by Litvin et al, the cutter radii of respective outer and inner blade edges in the duplex or double-cut method and therewith the centers of rotation of the cutter heads as well as the center of rotation of a generating gear are altered in relation to the settings for manufacturing the mating or meshing gear. This would require cutter heads provided with adjustable cutter radii. In order to render possible the use of commercially available cutter heads, provision is made for achieving the alternation of the cutter radii by inclination of the cutter-head axes.
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BACKGROUND OF THE INVENTION
This invention relates to radio broadcasting and, more particularly, to methods of and apparatus for equalizing the demodulated signal in a receiver for an amplitude modulated compatible digital broadcasting system.
There has been increasing interest in the possibility of broadcasting digitally encoded audio signals to provide improved audio fidelity. Several approaches have been suggested. One such approach, set forth in U.S. Pat. No. 5,588,022, teaches a method for simultaneously broadcasting analog and digital signals in a standard AM broadcasting channel. An amplitude modulated radio frequency signal having a first frequency spectrum is broadcast. The amplitude modulated radio frequency signal includes a first carrier modulated by an analog program signal. Simultaneously, a plurality of digitally modulated carrier signals are broadcast within a bandwidth which encompasses the first frequency spectrum. Each of the digitally modulated carrier signals is modulated by a portion of a digital program signal. A first group of the digitally modulated carrier signals lies within the first frequency spectrum and is modulated in quadrature with the first carrier signal. Second and third groups of the digitally modulated carrier signals lie outside of the first frequency spectrum and are modulated both in-phase and in-quadrature with the first carrier signal.
The waveform in the AM compatible digital audio broadcasting system described in U.S. Pat. No. 5,588,022, was been formulated to provide sufficient data throughput for the digital signal while avoiding crosstalk into the analog AM channel. Multiple carriers are employed by means of orthogonal frequency division multiplexing (OFDM) to bear the communicated information.
Monophonic detectors for consumer AM radios respond only to the envelope and not the phase of the received signal. Because of the use of the multiple digitally modulated carriers, there is a need for a means to reduce the envelope distortion caused by this hybrid signal. U.S. patent application Ser. No. 08/671,252, assigned to the assignee of the present invention, discloses a method for reducing envelope distortion in an AM compatible digital audio broadcasting system. Certain digital carriers that are above the frequency of the analog AM carrier have an associated digital carrier that is at an equal frequency offset below the analog AM carrier. The data and modulation placed on the upper digital carrier and its counterpart are such that the signal resulting from their addition has no component that is in-phase with the analog AM carrier. Digital carrier pairs arranged in this way are said to be complementary. This configuration delivers dramatic fidelity improvements to analog AM reception of AM compatible digital broadcast signals.
At the receiver, the digital signal is demodulated by means of a Fast Fourier Transform (FFT). One possible method and associated apparatus is described in U.S. Pat. No. 5,633,896. That patent discloses a demodulation technique which minimizes the undesired crosstalk between the analog signal and the digital signals in an AM compatible digital audio broadcasting (AM DAB) system using an orthogonal frequency division multiplexed (OFDM) modulation format, by employing dual fast Fourier transform processes on separate respective in-phase and quadrature-phase components of a received OFDM digital signal. The output of the quadrature channel is used to recover the complementary data, and the resultant processed component signals are summed to recover the non-complementary data.
The received multi-carrier signal requires equalization in the presence of dynamic channel response variations. Without such equalization, a very distorted signal would be detected and the digital broadcasting signal information would be unrecoverable. An equalizer enhances the recoverability of the digital audio broadcasting signal information. One such equalizer is disclosed in U.S. Pat. No. 5,559,830. The equalizer disclosed therein includes means for receiving an AM compatible digital audio broadcasting waveform and storing that waveform as a waveform vector. The equalizer then processes that waveform by multiplying the waveform vector by an equalization vector. This equalization vector comprises a plurality of equalizer coefficients, each of the coefficients initially set to a predetermined value. The equalizer then compares each location of the processed waveform vector with a stored waveform vector. The equalizer selects as the signal that vector location closest to the stored waveform vector. Preferably, the equalizer includes means for updating the equalizer coefficients using the waveform vector, the processed waveform vector, and the stored waveform vector to provide immunity to noise.
In the equalizers of both Pat. Nos. 5,633,896 and 5,559,830, frequency domain information is presented to the equalizer as a frequency domain vector. Each block of frequency domain information is stored in a storage array. This storage array vector is multiplied by a plurality of equalizer coefficients. The resulting product of this multiplication is the equalized signal. A set of exact values is known a priori in the equalizer against which each vector location of the equalized signal can be compared. The ideal value closest to that described in the vector location is chosen as the actual signal value. The vector of decisions is stored in a decision array. Using the received signal, the equalized signal and decision array, an equalizer coefficient estimator calculates coefficient estimates. The rate of coefficient update determines equalizer noise immunity and convergence rate. Coefficients in different parts of the band may be updated at different rates depending on knowledge of the distortion mechanism. U. S. Pat. Nos. 5,633,896 and 5,559,830 are hereby incorporated by reference.
While the dual FFT technique can improve system performance in a channel that has symmetric magnitude and anti-symmetric phase about the AM carrier frequency over the frequency range of the complementary carriers, for channels with non-symmetric magnitude or non-anti-symmetric phase, the process of combining the complementary carrier FFT outputs destroys the non-symmetric magnitude and non-anti-symmetric phase information and the signal that drives the equalizer is not correct. There exists a need for a demodulation method which can preserve non-symmetric magnitude and non-anti-symmetric phase information in such circumstances. The present invention seeks to provide an improved equalization method and receivers which include the method.
SUMMARY OF THE INVENTION
The present invention provides a method of estimating the equalizer coefficients for the complementary carriers while still retaining the benefits of combining the information from the complementary carrier FFT outputs. The method uses information from the non-complementary carriers to estimate, via interpolation, the equalizer coefficients for the complementary carriers.
The equalization method of the present invention is used to process an amplitude modulated compatible digital broadcasting signal including an amplitude modulated radio frequency signal having a first frequency spectrum, the amplitude modulated radio frequency signal having a first carrier modulated by an analog program signal, a plurality of digitally modulated carrier signals positioned within a bandwidth which encompasses the first frequency spectrum, a first group of the digitally modulated carrier signals including complementary carriers and lying within the first frequency spectrum, and second and third groups of the digitally modulated carrier signals including non-complementary carriers and lying outside of the first frequency spectrum. The method comprises the steps of producing a first signal representative of in-phase components of the amplitude modulated compatible digital broadcasting signal; producing a second signal representative of the quadrature-phase components of the amplitude modulated compatible digital broadcasting signal; using the first and second signals as the real and imaginary inputs to take the Fast Fourier Transform of the first and second signals to produce a plurality of transformed signals representative of frequency domain data; processing said transformed signals by multiplying the transformed signals by an equalization vector, the equalization vector comprising a plurality of equalizer coefficients; and updating the equalizer coefficients used for the complementary signals by interpolating coefficients of the vector for the non-complementary signals.
The invention also encompasses the operation of radio frequency receivers which utilize the above method, as well as apparatus that performs the above method and radio frequency receivers which include the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily apparent to those skilled in the art by reference to the accompanying drawings wherein:
FIG. 1 is a diagrammatic representation of a prior art composite analog AM and digital broadcasting signal having carriers positioned in accordance with the present invention;
FIG. 2 is a block diagram of a receiver which may include an equalizer that operates in accordance with this invention;
FIG. 3 is a functional block diagram which illustrates the operation of a demodulator and adaptive equalizer in accordance with this invention; and
FIGS. 4 and 5 are diagrams showing the magnitude of responses of the equalizer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides a method for equalizing carriers in a broadcast signal which includes both an analog amplitude modulated signal and a digital signal on the same channel assignment as the existing analog AM broadcasting allocation. The technique of broadcasting the digital signal in the same channel as an analog AM signal is called in-band on-channel (IBOC) broadcasting. This broadcasting is accomplished by transmitting a digital waveform by way of a plurality of orthogonal frequency division modulated (OFDM) carriers, some of which are modulated in-quadrature with the analog AM signal and are positioned within the spectral region where the standard AM broadcasting signal has significant energy. The remaining digital carriers are modulated both in-phase and in-quadrature with the analog AM signal and are positioned in the same channel as the analog AM signal, but in spectral regions where the analog AM signal does not have significant energy. In the United States, the emissions of AM broadcasting stations are restricted in accordance with Federal Communications Commission (FCC) regulations to lie within a signal level mask defined such that: emissions 10.2 kHz to 20 kHz removed from the analog carrier must be attenuated at least 25 dB below the unmodulated analog carrier level, emissions 20 kHz to 30 kHz removed from the analog carrier must be attenuated at least 35 dB below the unmodulated analog carrier level, and emissions 30 kHz to 60 kHz removed from the analog carrier must be attenuated at least [35 dB+1 dB/kHz] below the unmodulated analog carrier level.
FIG. 1 shows the spectrum of an AM digital audio broadcasting signal of a type which can be utilized by the present invention. Curve 10 represents the magnitude spectrum of a standard broadcasting amplitude modulated signal, wherein the carrier has a frequency of f 0 . The FCC emissions mask is represented by item number 12 . The OFDM waveform is composed of a series of data carriers spaced at f 1 =59.535 . 10 6 /(131072), or about 454 Hz. A first group of twenty four of the digitally modulated carriers are positioned within a frequency band extending from (f 0 −12 f 1 ) to (f 0 +12 f 1 ), as illustrated by the envelope labeled 14 in FIG. 1 . Most of these signals are placed 39.4 dB lower than the level of the unmodulated AM carrier signal in order to minimize crosstalk with the analog AM signal. Crosstalk is further reduced by encoding this digital information in a manner that guarantees orthogonality with the analog AM waveform. This type of encoding is called complementary encoding (i.e. complementary BPSK, complementary QPSK, or complementary 32 QAM) and is more fully described in the previously discussed copending application Ser. No. 08/671,252. Complementary BPSK modulation is employed on the innermost digital carrier pair at f 0 ±f 1 to facilitate timing recovery. These carriers are set at a level of −28 dBc. All other carriers in this first group have a level of −39.4 dBc and are modulated using complementary 32 QAM for the 48 and 32 kbps encoding rates. Complementary 8 PSK modulation is used on carriers ranging from (f 0 −11 f 1 ) to (f 0 −2 f 1 ) and from (f 0 +2f 1 ) to (f 0 +11 f 1 ) for the 16 kbps encoding rate. For all three encoding rates, the carriers at (f 0 −12 f 1 ) and (f 0 +12 f 1 ) carry supplementary data and may be modulated using complementary 32 QAM.
Additional groups of digital carriers are placed outside the first group. The need for these digital waveforms to be in-quadrature with the analog signal is eliminated by restricting the analog AM signal bandwidth. The carriers in a second and a third group, encompassed by envelopes 16 and 18 respectively, may be modulated using, for example, 32 QAM for the 48 and 32 kbps rates, and 8 PSK for the 16 kbps rate. The carriers are set at levels of −30 dBc for all encoding rates.
FIG. 2 is a block diagram of a receiver constructed to receive the composite digital and analog signals of FIG. 1 . An antenna 110 receives the composite waveform containing the digital and analog signals and passes the signal to conventional input stages 112 , which may include a radio frequency preselector, an amplifier, a mixer and a local oscillator. An intermediate frequency signal is produced by the input stages on line 114 . This intermediate frequency signal is passed through an automatic gain control circuit 116 to an I/Q signal generator 118 . The I/Q signal generator produces an in-phase signal on line 120 and a quadrature signal on line 122 . The in-phase channel output on line 120 is input to an analog-to-digital converter 124 . Similarly, the quadrature channel output on line 122 is input to another analog-to-digital converter 126 . Feedback signals on lines 120 and 122 are used to control the automatic gain control circuit 116 . The signal on line 120 includes the analog AM signal which is separated out as illustrated by block 140 and passed to an output stage 142 and subsequently to a speaker 144 or other output device.
An optional highpass filter 146 may be used to filter the in-phase components on line 128 to eliminate the energy of the analog AM signal and to provide a filtered signal on line 148 . If the highpass filter is not used, the signal on line 148 is the same as that on line 128 . A demodulator 150 receives the digital signals on lines 148 and 130 , and produces output signals on lines 154 . These output signals are passed to an equalizer 156 and to a data rate filter and data decoder 158 . To obtain higher signal-to-noise ratios (SNR) for the complementary carriers, the FFT outputs for pairs of complementary carriers are combined. The output of the data decoder is sent to a deinterleaving circuit and forward error correction decoder 164 in order to improve data integrity. The output of the deinterleaver/forward error correcting circuit is passed to a source decoder 166 . The output of the source decoder is delayed by circuit 168 to compensate for the delay of the analog signal at the transmitter and to time align analog and digital signals at the receiver. The output of delay circuit 168 is converted to an analog signal by a digital-to-analog converter 160 to produce a signal on 162 which goes to the output stage 142 .
FIG. 3 is a functional block diagram which illustrates the operation of a demodulator 150 and an adaptive equalizer 156 in accordance with the present invention. Both in-phase (I) and quadrature (Q) signals are provided on lines 148 and 130 as inputs to a windowing and guard interval removal circuit. These signals may be provided by using down converter elements similar to those shown in FIG. 2 . The window should be applied such that the digital carriers remain orthogonal, or at least the lack of orthogonality among the digital carriers is small enough not to impact system performance. A method of applying a window that preserves orthogonality among the carriers has been developed. In a specific implementation of the method, a root-raised cosine window is applied at the transmitter and receiver. For this window, the tapering occurs on the first and last seven samples of the 135 samples in a baud. After the window has been applied at the receiver, the last seven samples are added to the first seven samples, where the 129th sample is added to the first sample, the 130th sample is added to the second sample, and this pattern continues with the 135th sample being added to the seventh sample. The resulting 128 points are input to an FFT. In some cases it may be advantageous to perform the windowing and guard band removal operations prior to processing by highpass filter 146 . The outputs from the windowing and guard interval removal circuit 151 are input to the FFT 153 . The output of the FFT is input by way of lines 154 to the coefficient multiplier 157 . The coefficient multiplier operates on the frequency domain data and adjusts the magnitude and phase of each OFDM carrier to counteract the effects of channel perturbations, transmitter and receiver filters, the transmit and receive antennas, and other factors and processing that affect the magnitude and phase of the signal. At the outputs 174 and 176 of the coefficient multiplier, the information for pairs of the complementary carriers is combined as illustrated by block 178 . Specifically, this may be accomplished by taking the average of the frequency domain data for each pair of complementary carriers, where the negative conjugate of the frequency domain data for one of the carriers is used. Combining the complementary carrier information in this manner results in increased signal-to-noise ratios for the complementary carriers. This combined information for the complementary carriers, as well as the coefficient multiplier outputs on lines 180 and 182 for the non-complementary carriers is input to a processor 184 that determines which of the frequency domain constellation points was transmitted. These decisions, along with the pre-equalized constellation points and the previous values of the equalizer coefficients are used to update the equalizer coefficients as illustrated by block 186 . Block 186 can utilize a known algorithm such as the least mean squares (LMS) or recursive least squares (RLS) to update the equalizer coefficients. The output of equalizer 156 of FIG. 2 can consist of the combination of the outputs on lines 174 , 176 , 180 , and 182 , or it can consist of the output of the symbol decisions processing 185 , where lines 185 contain decisions for the complementary and non-complementary carriers. The output used depends on the type of data required for further processing, which may especially depend on the type of FEC used in the system.
Pat. No. 5,559,830, issued Sep. 24, 1996 describes one mode of operation for an equalizer having an equalizer coefficient update algorithm. The present invention enhances the operation of the equalizer and equalizer coefficient update algorithm by considering the effects that occur when the equalizer coefficients should have non-symmetric magnitude or non-anti-symmetric phase about the center of the FFT.
If the in-phase input to the FFT is highpass filtered to eliminate the analog signal, the output of the FFT, which is input to the equalizer coefficient update algorithm, has certain symmetry properties. Specifically, since the in-phase part of the FFT input has nearly zero energy for the complementary carriers, the output of the FFT will be have nearly anti-hermitian symmetry for the complementary carriers. The output of the symbol decision processor for the complementary carriers will have the same property. Since these two anti-hermitian signals serve as the input to the equalizer coefficient update routine, the equalizer coefficients will be constrained to have a magnitude response that is symmetric and a phase response that is anti-symmetric about the center frequency of the FFT. Therefore, the equalizer coefficients will not converge to the proper values when the equalizer coefficients should have non-symmetric magnitude or non-anti-symmetric phase about the center of the FFT. FIG. 4 illustrates an example of this situation. For the case shown in FIG. 4, it is assumed that the channel magnitude response is not symmetric about the center frequency of the FFT. FIG. 4 actually shows the inverse of the channel response 188 because this is the desired response for the equalizer. The response 190 that would be obtained from the equalizer magnitude is also shown in FIG. 4 . For clarity, the illustrated equalizer response is displaced upward slightly so it can be distinguished from the inverse channel response. Note that the response follows the inverse channel response in the regions 192 and 194 of the non-complementary carriers. However, the equalizer response is not correct in the region 196 of the complementary carriers because it is forced to have a symmetric magnitude response in this spectral region.
If the highpass filter is not used on the in-phase signal to eliminate the analog signal prior to the FFT, the FFT output for the non-complementary carriers could be noisy due to leakage of the analog signal into the non-complementary carriers that are closest to the analog AM carrier frequency. In addition, when the equalizer coefficients should have symmetric magnitude and anti-symmetric phase about the analog AM carrier, the lack of a highpass filter leads to noisier estimates of the equalizer coefficients for the complementary carriers than when a highpass filter is used. Also, if the equalizer coefficients should have non-symmetric magnitude or non-anti-symmetric phase about the analog AM carrier frequency, estimation of the equalizer coefficients for the complementary carriers becomes difficult because the analog signal and complementary carriers are no longer separated into the in-phase and quadrature-phase components, respectively. Long term averaging could be used to obtain the proper equalizer coefficients for static phenomenon that require the equalizer coefficients to have non-symmetric magnitude or non-anti-symmetric phase about the center of the FFT. However, channel perturbations frequently have non-symmetric magnitude or non-anti-symmetric phase about the center of the FFT. These perturbations are transient in nature and occur too rapidly to be corrected by long term averaging.
Therefore, whether or not a highpass filter is used to eliminate the analog signal, the equalizer coefficients for the complementary carriers will not be useful when the ideal equalizer coefficients for the complementary carriers should have a non-symmetric magnitude or non-anti-symmetric phase about the center of the FFT.
Interpolation of the equalizer coefficients across the complementary region can be used to overcome this disadvantage. If the control loops of the receiver such as the automatic gain control (AGC), carrier tracking, and symbol tracking are at the proper values, the center frequency of the FFT should be at a known, constant magnitude and phase. Therefore, the information from the spectral regions 192 and 194 outside of the complementary carrier region 196 can be used to interpolate and estimate the proper equalizer coefficients for the complementary carriers. In reference to FIG. 3, the processing when interpolation is used is implemented in the following manner. The coefficient multiplier 157 outputs the equalized signals for the non-complementary carriers on lines 180 and 182 and equalized signals for the complementary carriers on lines 174 and 176 . The symbol decisions processor 184 outputs decisions for only the non-complementary carriers on lines 187 , in contrast to the case where interpolation is not used and lines 187 include the decisions for the complementary carriers. The equalizer coefficient update circuit 186 updates the coefficients for the non-complementary carriers. Then the coefficients for the complementary carriers are updated by interpolation using the known value at the center of the channel and the values of the coefficients for the non-complementary carriers. FIG. 5 shows an example where linear interpolation is used to determine the equalizer coefficients across the center of the channel. As can be seen, if the channel response 198 is relatively smooth, the interpolated equalizer coefficients are near to the ideal values and the equalizer magnitude response 200 closely follows the inverse channel magnitude response.
Several variations of interpolation are possible. For example, the value of the equalizer coefficient for the first OFDM carriers outside of the complementary region could be used to linearly interpolate from their values to the value at the center of the channel. Linear interpolation has been found to be satisfactory in the large majority of cases where the signal is in the commercial AM broadcast band (530 kHz to 1710 kHz) and the width of the complementary region is less than 10 kHz. As an alternative, it may be desirable to use non-complementary carriers that are further away from the center of the channel if the non-complementary carrier or carriers that are located closest to the complementary carrier region are affected by filters such as the highpass filter that can be used to eliminate the analog signal from the in-phase portion of the received signal. Also, information from many of the non-complementary carriers could be used in the interpolation process. Interpolation algorithms other than linear could be used. Some of the well known interpolation algorithms include cubic spline, polynomial interpolation, FFT based interpolation, and exponential or logarithmic curve fitting. The non-complementary equalizer coefficients used for the interpolation and the complementary equalizer coefficients obtained from the interpolation can be averaged over time to reduce the effects of noise. Smoothing across frequency can also be used to reduce the effects of noise. Instead of interpolating the linear magnitude of the coefficients, interpolation on a log magnitude scale may be advantageous. Alternatively, instead of interpolating the magnitude and phase of the equalizer coefficients, it may be desirable to interpolate the corresponding real and imaginary components of the coefficients (or Cartesian coordinates) that can be used to represent the equalizer coefficients.
This invention provides a system for adaptively equalizing an amplitude modulated compatible digital audio broadcast signal. In the foregoing specification certain preferred practices and embodiments of this invention have been set out, however, it will be understood that the invention may be otherwise embodied within the scope of the following claims.
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A method is provided for equalizing an amplitude modulated compatible digital broadcasting signal which includes an amplitude modulated radio frequency signal having a first frequency spectrum, the amplitude modulated radio frequency signal having a first carrier modulated by an analog program signal, a plurality of digitally modulated carrier signals positioned within a bandwidth which encompasses the first frequency spectrum, a first group of the digitally modulated carrier signals including complementary signals and lying within the first frequency spectrum, and second and third groups of the digitally modulated carrier signals including non-complementary signals and lying outside of the first frequency spectrum. The method includes the steps of producing a first signal representative of in-phase components of the amplitude modulated compatible digital broadcasting signal; producing a second signal representative of quadrature-phase components of the amplitude modulated compatible digital broadcasting signal; using the first and second signals as the real and imaginary inputs to take the Fast Fourier Transform of the first and second signals to produce a plurality of transformed signals representative of frequency domain data; processing the transformed signals by multiplying the transformed signals by an equalization vector, with the equalization vector comprising a plurality of equalizer coefficients; and updating the equalizer coefficients used for the complementary signals by interpolating coefficients of the vector for the non-complementary signals. The invention also encompasses the operation of radio frequency receivers which utilize the above method, as well as apparatus that performs the above method and radio frequency receivers which utilize the above equalization method.
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FIELD OF THE INVENTION
[0001] The present invention relates to a radioactive transition metal-imido heterocomplex, a radiopharmaceutical comprising said complex and a process for producing thereof. More particularly, the complex of the invention comprises an imido derivative of radioactive technetium or rhenium and two different ligands coordinated therewith.
STATE OF THE ART
[0002] The 99m Tc-imido core has been only generically cited among a series of new cores suitable for the development of technetium radiopharmaceuticals (Archer C. et al. WO 91/03262 and references therein). Despite a few examples obtained at “carrier added (ca)” or, in other words, macroscopic level, using 99 Tc and cold Re, in which the presence of the imido group was clearly established, the transfer of this chemistry at “no carrier added (nca)” or, in other words, microscopic level, has met severe obstacles so far. The terms “macroscopic” or “carrier added” level refer to chemical reactions occurring at concentrations ranging from 10 −3 to 10 −5 M. Reactions are performed in conventional laboratories (if necessary approved for low level radioactivity) using from 1 to 200 mg amounts of non-radioactive Re or radioactive 99 Tc. The terms “microscopic” or “no carrier added” level refer to reactions occurring at concentrations ranging from 10 −6 to 10 −9 M with micrograms to nanograms amounts of radioactive 99m Tc or of radioactive 188 Re (see also IUPAC Compendium of Chemical Terminology, 2nd Edition (1997), wherein the following definition is provided for “no carrier added”: “ . . . a preparation of a radioactive isotope which is essentially free from stable isotopes of the element in question . . . ”). These reactions are routinely performed in hospital Nuclear Medicine Departments for clinical purposes (Deutsch, E., Libson, K., Recent advances in technetium chemistry: bridging inorganic chemistry and nuclear medicine , Comments Inorg. Chem., 3, 83-103, 1984).
[0003] Working at macroscopic level with 99 Tc, only five crystal structures of Tc(V)-imido species have been reported. They include [Tc(NR)Cl 3 (PPh 3 ) 2 ], where R is phenyl (Nicholson T. et al. Inorg. Chim. Acta, 187 (1991) 51) or tolyl (Dilworth J. et al. in Technetium in Chemistry and Nuclear Medicine— 3, Raven Press, New York, (1990), 109). By varying the bulkiness of both the halide (from Cl to Br) and/or the phosphine (from PPh 3 to PMePh 2 and PMe 2 Ph), three additional phenyl-imido compounds have been produced, i.e.: [Tc(NPh)Cl 3 (PMePh 2 ) 2 ], [Tc(NPh)Br 3 (PMePh 2 ) 2 ] (Rochon F. D. et al. Inorg. Chem. 34 (1995) 2273) and [Tc(NPh)Cl 2 (PMe 2 Ph) 3 ] + (Nicholson T. et al. Inorg. Chim. Acta, 230 (1995) 205).
[0004] Nevertheless, no specific disclosure, nor even suggestions, have ever been made on the possibility of successfully transferring the above preparations also at microscopic level.
[0005] All the above species are six-coordinated compounds with slight distortion from the ideal octahedron. The co-ordination sphere is totally filled with monodentate ligands (halides and monophosphines) that do not impose heavy steric constraints. In this connection the Tc atom moves off the mean basal plane towards the imido unit by only 0.11 Å. The imido core is essentially linear (mean Tc═N—C angle 175.70) with a marked portion of the Tc—N bond showing double bond character (mean value 1.71 Å; see G. Bandoli et al., Coord. Chem. Rev., 214 (2001) 43).
[0006] The possibility to introduce chelate ligands in the co-ordination sphere of Tc(V)-imido compounds was demonstrated separately by different authors. Nicholson et al. ( Inorg. Chim. Acta, 196 (1992) 27) introduced a simple bidentate diphosphine, i.e. 1,2-bis (diphenylphosphine)ethane (dppe) to yield [Tc(NPh)Cl 3 (dppe)]. Tisato et al. ( J. Organom. Chem. 637-639 (2001) 772) utilised the 1,2-bis (diphenylphosphine)ferrocenyl residue (dppf) to produce the analogous [Tc(NPh)Cl 3 (dppf)] complex. Similarly, rhenium (Re) complexes where synthesized, by using the bidentate (2-diphenylphosphine)benzeneamine (H 2 dpa), or the tetradentate N,N′-bis[(2-diphenylphosphine)phenyl]propane-1,3-diamine (Refosco F. et al, J. Chem. Soc. Dalton Trans 1998, 923-930).
[0007] Notwithstanding the above results, successive extensive efforts to stabilize the 99m Tc-imido core have surprisingly failed, because no appropriate combinations of donor atoms was found to support this group, while, on the contrary, this target was successfully achieved in the case of the somewhat similar 99m Tc-oxo and 99m Tc-nitrido cores. Oxo [ 99m Tc(O)] 3+ , imido [ 99m Tc(NR)] 3+ and nitrido [ 99m Tc(N)] 2+ moieties are isoelectronic cores, the metal being in the 5 + oxidation state, and, in this connection, the technetium-imido group can be considered as intermediate between oxo and nitrido cores. Previous investigations have established that Tc(V)-oxo groups are readily stabilized by tetradentate ligands, as shown by N 4 -hexamethylpropylene amine oxime (HM-PAO), N 3 S-mercaptoacetyltriglycyl (MAG 3 ) and N 2 S 2 -ethylcysteine dimer (ECD) in the clinically used Ceretec®, Technescan® and Neurolite® radiopharmaceuticals. On the other hand, the Tc(V)-nitrido group prefers a combination of two different polydentate ligands. Previous studies on 99 Tc-imido complexes have shown that distorted octahedral environments are usually achieved, the coordination being supported by monodentate ligands, preferably tertiary monophosphines and halides. Attempts to replace the monodentate P-based donors present in the prototype precursor [Tc(NPh)Cl 3 (PPh 3 ) 2 ] with various polydentate chelates were not successful, thus indicating that the imido group should be stabilized only by the presence of monodentate monophosphine ligands.
DESCRIPTION OF THE INVENTION
[0008] It has now surprisingly been found that it is possible to replace the two monodentate triphenylphosphine substituents with a tridentate heterodiphosphine ligand L 1 which comprises an electron donor heteroatom in the spacer chain linking said two phosphine groups, without affecting the stability of the imido group in the resulting [(Me═N—R)Y 2 (L 1 )] + Y − compounds, wherein Y is a leaving group, such as a halogen atom, an hydroxy or an alkoxy group. The facial configuration of the tridentate hetero-diphosphine chelate induces a cis-coordination of the two Y groups, which in turn can be easily substituted with suitable bidentate ligands L 2 to give the final desired [(Me═N—R)L 1 L 2 ] + Z − metal heterocomplex.
[0009] Accordingly, the present invention primarily provides a radioactive transition metal-imido hetero-diphosphine complex compound of formula (I):
[(Me═N—R)L 1 L 2 ] + Z − (I),
wherein:
Me is a radioactive transition metal selected from the group consisting of 99m Tc, 186 Re, 188 Re;
R is a C 1 -C 15 linear or branched alkyl or alkenyl residue, optionally interrupted by —O—, —S—, —N(R′)—, where R′ is H or C 1 -C 6 alkyl, and/or optionally substituted with halogen, hydroxy, C 1 -C 5 alkoxy, carboxy, ester, thiol, primary or secondary amino or amido groups, or R is phenyl or an aryl residue, being R optionally substituted with a biologically active substance, wherein said biologically active substance is selected among sugars, amino acids, fatty acids, vitamins, hormones, peptides, catecholamines, said catecholamines being optionally conjugated, via peptidic bond, to the other above mentioned biologically active substances;
[0010] L 1 is a tridentate hetero-diphosphine ligand of formula (II):
wherein:
R 1 , R 2 , R 3 and R 4 , which may be the same or different, have the same meanings as R;
X is oxygen, sulphur, NR 5 , wherein R 5 is hydrogen or R;
n is an integer ranging from 1 to 5;
L 2 is a bidentate ligand, which comprises a combination of two donor atoms, selected from the group consisting of oxygen, sulphur and nitrogen, said atoms being preferably negatively charged and being separated by a spacer of 2 to 4 members, said spacer being an aliphatic chain or part of an aromatic ring, L 2 being optionally conjugated to a biologically active substance as above defined;
Z − is a mononegative counter-ion selected from the group consisting of Cl − , Br − , OH − , ClO 4 − , alkoxylate, preferably EtO − , tetrafluoroborate.
[0011] Preferred R are methyl, ethyl, propyl, isopropyl, butyl, isobutyl, octyl, decyl, dodecyl, propenyl, butenyl, pentenyl, phenyl, benzyl, tolyl, 4-methoxy-benzyl, 4-ethoxy-benzyl, salicyl.
[0012] Preferred tridentate hetero-diphosphine ligands L 1 of formula (II) are those where n=2. Most preferred ligands L 1 are selected from the group consisting of:
[0013] (C 6 H 5 ) 2 PCH 2 CH 2 N(H)CH 2 CH 2 P(C 6 H 5 ) 2 ;
[0014] (C 6 H 5 ) 2 PCH 2 CH 2 N(CH 3 )CH 2 CH 2 P(C 6 H 5 ) 2 ;
[0015] (CH 3 ) 2 PCH 2 CH 2 N(CH 3 )CH 2 CH 2 P(CH 3 ) 2 ;
[0016] (C 6 H 5 ) 2 PCH 2 CH 2 SCH 2 CH 2 P(C 6 H 5 ) 2 ;
[0017] (C 6 H 5 ) 2 PCH 2 CH 2 OCH 2 CH 2 P(C 6 H 5 ) 2 ;
[0018] (C 6 H 5 ) 2 PCH 2 CH 2 N(CH 2 CH 2 OCH 3 )CH 2 CH 2 P(C 6 H 5 ) 2 .
[0019] Bidentate ligands L 2 preferably comprise a 2 or 3 membered spacer as defined above between the two electron-donor atoms. Suitable combinations of electron-donor atoms, preferably negatively charged, are [O − ,O − ], [N − ,O − ], [S − ,O − ], [N − ,N − ], [N − ,S − ] and [S − ,S − ]. Preferred bidentate ligands are catecholate (2−) ; carbonate (2−) ; 1,2-aminophenolate (2−) ; 1,2-benzenedithiolate (2−) ; ethyleneglycolate (2−) ; ethylenediaminate (2−) ; ethylenedithiolate (2−) ; 1,2-phenylenediaminate (2−) ; 1,2-aminothiophenolate (2−) ; thiosalicylate (2−) ; 1,2-aminoethanolate (2−) and the like.
[0020] The bidentate ligands L 2 preferably carry a biologically active substance as defined above. Among said biologically active substances, preferred are catecholamines, like dopamine, L-DOPA and 3-hydroxythyramine. Catecholamines may, in turn, be conjugated, via peptidic bond, to other physiologically active substances. In a preferred embodiment of the invention, vitamin H is conjugated to dopamine.
[0021] The radioactive compounds of formula (I) can be obtained by reacting an intermediate compound of formula (III):
[(Me═N—R)Y 2 (L 1 )] + Y − (III),
with a bidentate ligand L 2 ,
wherein Me, R, L 1 and L 2 are as defined above and Y is halogen, preferably chlorine, or bromine, hydroxy or alkoxy, preferably ethoxy, or a leaving group which easily undergoes nucleophilic substitution.
[0022] The reaction is usually carried out in an organic solvent, in the presence of an organic base, or under buffered conditions, preferably in phosphate buffer. Preferred solvents are alcohols and chlorinated solvents. Preferred organic bases are tertiary amines, more preferred is triethylamine. The reaction temperature ranges from room temperature to the reflux temperature of the solvent.
[0023] The final product is separated and purified with conventional techniques like salification, crystallization, chromatography as described in detail in the following experimental section.
[0024] Intermediate compounds of formula (III) are in turn synthesized as described in Scheme 1 below from oxides of radioactive transition metals, preferably 99m TcO 4 − , 186 ReO 4 − , or 188 ReO 4 − , more preferably 99m TcO 4 − , which are treated with an excess of tertiary monophosphines, preferably PPh 3 , in acidic hydro-alcoholic solutions and in the presence of a suitable imido donor (D), to give an imido complex of formula (IV), wherein Me, R and Y are as defined above. Successive treatment with an above described ligand L 1 affords the desired intermediates of formula (III).
[0025] Suitable imido donors D according to the invention are preferably 1-substituted-2-acetyl hydrazine, most preferably I-phenyl-2-acetyl hydrazine (PAH).
[0026] The reaction of L 1 with imido complexes of formula (IV) is preferably carried out in organic solvents like alcohols, chlorinated solvents, acetonitrile or a mixture thereof, optionally in the presence of an organic base like triethylamine, at a temperature ranging from room temperature to the reflux temperature of the solvent. The final purification of the desired intermediate of formula (III) is thoroughly described in the following experimental section. It has finally been demonstrated that the preferred 99m Tc-imido heterocomplexes according to the invention can be obtained at microscopical level via a three-step approach starting from pertechnetate sodium salt eluted from a commercial 99 Mo/ 99m Tc generator. In the first step pertechnetate is treated with an excess of tertiary monophosphine in hydro-alcoholic solutions acidified with hydrochloric acid and in the presence of 1-phenyl-2-acetyl hydrazine. In the second step, addition of the tridentate hetero-diphosphine ligand in an organic solvent affords the intermediate species [ 99m Tc(NPh)Cl 2 (L 1 )] + Y − . By adjusting pH at 7.4 with phosphate buffer, and by adding the preferred bidentate ligand L 2 , the desired imido heterocomplex is produced in high radiochemical yield (see Table 1).
[0000] Preferred complexes of the invention are:
[0027] [ 99m Tc(NPh)(PNHP)(O,N-ap)];
[0028] [ 99m Tc(NPh)(PNHP)(O,O-car)];
[0029] [ 99m Tc(NPh)(PNMeP)(O,N-ap)];
[0030] [ 99m Tc(NPh)(PNMeP)(S,N-atp)];
[0031] [ 99m Tc(NPh)(PNMeP)(O,O-cat)];
[0032] [ 99m Tc(NPh)(PNMeP)(S,O-tsal)];
[0033] [ 99m Tc(NPh)(PNMeP)(S,S-bdt)];
[0000] wherein
[0034] PNHP means (C 6 H 5 ) 2 PCH 2 CH 2 N(H)CH 2 CH 2 P(C 6 H 5 ) 2 ;
[0035] PNMeP means (C 6 H 5 ) 2 PCH 2 CH 2 N(CH 3 )CH 2 CH 2 P(C 6 H 5 ) 2 ;
[0036] O,N-ap means 2-aminophenolate (2−) ;
[0037] S,N-atp means 2-aminothiophenolate (2−) ;
[0038] O,O-cat means catecholate (2−) ;
[0039] O,O-car means carbonate (2−) ;
[0040] S,O-tsal means thiosalicylate (2−) ;
[0041] S,S-bdt means 1,2-benzenedithiolate (2−)
[0042] The reactivity of imido-containing species has been thoroughly studied at macroscopic level using [ 99 Tc(NPh)Cl 3 (PPh 3 ) 2 ] and [Re(NPh)Cl 3 (PPh 3 ) 2 ] as precursors.
[0043] These precursors react with tridentate hetero-diphosphine ligands L 1 to yield intermediate compounds of the type [Me(NPh)Cl 2 L 1 )][Cl]. The hetero-diphosphine ligand acts as a tridentate donor due to the presence of the electron-donor X heteroatom interposed in the diphosphine chain and gives rise to three different octahedral configurations, shown by the following formulas (IIIA): fac,cis (IIIB) mer,cis and (IIIC) mer,trans.
[0044] In formulae (IIIA), (IIIB) and (IIIC) a denotes the positions occupied by ligand L 1 and b denotes the positions occupied by ligand Y.
[0045] The halide group, positioned trans with respect to the imido core in the intermediate mer,cis-[Me(NPh)Cl 2 (L 1 )] + compounds, easily undergoes substitution with nucleophilic ligands (such as ethanolate), indicating that halide ligands are labile and good leaving groups. In similar substitution reactions, cis-positioned halides are replaced by bidentate nucleophilic ligands such as ethyleneglycol or catechol or the like to yield imido heterocomplexes of the type [Me(NPh)L 1 L 2 ] + Z − . Thus, both mer,cis-[Me(NPh)Cl 2 L 1 ] + and fac,cis-[Me(NPh)Cl 2 L 1 ] + isomers are useful intermediates for the production of mixed imido heterocomplexes. On the contrary, the mer,trans-[Me(NPh)Cl 2 L 1 ] + isomers give rise to the heterocomplexes in a negligible yield, as a result of heavy steric constraints imposed by the meridional coordination of the L 1 diphosphine combined with the trans-halide configuration. Thus, a reciprocal cis-position of the halide groups in the intermediate compounds is an essential pre-requisite for obtaining heterocomplexes of the invention.
[0046] The stereochemistry of the L 1 ligand in the final heterocomplex is always facial, the bidentate ligand L 2 filling the residual two positions on the equatorial plane of the octahedron.
[0047] The present invention is illustrated in further detail in the following examples.
EXAMPLES
[0048] The tridentate hetero-diphosphine ligands L 1 and the bidentate ligands L 2 used in the following examples are abbreviated as follows:
[0049] Tridentate hetero-diphosphine ligands L 1 :
[0000] PNHP; (C 6 H 5 ) 2 PCH 2 CH 2 N(H)CH 2 CH 2 P(C 6 H 5 ) 2
[0000] PNMeP; (C 6 H 5 ) 2 PCH 2 CH 2 N(CH 3 )CH 2 CH 2 P(C 6 H 5 ) 2
[0000] MePNMePMe; (CH 3 ) 2 PCH 2 CH 2 N(CH 3 )CH 2 CH 2 P(CH 3 ) 2
[0000] PNOMeP; (C 6 H 5 ) 2 PCH 2 CH 2 N(CH 2 CH 2 OCH 3 )CH 2 CH 2 P(C 6 H 5 ) 2
[0000] POP; (C 6 H 5 ) 2 PCH 2 CH 2 OCH 2 CH 2 P(C 6 H 5 ) 2
[0000] PSP; (C 6 H 5 ) 2 PCH 2 CH 2 OCH 2 CH 2 P(C 6 H 5 ) 2
[0050] Bidentate ligands L 2 :
[0000] O,O-cat; catecholate (2−)
[0000] O,O-car; carbonate (2−)
[0000] N,N-pda; 1,2-phenylenediaminate (2−)
[0000] S,S-bdt; 1,2-benzenedithiolate (2−)
[0000] O,O-eg; ethyleneglycolate (2−)
[0000] N,N-en; ethylenediaminate (2−)
[0000] S,S-edt; ethylenedithiolate (2−)
[0000] O,N-ap; 1,2-aminophenolate (2−)
[0000] S,N-atp; 1,2-aminothiophenolate (2−)
[0000] O,S-tsal; thiosalicylate (2−)
[0000] O,N-ae; 1,2-aminoethanolate (2−)
[0051] Chemistry at macroscopic (ca) level by using 99 Tc and Re
Example 1
Synthesis of mer,cis-[ 99 Tc(NPh)Cl 2 (PNEP)][Cl]
[0052] To a solution of [Tc(NPh)Cl 3 (PPh 3 ) 2 ] (45 mg) in dichloromethane/methanol (5 mL/1 mL) a 1.1 equivalent of solid PN(H)P was added under stirring. The brown mixture, in 2 minutes, turned brown-green. After 3 h the solution was taken to dryness with a flow of nitrogen. The oily residue was treated with diethyl ether and the resulting brown-green solid filtered. The crude solid was washed on the filter with acetone (2 mL). The light green solid was dried under nitrogen (yield 22 mg, 60%). The product is soluble in chlorinated solvents and acetonitrile, slightly soluble in alcohols, insoluble in diethyl ether.
[0053] 31 P-NMR (300 MHz, CDCl 3 , ppm): 31.6 (bs).
[0054] 1 H-NMR (300 MHz, CDCl 3 , ppm): 9.70 (bs, 1H; N—H), 8.06 (m, 4H, PPh 2 ), 7.51 (m, 13H, PPh 2 +NPhγ,α), 7.02 (m, 6H, PPh 2 ), 6.86 (t, 2H, NPhp), 3.97 (bt, 2H, CH 2 ), 3.34 (bm, 6H, CH 2 ).
Example 2
Synthesis of mer,cis-[Re(NPh)Cl 2 (PNHP)][Cl]
[0055] To a suspension of [Re(NPh)Cl 3 (PPh 3 ) 2 ] (104 mg, 0.11 mmol) in CH 2 Cl 2 , an excess of PNHP.HCl (75 mg, 0.16 mmol) dissolved in CH 2 Cl 2 with 50 μl of NEt 3 (0.38 mmol) was added dropwise. The reaction mixture was refluxed for 2 hours and then stirred overnight at room temperature. The resulting solution was olive-green. The solvent was removed and the green solid washed with diethyl ether, water and dried under vacuum. The 31 P-NMR spectrum of such solid in CDCl 3 showed two peaks at 4.3 an 8.4 ppm, which suggest the presence of two new products. A pure product was obtained by crystallization from a CH 2 Cl 2 /n-hexane mixture. Grey-blue crystals were obtained (final yield 30-40%) and the compound was identified as [Re(NPh)Cl 2 (PN(H)P)]Cl. The product is stable in air and soluble in CH 2 Cl 2 , CHCl 3 , quite soluble in EtOH and MeOH, insoluble in H 2 O, hexane and Et 2 O.
[0056] 31 P-NMR (300 MHz, CDCl 3 , ppm): 8.48 (s).
[0057] 1 H-NMR (300 MHz, CDCl 3 , ppm): 8.07(m, 4H, PPh 2 ), 7.71 (d, 2H,), 7.50 (m, 11H, PPh 2 +NPhγ), 7.03 (m, 6H, PPh 2 ), 6.87 (t, 2H, NPhβ), 4.01 (bt, 2H, CH 2 ), 3.39 (bm, 2H, CH 2 ), 3.22 (bm, 4H, CH 2 ), 9.5 (b, 1H, NH).
Example 3
Synthesis of mer,cis-[Re(NPh)(OEt)Cl(PNHP)][Cl]
[0058] To a suspension of [Re(NPh)Cl 3 (PPh 3 ) 2 ] (52 mg, 0.057 mmol) in EtOH, an excess of PNHP.HCl (43 mg, 0.089 mmol) dissolved in EtOH with 25 μl of NEt 3 (0.19 mmol) was added dropwise. The reaction mixture was refluxed for 4 hours: the resulting solution was green-yellowish. The volume was reduced under a nitrogen stream and Et 2 O was added: after few hours large bright blue crystals of [Re(NPh)(OEt)Cl(PNHP)]Cl had been formed.
[0059] 31 P-NMR (300 MHz, CDCl 3 , ppm): −0.20 (s).
[0060] 1 H-NMR (300 MHz, CDCl 3 , ppm): 9.5 (b, 1H, NH), 8.00 (m, 4H, PPh 2 ), 7.53 (m, 13H, PPh 2 +NPh), 7.07 (m, 6H, PPh 2 ), 6.87 (t, 2H, NPhp), 3.99 (bt, 2H, CH 2 ), 3.41 (m, 2H, CH 2 ), 3.18 (m, 2H, CH 2 ), 2.98 (m, 2H, CH 2 ), 2.64 (q, 2H; O—CH 2 —CH 3 ), -0.13 (t, 3H; O—CH 2 —CH 3 ).
Example 4
Synthesis of fac,cis-[Re(NPh)Cl 2 (PNMeP)][Cl]
[0061] To a suspension of [Re(NPh)Cl 3 (PPh 3 ) 2 ] in CH 2 Cl 2 a slight excess of PNMeP (86 mg, 0.19 mmol) was added. The reaction mixture was refluxed for 24 h. The volume of the resulting green-yellowish solution was reduced and Et 2 O was added. A TLC analysis of the precipitate showed a mixture of different products, so separation by means of a cromatographic column was performed (silica gel, CHCl 3 /EtOH 3/2). Two yellow and a green fraction were collected. The green product was identified as [Re(NPh)Cl 2 (PNMeP)]Cl.
[0062] 31 P{H}-NMR (300 MHz, CDCl 3 , ppm): 19.9 (s).
[0063] 1 H-NMR (300 MHz, CDCl 3 , ppm): 4.08, 3.45 and 2.95 (m, 8H CH 2 ), 2.61 (s, 3H, CH 3 ).
Example 5
Synthesis of mer,trans-[Re(NPh)Cl 2 (PNMeP)][Cl]
[0064] [Re(NPh)Cl 3 (PPh 3 ) 2 ] (100 mg, 0.11 mmol) and PNMePHCl (86 mg, 0.17 mmol) were mixed in acetonitrile. By refluxing for 15 minutes the reaction mixture became light green. Additional reflux deposited a green solid within a few hours. After 4 h the mixture was allowed to reach room temperature and filtered. The green powder was washed with Et 2 O and resulted soluble in CH 2 Cl 2 , quite soluble in CHCl 3 and almost insoluble in Et 2 O and benzene. NMR analysis evidenced the presence of two isomers in solution (yield 70%), then characterised as cis-[Re(NPh)Cl 2 (PNMeP)]Cl HCl. 1 H-NMR (300 MHz, CD 2 Cl 2 , ppm): 6.59 (d); 6.74 (t); 7.45 (t) (5H, NPh); 7.10 (m); 7.24 (m); 7.37 (m); 7.55 (m); 7.70 (m); 7.85 (m); 7.96 (m) (20H, PPh 2 ); 3.74(m); 3.35 (m); 3.08 (m) (8H, CH 2 ); 2.99 (d); 2.69 (d) CH 3 . 31 P {H} NMR (300 MHz,CD 2 Cl 2 ,ppm): −25.1 (s); −26.9 (s). The pale-green powder (cis-[Re(NPh)Cl 2 (PNMeP)]Cl HCl) was dissolved in CH 2 Cl 2 in the presence of an excess of NEt 3 . NMR analysis evidenced the quantitative conversion into the mer,trans-[Re(NPh)Cl 2 (PNMeP)]Cl complex.
[0065] 31 P-NMR (300 MHz, CDCl 3 ,ppm): 19.9 (s)
[0066] 1 H-NMR (CDCl 3 , ppm)=7.6-7.1 (20H; PPh 2 ) 4.08, 3.45 and 2.95 (m, 8H; methylene protons); 2.61 (s, 3H; CH 3 ).
Example 6
Synthesis of fac-[ 99 Tc(NPh)(O,O-cat)(PNHP)][ClO 4 ]
[0067] To a solution of [ 99 Tc(NPh)Cl 2 (PNHP)][Cl], prepared according to Example 1, (26 mg, 0.04 mmol) in methanol (5 mL), catechol (5.2 mg, 0.047 mmol) and triethylamine (6.7 μL, 0.047 mmol) were added. The colour of the mixture turned immediately deep purple. The solution was stirred for 4 h and concentrated to 2 mL by a nitrogen flow. A drop of a saturated NaClO 4 solution in MeOH was added to the solution. After 1 day, dark-grey crystals were formed; they were collected on a filter and washed with a 1×2 mL of MeOH.
[0068] 31 P-NMR (300 MHz, CDCl 3 , ppm): 46.5 (bs).
[0069] 1 H-NMR (300 MHz, CDCl 3 , ppm): 7.77 (t, 4H), 7.49 (t, 4H,), 7.40 (t, 4H), 7.22 (m, 6H) 7.02 (m, 7H), 6.87 (m, 2H), 6,71 (m, 2H), 3.5-2.7 (8H).
Example 7
Synthesis of fac-[Re(NPh)(O,O-cat)(PNHP)][Cl]
[0070] To a bluish solution of [Re(NPh)Cl 2 (PNHP)]Cl, prepared according to Example 2, in CH 2 Cl 2 (40 mg, 0.05 mmol) catechol (H 2 cat) (5 mg, 0.045 mmol) and 20 μl of NEt 3 were added at room temperature. The reaction mixture immediately turned red. The solution was stirred overnight at room temperature. After 15 h the solvent was removed, the residue was treated with diethyl ether and the resulting red-brown solid filtered and washed several times with n-hexane, diethyl ether and water. [Re(NPh)(O,O-cat)(PNHP)]Cl was obtained with a final yield of 53%. 1 H-NMR (300 MHz, CDCl 3 ): 7.85-7.07 (m, 25H, NPhT and PPh 2 ), 6.91-6.73 (m, 4H, cath). 31 P-NMR: 19.5 (s). A stoichiometric amount of NBu 4 BF 4 was added to a CH 2 Cl 2 solution of [Re(NPh)(O,O-cat)(PNHP)]Cl and by addition of n-hexane a red-orange product precipitated. Accoprding to the elemental analysis, this powder was characterized as the tetrafluoroborate salt of [Re(NPh)(O,O-cat)(PNHP)]
[0071] 31 P-NMR: 19.5 (s).
[0072] El. Anal.: ReN 2 C 40 H 38 O 2 P 2 BF 4 , MW 913.7
[0073] Calcd. C 52.6, N 3.2, H 5.1
[0074] Found: C 52.9, N 3.2, H 5.1.
Example 8
Synthesis of fac-[Re(NPh)(O,O-eg)(PNHP)][Cl]
[0075] To a bluish solution of [Re(NPh)Cl 2 (PNHP)]Cl of Example 2 in CH 2 Cl 2 (40 mg, 0.05 mmol) 30 μl of ethylene glycol and 20 μl of NEt 3 were added at room temperature. The reaction mixture was refluxed for 1 h and then stirred at room temperature for 24 h. The solution became grey. After removal of the solvent with a gentle nitrogen stream, the oily residue was treated with diethyl ether and the resulting grey solid filtered. The crude solid was purified washing, on the filter, with n-hexane and water. Grey crystals of [Re(NPh)(O,O-eg)(PNHP)]Cl, suitable also for X-ray diffractometric analysis, were obtained by crystallization from a CH 2 Cl 2 /n-hexane solution. 31 P {H} NMR (300 MHz, CD 2 Cl 2 ) 17.2. 1 H-NMR (300 MHz, CDCl 3 ): 7.74-6.91 (m, 25H, NPh and PPh 2 ), 4.98 (b, 1H, NH), 4.78 (d, 2H, CH 2 ), 4.60 (d, 2H, CH 2 ), 3.2-2.9 (m, 8H, PCH 2 CH 2 N).
Example 9
Synthesis of fac-[Re(NPh)(O,O-eg)(PNMeP)][Cl]
[0076] To a solution of fac,cis-[Re(NPh)Cl 2 (PNMeP)]Cl of Example 4 in CH 3 CN (50 mg, 0.06 mmol) 30 μl of ethylene glycol and 20 μl of NEt 3 were added. The reaction mixture was refluxed for 24 h. The volume of the dark green solution was reduced and the oily residue was dissolved in CH 2 Cl 2 , The excess of ethylene glycol was removed by water extraction. The organic phase was dried and a green powder, characterised as fac-[Re(NPh)(O,O-eg)(PNMeP)]Cl was recovered (yield 43%).
[0077] 1 H-NMR (300 MHz, CDCl 3 , 5 ppm): 6.98-7.48 (m, 25H, NPh and PPh 2 ); 4.91-4.76 (m, 4H CH); 3.58 (m), 3.27 (m) e 2.27 (m) (8H, —CH 2 CH 2 —PNP; 2.34 (s,3H,N—CH 3 ).
[0078] 31 P(CDCl 3 ): =24.3 (s).
Example 10
Synthesis of fac-[Re(NPh)(O,N-ap)(PNMeP)][Cl]
[0079] To a suspension of [Re(NPh)Cl 3 (PPh 3 ) 2 ] in CH 2 Cl 2 (90 mg, 0.1 mmol) PNMeP (53 mg, 0.11 mmol) was added at room temperature. After 5 minutes 1,2 aminophenol (17 mg, 0.16 mmol) and 20 μl of NEt 3 were added and the reaction mixture was refluxed. After 10 minutes the solution turned from green to dark brown. After refluxing for 30 min the solution was stirred overnight at room temperature. The solvent was removed and the residue treated with diethyl ether. The red brown solid was filtered and re-dissolved in CH 2 Cl 2 . Elution from a silica column with CHCl 3 /MeOH 85/15 separated a yellow by-product and the red fac-[Re(NPh)(O,N-ap)(PNMeP)]Cl.
[0080] 31 P(CDCl 3 ): =17.8 (d), 10.1 (d).
[0081] Chemistry at microscopic (nca) level by employing 99m Tc)
Example 11
Synthesis of the Intermediate [ 99m Tc(NPh)Cl 2 L 1 )] + Y − .
[0082] 0.1 mL of saline physiological solution containing [ 99m TcO 4 ] − (50 Mbq) were added to a vial containing 10 mg of PAH, 3 mg of PPh 3 0.1 mL of 1 M HCl and 1.5 mL of MeOH. The resulting solution was heated at 65° C. for 30 min. After this, 0.2 mL of an alcoholic solution containing 3 mg of an appropriate L 1 hetero-diphosphine ligand (PNHP or PNMeP or PNOMeP) was added. The resulting solution was maintained at 65° C. for further 30 min.
[0083] TLC analysis of the intermediate [ 99m Tc(NPh)Cl 2 L 1 )] + species showed a mixture of different products. This behaviour is in agreement with the evidences produced at macroscopic level, where some intermediate species were characterised.
Example 12
Synthesis of [ 99m Tc(NPh)L 1 L 2 ] + Z − .
[0084] This three-step preparation involves the preliminary formation of a mixture of intermediate complexes of general formula [ 99m Tc(NPh)Y 2 L 1 ] (Y=halides, water, hydroxyl, alkoxy) followed by its conversion into the final asymmetrical compound by reactions with the bidentate ligand L 2 . In detail, 0.250 mL of phosphate buffer 1 M, pH 7.4, followed by 0.2 mL of methanol solution containing 5 mg of an appropriate bidentate ligand L 2 were added to the vial containing the intermediate compound, obtained as reported above. The mixture was heated at 65° C. for 1 h. The radiochemical yields evaluated by TLC chromatography are reported in Table 1.
TABLE 1 Complexes TLC, Rf Yield % [ 99m Tc(NPh)(PNHP)(O,N-ap)] 0.42 b 62 [ 99m Tc(NPh)(PNMeP)(O,N-ap)] 0.24 a ; 0.45 b ; 0.14 c 97 [ 99m Tc(NPh)(PNMeP)(S,N-atp)] 0.28 a ; 0.28 c 85 [ 99m Tc(NPh)(PNMeP)(O,O-cat)] 0.85 a ; 0.85 c ; 0.5 d 91 [ 99m Tc(NPh)(PNMeP)(S,O-tsal)] 0.78 a ; 0.75 c , 0.35 d 90 [ 99m Tc(NPh)(PNMeP)(S,S-bdt)] 0.74 a ; 1 b,c,d 98 TLC SiO 2 : a EtOH/CHCl 3 /C 6 H 6 (1/2/1.5); b CHCl 3 /MeOH (2% NH 4 OH 20%) 85/15; c CHCl 3 /MeOH (2% NH 4 OH 20%) 90/10; d CHCl 3 /MeOH (2% NH 4 OH 20%) 95/5
[0085] Rf values shown by the compounds of Table 1 are in full accord with the ones shown by the corresponding compounds obtained at macroscopic level, using 99 Tc, thus confirming that for the compounds of the invention the transfer from macro to micro level is possible.
[0086] The metal-imido hetero-diphosphine complexes of the present invention proved useful in the radiopharmaceutical field, either in radiodiagnostic imaging, when 99m Tc is the employed radioactive metal, or in radiotherapy, when 186 Re and 188 Re are the radioactive metals.
[0087] Accordingly, the invention encompasses also the use of these complexes in the diagnostic and/or therapeutic radiopharmaceutical field and the pharmaceutical compositions comprising said compounds in admixture with pharmaceutically acceptable carriers and/or excipients.
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The present invention provides radioactive metal heterocomplexes of formula (I): [(Me═N—R)L 1 L 2 ]+Z. (I), wherein Me, R, L 1 L 2 and Z − have the meanings indicated in the description. The complexes include a trivalent radioactive metal-imido group, typically a technetium- or rhenium-imido group, strongly stabilized by the presence of an ancillary tridentate hetero-diphosphine ligand L 1 , which allows the formation of substitution-inert [(Me═N—R)L 1 ] moieties. Such moieties are fixed in an intermediate [(Me═N—R)Y 2 L 1 )] + compound which contains two labile, cispositioned, Y ligands, where Y is preferably an halide group. The latter are easily replaced by a bidentate ligand L 2 to give the final [(Me═N—R)L 1 L 2 ] + Z − heterocomplexes. The complexes of the invention are useful for the preparation of radiopharmaceuticals: in fact, a bioactive fragment which confers biological target-seeking properties can be introduced either on the L 2 framework or the imido R group.
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This application is a division of U.S. application Ser. No. 09/990,422, filed Nov. 21, 2001, now U.S. Pat. No. 6,719,784, which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to methods of preparing tubular prostheses, and, more particularly, to techniques for forming multi-layered prostheses.
BACKGROUND OF THE INVENTION
Formation of prostheses from polytetrafluoroethylene (PTFE), particularly expanded polytetrafluoroethylene (ePTFE) is well known in the prior art. ePTFE includes a node and fibril structure, having longitudinally extending fibrils interconnected by transverse nodes. The nodes are not particularly strong in shear, and, thus, ePTFE structures are susceptible to failure in a direction parallel to the fibril orientation. ePTFE structures (tubes, sheets) are typically paste extruded, and, the fibrils are oriented in the extrusion direction.
Vascular grafts formed of ePTFE are well known in the art. Where sutures have been used to fix such grafts, suture hole elongation and propagation of tear lines from suture holes have been noted.
To overcome the deficiencies of the prior art, techniques have been developed which re-orient the node and fibril structure of an ePTFE element to be transverse to the extrusion direction. By orienting the fibrils at an angle relative to the extrusion direction, the tear strength of a respective product may be greatly improved. In one technique set forth in U.S. Pat. Nos. 5,505,887 and 5,874,032, both to Zdrahala et al., an extrusion machine is described having a counter-rotating die and mandrel arrangement. Accordingly, upon being extruded, a single-layer unitary PTFE tube is formed having an outer surface twisted in one helical direction, and an inner surface twisted in an opposite helical direction. Although tubes formed in accordance with the method of U.S. Pat. Nos. 5,505,887 and 5,874,032 are expandable to form an ePTFE structure, the fibrils of the structure are oriented generally parallel to the expansion direction after expanding as shown in the micrograph of FIG. 5 in U.S. Pat. No. 5,874,032. Also, the tube tends to thin out unevenly under expansion, and, suffers from “necking”.
SUMMARY OF THE INVENTION
To overcome the deficiencies of the prior art, a method is provided wherein ePTFE tubes are counter-rotated, coaxially disposed, and fixed one to another to form a composite multi-layer prosthesis. By rotating the tubes, the tubes each becomes helically twisted with its node and fibril configuration being angularly offset throughout from the longitudinal axis of the tube (and, thus, angularly offset from the extrusion direction of the tube). With counter-rotation, the nodes and fibrils of the two tubes are also angularly offset from each other, resulting in a relatively strong composite structure. The composite multi-layer structure is akin to plywood, where alternating layers have differently oriented grain directions.
These and other features will be better understood through a study of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an elevational view of an ePTFE tube;
FIG. 2A is an elevational view of a helically wound tube twisted in a first rotational direction;
FIG. 2B is a schematic of the node and fibril orientation of the first tube in a helically wound state;
FIG. 3A is an elevational view of a helically wound tube twisted in a second rotational direction;
FIG. 3B is a schematic of the node and fibril orientation of the second tube in a helically wound state;
FIG. 4A is an elevational view of a prosthesis formed in accordance with the subject invention;
FIG. 4B is a schematic of the node and fibril orientations of the composite prosthesis; and,
FIG. 5 is an exploded view of a prosthesis having a radially-expandable support member.
DETAILED DESCRIPTION OF THE INVENTION
The invention herein provides a multi-layer prosthesis which may be used as a graft to replace a portion of a bodily passageway (e.g., vascular graft), or within a bodily passageway to maintain patency thereof, such as an endovascular stent-graft. In addition, the prosthesis can be used in other bodily applications, such as the esophagus, trachea, colon, biliary tract, urinary tract, prostate, and the brain.
The prosthesis is composed of multiple layers, including coaxially disposed ePTFE tubes. To illustrate the invention, reference will be made to the use of two ePTFE tubes, although any number may be utilized consistent with the principles disclosed herein. With reference to FIG. 1 , an ePTFE tube 10 is shown which extends along a longitudinal axis 12 . The ePTFE tube 10 is preferably formed by extrusion, thus having its fibrils generally parallel to the extrusion direction of the tube, which coincides with the longitudinal axis 12 . The ePTFE tube 10 includes a wall 14 (which is seamless if extruded), that extends about a lumen 16 . The wall 14 includes an inner luminal surface 18 facing the lumen 16 , and an outer, abluminal surface 20 . The ePTFE tube may be formed of any length and of various dimensions, although it is preferred that the dimensions be generally constant throughout the length thereof. In describing first and second tubes of the invention, like reference numerals will be used to describe like elements, but with the extensions “A” and “B” for differentiation. Elements associated with a first tube will have the extension “A”, while elements associated with a second tube will have the extension “B”.
Referring to FIG. 2A , a first ePTFE tube 10 A is shown disposed along a longitudinal axis 12 A. The first tube 10 A is twisted about its longitudinal axis 12 A in a first rotational direction, such as clockwise, as shown in FIG. 2A . The tube 10 A may be twisted over any given range of degrees, although it is preferred that the tube be twisted at least 10 degrees. Accordingly, as represented by the hypothetical reference axis 22 A, the first tube 10 A is helically wound in the first rotational direction. As a result and as shown in FIG. 2B , fibrils 24 A are generally parallel to the reference axis 22 A, with the fibrils 24 A being angularly offset an angle α from the longitudinal axis 12 A, and, thus, being also angularly offset the angle α from the original extrusion direction of the first tube 10 A. Nodes 26 A are generally perpendicular to the fibrils 24 A. With the fibrils 24 A, and the nodes 26 A, being obliquely disposed relative to the longitudinal axis 12 A, failure along the longitudinal axis 12 A may be reduced.
Referring to FIGS. 3A and 3B , a second ePTFE tube 10 B is shown being twisted in a second rotational direction different than the first rotational direction of the first tube 10 A. As shown in FIG. 3A , the second ePTFE tube is twisted in a counterclockwise direction. The particular rotational direction of twisting may be switched for the first and second tubes 10 A and 10 B. As with the first tube 10 A, the amount of twisting of the second tube 10 B may be varied, although it is preferred that at least a 10 degree displacement be provided. The helically wound distortion of the second tube 10 B is represented by the hypothetical reference axis 22 B. As shown in FIG. 3B , fibrils 24 B are generally parallel to the reference axis 22 B and are angularly offset an angle β from the longitudinal axis 12 B (and, thus, the extrusion direction). Nodes 26 B are generally perpendicular to the fibrils 26 A. The oblique disposition of the fibrils 24 B and the nodes 26 B resists failure along the longitudinal axis 12 B.
FIG. 4A shows a prosthesis 100 including the first tube 10 A, in its twisted helical state being coaxially disposed within, and fixed to, the second tube 10 B, in its twisted helical state. It is preferred that the tubes 10 A and 10 B be generally coextensive, although the ends of the tubes need not be coterminous. Because of the different rotational orientations of the node and fibril structures of the tubes 10 A and 10 B, the node and fibril structures are angularly offset from each other. In particular, as shown schematically in FIG. 4B , because of the coaxial arrangement of the tubes 10 A, 10 B, the longitudinal axes 12 A and 12 B are generally colinear. Also, the fibrils 24 A of the first tube 10 A are angularly offset from the fibrils 24 B of the second tube 10 B by an angle γ. The angular offset of the fibrils 24 A and 24 B provides the prosthesis 100 with resistance against failure not provided by either tube 10 A, 10 B alone. In a preferred embodiment, with the angles α and β being each at least 10 degrees, the angle γ will be at least 20 degrees. Preferably, the node and fibrils of each of the tubes 10 A, 10 B are generally-equally angularly offset throughout the respective tube 10 A, 10 B.
Because the first tube 10 A is disposed within the second tube 10 B, the second tube 10 B is formed dimensionally slightly larger to accommodate the first tube 10 A within its lumen 16 B.
As an alternative, only one of the tubes 10 A, 10 B may be twisted. The node and fibrils of the two tubes 10 A, 10 B would, nevertheless, be angularly offset.
In a preferred manner of preparing the prosthesis 100 , the first tube 10 A is provided and mounted onto a mandrel where it is twisted into its desired helical configuration. The twisted configuration of the first tube 10 A is maintained. The second tube 10 B is provided and twisted as desired, and in its twisted state telescoped over the first tube 10 A. The first and second tubes 10 A and 10 B are fixed together using any technique known to those skilled in the art, preferably sintering. Adhesive may also be used to bond the tubes, such as a thermoplastic fluoropolymer adhesive (e.g., FEP). Once fixed, the prosthesis 100 is prepared.
Although reference has been made herein to extruded ePTFE tubes, tubes formed by other techniques may also be used, such as with rolling a sheet, or wrapping a tape. Generally, with these non-extrusion techniques, the fibrils of the ePTFE will not initially be oriented parallel to the longitudinal axis of the tube, but rather transverse thereto. These non-extruded tubes may replace one or more of the tubes 10 A, 10 B in a non-twisted state or in a twisted state.
As shown in FIG. 5 , the prosthesis 100 may also include a radially expandable support member 28 , which may be disposed interiorly of the first tube 10 A, exteriorly of the second tube 10 B, or interposed between the two tubes 10 A, 10 B. Additionally, multiple support members located at the aforementioned locations may be provided. The radially expandable support member 28 may be fixed to the tubes 10 A, 10 B using any technique known to those skilled in the art, such as bonding. Additionally, with the radially expandable support member 28 being interposed between the tubes 10 A, 10 B, the tubes 10 A, 10 B may be fixed together through any interstices formed in the radially expandable support member 28 .
The radially expandable support member 28 may be of any construction known in the prior art which can maintain patency of the prosthesis 100 . For example, as shown in FIG. 5 , the radially-expandable support member 28 may be a stent. The particular stent 28 shown in FIG. 5 is fully described in commonly assigned U.S. Pat. No. 5,693,085 to Buirge et al., and the disclosure of U.S. Pat. No. 5,693,085 is incorporated by reference herein. The stent may be an intraluminally implantable stent formed of a metal such as stainless steel or tantalum, a temperature-sensitive material such as Nitinol, or alternatively formed of a superelastic alloy or suitable polymer. Although a particular stent construction is shown with reference to the present invention, various stent types and stent constructions may be employed for the use anticipated herein. Among the various useful radially-expandable support members 28 include, without limitation, self-expanding stents and balloon expandable stents. The stents may be capable of radially contracting as well. Self-expanding stents include those that have a spring-like action which causes the stent to radially expand or stents which expand due to the memory properties of the stent material for a particular configuration at a certain temperature. Other materials are of course contemplated, such as stainless steel, platinum, gold, titanium, tantalum, niobium, and other biocompatible materials, as well as polymeric stents. The configuration of the radially-expandable support member 28 may also be chosen from a host of geometries. For example, wire stents can be fastened in a continuous helical pattern, with or without wave-like forms or zig-zags in the wire, to form a radially deformable stent. Individual rings or circular members can be linked together such as by struts, sutures, or interlacing or locking of the rings to form a tubular stent.
Furthermore, the prosthesis 100 may be used with additional layers which may be formed of polymeric material and/or fabric. Furthermore, any layer or portion of the prosthesis 100 , including the tubes 10 A, 10 B, may be impregnated with one or more therapeutic and pharmacological substances prior to implantation of the prosthesis 100 for controlled release over an extended duration. It is anticipated that the prosthesis 100 can be partially or wholly coated with hydrophilic or drug delivery-type coatings which facilitate long-term healing of diseased vessels. Such a coating is preferably bioabsorbable, and is preferably a therapeutic agent or drug, including, but not limited to, anti-thrombogenic agents (such as heparin, heparin derivatives, urokinase, and PPack (dextrophenylalanine proline arginine chloromethylketone); anti-proliferative agents (such as enoxaprin, angiopeptin, or monoclonal antibodies capable of blocking smooth muscle cell proliferation, hirudin, and acetylsalicylic acid); anti-inflammatory agents (such as dexamethasone, prednisolone, corticosterone, budesonide, estrogen, sulfasalazine, and mesalamine); antineoplastic/antiproliferative/anti-miotic agents (such as paclitaxel, 5-fluorouracil, cisplatin, vinblastine, vincristine, epothilones, endostatin, angiostatin and thymidine kinase inhibitors); anesthetic agents (such as lidocaine, bupivacaine, and ropivacaine); anti-coagulants (such as D-Phe-Pro-Arg chloromethyl keton, an RGD peptide-containing compound, heparin, antithrombin compounds, platelet receptor antagonists, anti-thrombin antibodies, anti-platelet receptor antibodies, aspirin, prostaglandin inhibitors, platelet inhibitors and tick antiplatelet peptides); vascular cell growth promotors (such as growth factor inhibitors, growth factor receptor antagonists, transcriptional activators, and translational promotors); vascular cell growth inhibitors (such as growth factor inhibitors, growth factor receptor antagonists, transcriptional repressors, translational repressors, replication inhibitors, inhibitory antibodies, antibodies directed against growth factors, bifunctional molecules consisting of a growth factor and a cytotoxin, bifunctional molecules consisting of an antibody and a cytotoxin); cholesterol-lowering agents; vasodilating agents; and agents which interfere with endogenous vascoactive mechanisms.
Various changes and modifications can be made in the present invention. It is intended that all such changes and modifications come within the scope of the invention as set forth in the following claims.
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A prosthesis, and method for forming same, are provided which includes expanded polytetrafluoroethylene (ePTFE) tubes having angularly offset node and fibril configurations. Also, the node and fibril configurations are angularly offset from the longitudinal axes of the respective tubes, providing resistance against failure in the longitudinal direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage entry under 35 USC §371(b) of International Application No. PCT/US2011/050393, filed Sep. 2, 2011, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/379,414 filed on Sep. 2, 2010, the entire disclosures of which are incorporated herein by reference.
GOVERNMENT RIGHTS
This invention was made with government support under GM53386 awarded by the National Institutes of Health. The government has certain rights in the invention.
TECHNICAL FIELD
This invention relates to compounds that inhibit HIV proteolytic enzymes and processes for preparing the compounds. The invention also relates to methods of using the disclosed compounds for treating patients infected with HIV.
BACKGROUND AND SUMMARY
The AIDS epidemic is one of the most challenging problems in medicine in the 21st century. A retrovirus designated human immunodeficiency virus (HIV) is the etiological agent of the complex disease that includes progressive destruction of the immune system (acquired immune deficiency syndrome; AIDS) and degeneration of the central and peripheral nervous system. This virus was previously known as LAV, HTLV-III, or ARV. A common feature of retrovirus replication is the extensive post-translational processing of precursor polyproteins by a vitally encoded protease to generate mature vital proteins required for virus assembly and function. Inhibition of this processing prevents the production of normally infectious virus. It has been previously demonstrated that genetic inactivation of the HIV encoded protease resulted in the production of immature, non-infectious virus particles. These results indicate that inhibition of the HIV protease represents a viable method for the treatment of AIDS and the prevention or treatment of infection by HIV.
Among many strategies to combat this disease, highly active antiretroviral therapy (HAART) with HIV protease inhibitors (PIs) in combination with reverse transcriptase inhibitors (RTIs) continues to be the first line treatment for control of HIV infection. This treatment regimen has definitely improved quality of life, enhanced HIV management, and halted the progression of the disease. However, despite these impressive successes, there remain many challenges to treating this devastating disease, including decreasing both the toxicity of and complexity of these treatment regimens. In addition, there is a growing population of patients that are developing multi-drug resistant strains of HIV, and there is ample evidence that these strains can be further transmitted.
HAART has had a major impact on the AIDS epidemic in industrially advanced nations; however, eradication of human immunodeficiency virus type 1 (HIV 1) appears to be currently unachieved, in part due to the viral reservoirs remaining in blood and infected tissues. The limitation of antiviral therapy of AIDS is also exacerbated by complicated regimens, the development of drug-resistant HIV-1 variants, and a number of inherent adverse effects. However, a number of challenges have nonetheless been encountered in bringing about the optimal benefits of the currently available therapeutics of AIDS and HIV-1 infection to individuals receiving HAART. They include (i) drug-related toxicities; (ii) partial restoration of immunologic functions once individuals developed AIDS; (iii) development of various cancers as a consequence of survival prolongation; (iv) flame-up of inflammation in individuals receiving HAART or immune re-construction syndrome (IRS); and (v) increased cost of antiviral therapy. Such limitations of HAART are exacerbated by the development of drug-resistant HIV-1 variants.
Efforts to counter the development of resistance with new compounds have been recently reported (Ghosh A K, et al., Bioorg. Med. Chem. Lett. 1998; Ghosh A K, et al., Farmaco 2001; Ghosh A K, et al., ChemMedChem, 2006; Yoshimura K, et al., J. Virol. 2002; Koh Y, Nakata H, Maeda K., Antimicrob Agents Chemother, 2003). The FDA approved Darunavir on Jun. 23, 2006; on Oct. 21, 2008, FDA granted traditional approval to Prezista (darunavir), co-administered with ritonavir and with other antiretroviral agents, for the treatment of HIV-1 infection in treatment-experienced adult patients. In addition to the traditional approval, a new dosing regimen for treatment-naïve patients was approved (Tie Y, et al., Proteins 2007; Kovalevsky A Y, et al., J. Med. Chem. 2006; Ghosh A K, Chapsal B D, Weber I T, Mitsuya H., Acc. Chem. Res. 2008-; Ghosh A K, et al., J. Med. Chem. 2006; Ghosh A K, et al., J. Med. Chem. 2009; Ghosh A K, Chen Y., Tetrahedron Lett., 1995). One of the PIs, darunavir (DRV), was first approved for HIV/AIDS patients harboring drug-resistant HIV that do not respond to other antiretroviral drugs. Recently, DRV has received full approval for all HIV/AIDS patients including children infected with HIV-1. DRV incorporates a stereochemically defined fused bis-tetrahydrofuran (bis-THF) as the P2-ligand. Each of the documents cited herein is incorporated herein by reference. Inhibition of HIV-1 protease has been documented as an effective strategy for the treatment of HIV/AIDS.
Herein described are potent inhibitors of HIV protease, including against various multidrug-resistant HIV-1 variants. In one embodiment, inhibitors described herein show nearly a 10-fold inhibition improvement over Darunavir (DRV). In another embodiment, inhibitors described herein also potently block protease dimerization by at least a factor of 10-fold compared to DRV.
The invention described herein includes novel compounds and compositions for treating patients in need of relief from HIV, AIDS, and AIDS-related diseases. In addition, the invention described herein includes methods for treating HIV, AIDS, and AIDS-related diseases using the compounds described herein as well as known compounds that heretofore have not been used or described as being useful in the treatment of such diseases.
In an embodiment of the invention, a compound having the formula
or a pharmaceutically acceptable salt, isomer, mixture of isomers, crystalline form, non crystalline form, hydrate, or solvate thereof; wherein
X 1 is a bond or optionally substituted alkylene;
X 2 is a bond, C(O), S(O), S(O) 2 , optionally substituted amino, or optionally substituted alkylene;
R 1 and R 2 are in each instance independently selected from the group consisting of hydrogen, P(O)(OR) 2 and a prodrug forming group, where R is independently selected in each instance from hydrogen or alkyl;
R 3 is sulfonyl, acyl, amino, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, arylalkyl, heteroaryl, or heteroarylalkyl, each of which is optionally substituted;
R 4 is hydrogen, halogen, —OH, or —NO 2 , or R 4 is amino, alkoxyl, sulfonyl, acyl, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, and heteroaryl, each of which is optionally substituted; or R 3 , R 4 , X 2 and the attached nitrogen form an optionally substituted heterocyclyl;
R 5 and R 6 are independently in each instance hydrogen or selected from the group consisting of alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, arylalkyl, heteroaryl, and heteroarylalkyl, each of which is optionally substituted;
Z is
wherein * indicates the point of attachment; m is 0, 1, or 2;
W 1 and W 2 are in each instance independently selected from the group consisting of optionally substituted alkylene, alkyleneoxy, alkyleneamino, alkylenethio, alkylenesulfoxyl, and alkylenesulfonyl;
W 3 and W 4 are in each instance independently selected from the group consisting of amino, oxygen, alkylene, alkyleneoxy, alkyleneamino, and heteroalkylene, wherein at least one of W 1 or W 2 is oxygen, and wherein when one of W 1 or W 2 is optionally substituted methylene, at least one of W 3 or W 4 is oxygen or alkyleneoxy, and wherein Z does not include a peroxide bond, a sulfenate bond, or a sulfenamide bond;
X 3 is a bond or optionally substituted methylene; and
Y is hydrogen, hydroxyl, or carbonyl, or amino, acyl, sulfonyl, alkyl, or heteroalkyl, each of which is optionally substituted is described.
In another embodiment
or a pharmaceutically acceptable salt, isomer, mixture of isomers, crystalline form, non crystalline form, hydrate, or solvate thereof; wherein
X 1 is a bond or optionally substituted alkylene;
X 2 is a bond, C(O), S(O), S(O) 2 , optionally substituted amino, or optionally substituted alkylene;
R 1 and R 2 are in each instance independently selected from the group consisting of hydrogen, P(O )(OR) 2 and a prodrug forming group, where R is independently selected in each instance from hydrogen or alkyl;
R 3 is sulfonyl, acyl, amino, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, arylalkyl, heteroaryl, or heteroarylalkyl, each of which is optionally substituted;
R 4 is hydrogen, halogen, —OH, or —NO 2 , or R 4 is amino, alkoxyl, sulfonyl, acyl, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, and heteroaryl, each of which is optionally substituted; or R 3 , R 4 , X 2 and the attached nitrogen form an optionally substituted heterocyclyl;
R 5 and R 6 are independently in each instance hydrogen or selected from the group consisting of alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, arylalkyl, heteroaryl, and heteroarylalkyl, each of which is optionally substituted;
Z is
wherein * indicates the point of attachment; n is 1, 2, or 3;
W 1 and W 2 are in each instance independently selected from the group consisting of optionally substituted methylene, oxygen, and amino;
W 3 and W 4 are in each instance independently selected from the group consisting of amino, oxygen, alkylene, and heteroalkylene, wherein at least one of W 1 or W 2 is oxygen, and wherein when one of W 1 or W 2 is optionally substituted methylene, at least one of W 3 or W 4 is oxygen, and wherein Z does not include a peroxide bond, a sulfenate bond, or a sulfenamide bond;
X 3 is a bond or optionally substituted methylene; and
Y is hydrogen, hydroxyl, or carbonyl, or amino, acyl, sulfonyl, alkyl, or heteroalkyl, each of which is optionally substituted is described.
In another embodiment, a pharmaceutical composition comprising a therapeutically effective amount of one or more of the compounds described herein for treating HIV infection is described.
In another embodiment, compounds described are used in the treatment of HIV, AIDS, and AIDS-related diseases. Also described herein is a method for treating a patient in need of relieve of an HIV infection, the method comprising the step of administering to a patient in need of relief from the HIV infection a therapeutically effective amount of one or more compounds of any of the compounds or the compositions described herein.
In another embodiment, described herein is the synthesis of a series of inhibitors for HIV-1 protease that incorporate conformationally constrained and stereochemically defined tris-tetrahydrofuran derivatives as the P2-ligands. These inhibitors have shown marked enzyme-inhibitory and antiviral potency. A number of these inhibitors are very potent against multi-drug resistant HIV-1 variants.
DETAILED DESCRIPTION
Embodiments of the invention are further described by the following enumerated clauses:
0. A compound having the formula
or a pharmaceutically acceptable salt, isomer, mixture of isomers, crystalline form, non crystalline form, hydrate, or solvate thereof; wherein
X 1 is a bond or optionally substituted alkylene;
X 2 is a bond, C(O), S(O), S(O) 2 , optionally substituted amino, or optionally substituted alkylene;
R 1 and R 2 are in each instance independently selected from the group consisting of hydrogen, P(O)(OR) 2 , and a prodrug forming group, where R is independently selected in each instance from hydrogen or alkyl;
R 3 is sulfonyl, acyl, amino, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, arylalkyl, heteroaryl, or heteroarylalkyl, each of which is optionally substituted;
R 4 is hydrogen, halogen, —OH, or —NO 2 , or R 4 is amino, alkoxyl, sulfonyl, acyl, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, and heteroaryl, each of which is optionally substituted; or R 3 , R 4 , X 2 and the attached nitrogen form an optionally substituted heterocyclyl;
R 5 and R 6 are independently in each instance hydrogen or selected from the group consisting of alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, arylalkyl, heteroaryl, and heteroarylalkyl, each of which is optionally substituted;
Z is
wherein * indicates the point of attachment; m is 0, 1, or 2;
W 1 and W 2 are in each instance independently selected from the group consisting of optionally substituted alkylene, alkyleneoxy, alkyleneamino, alkylenethio, alkylenesulfoxyl, and alkylenesulfonyl;
W 3 and W 4 are in each instance independently selected from the group consisting of amino, oxygen, alkylene, alkyleneoxy, alkyleneamino, and heteroalkylene, wherein at least one of W 1 or W 2 is oxygen, and wherein when one of W 1 or W 2 is optionally substituted methylene, at least one of W 3 or W 4 is oxygen or alkyleneoxy, and wherein Z does not include a peroxide bond, a sulfenate bond, or a sulfenamide bond;
X 3 is a bond or optionally substituted methylene; and
Y is hydrogen, hydroxyl, or carbonyl, or amino, acyl, sulfonyl, alkyl, or heteroalkyl, each of which is optionally substituted is described.
1. A compound having the formula
or a pharmaceutically acceptable salt, isomer, mixture of isomers, crystalline form, non crystalline form, hydrate, or solvate thereof; wherein
X 1 is a bond or optionally substituted alkylene;
X 2 is a bond, C(O), S(O), S(O) 2 , optionally substituted amino, or optionally substituted alkylene;
R 1 and R 2 are in each instance independently selected from the group consisting of hydrogen, P(O)(OR) 2 and a prodrug forming group, where R is independently selected in each instance from hydrogen or alkyl;
R 3 is sulfonyl, acyl, amino, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, arylalkyl, heteroaryl, or heteroarylalkyl, each of which is optionally substituted;
R 4 is hydrogen, halogen, —OH, or —NO 2 , or R 4 is amino, alkoxyl, sulfonyl, acyl, alkyl, heteroalkyl, cycloalkyl, cycloheteroalkyl, aryl, and heteroaryl, each of which is optionally substituted; or R 3 , R 4 , X 2 and the attached nitrogen form an optionally substituted heterocyclyl;
R 5 and R 6 are independently in each instance hydrogen or selected from the group consisting of alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, arylalkyl, heteroaryl, and heteroarylalkyl, each of which is optionally substituted;
Z is
wherein * indicates the point of attachment; n is 1, 2, or 3;
W 1 and W 2 are in each instance independently selected from the group consisting of optionally substituted methylene, oxygen, and amino;
W 3 and W 4 are in each instance independently selected from the group consisting of amino, oxygen, alkylene, and heteroalkylene, wherein at least one of W 1 or W 2 is oxygen, and wherein when one of W 1 or W 2 is optionally substituted methylene, at least one of W 3 or W 4 is oxygen, and wherein Z does not include a peroxide bond, a sulfenate bond, or a sulfenamide bond;
X 3 is a bond or optionally substituted methylene; and
Y is hydrogen, hydroxyl, or carbonyl, or amino, acyl, sulfonyl, alkyl, or heteroalkyl, each of which is optionally substituted. 2. The compound of clause 1 wherein Z is
wherein * indicates the point of attachment. 3. The compound of clause 1 or 2 wherein Z is
wherein W 2 is an oxygen; and * indicates the point of attachment. 4. The compound of any one of the preceding clauses wherein X 3 is a bond. 5. The compound of any one of the preceding clauses wherein n is 1 or 2. 6. The compound of any one of the preceding clauses wherein W 4 is optionally substituted ethylene or propylene. 7. The compound of any one of the preceding clauses wherein n is 1. 8. The compound of any one of the preceding clauses wherein W 4 is ethylene. 9. The compound of any one of the preceding clauses wherein Y is hydrogen. 10. The compound of any one of the preceding clauses wherein W 1 , W 2 , and W 3 are oxygen. 11. The compound of any one of the preceding clauses wherein Z is
11.1 The compound of any one of the preceding clauses wherein Z is
11.2 The compound of any one of the preceding clauses wherein Z is
12. The compound of any one of the preceding clauses wherein R 1 and R 2 are each hydrogen. 13. The compound of any one of the preceding clauses wherein R 5 is optionally substituted arylalkyl. 14. The compound of any one of the preceding clauses wherein X 1 is a bond and R 6 is hydrogen. 15. The compound of any one of the preceding clauses wherein X 2 is S(O) 2 and R 4 is optionally substituted aryl. 16. The compound of any one of the preceding clauses wherein R 3 is iso-butyl. 17. The compound of any one of the preceding clauses wherein X 2 is NR, where R is hydrogen or alkyl. 18. The compound of any one of the preceding clauses wherein X 4 is arylsulfonyl. 18a. The compound of any one of the preceding clauses wherein R 3 is optionally substituted arylalkyl. 18b. The compound of any one of the preceding clauses wherein W 2 is oxygen. 18c. The compound of any one of the preceding clauses wherein W 3 or W4 is oxygen. 18d. The compound of any one of the preceding clauses wherein W 2 and one of W 3 or W 4 is oxygen. 18e. The compound of any one of the preceding clauses wherein W 2 and W 3 are oxygen. 18f. The compound of any one of the preceding clauses wherein each of W 1 , W 2 , and W3 is oxygen. 18g. The compound of any one of the preceding clauses wherein W 1 is optionally substituted methylene. 18h. The compound of any one of the preceding clauses wherein X 1 is optionally substituted alkylene; and R 6 is aryl or arylalkyl, each of which is optionally substituted. 19. A pharmaceutical composition comprising a therapeutically effective amount of one or more compounds of any one of the preceding clauses for treating HIV infection. 20. The composition of clause 19 further comprising one or more carriers, diluents, or excipients, or a combination thereof. 21. A method for treating a patient in need of relieve of an HIV infection, the method comprising the step of administering to a patient in need of relief from the HIV infection a therapeutically effective amount of one or more compounds of any one of clauses 1 to 18h or the composition of clause 19 or 20. 21. The compound of clause 0 or 1 wherein Z is
22. The compound of clause 0 or 1 wherein Z is
wherein W 3 is optionally substituted methylene; and W 4 is —CH 2 O— or —OCH 2 —. 23. The compound of clause 0 or 1 wherein Z is
24. The compound of clause 0 or 1 wherein Z is
25. The compound of clause 0 or 1 wherein Z is
26. The compound of clause 0 or 1 wherein Z is
27. The compound of clause 0 or 1 wherein Z is
In another embodiment, a compound having the formula
W 1 ═W 2 ═W 3 ═O
W 1 ═CH 2 , W 2 ═W 3 ═O
W 1 ═O, W 2 ═CH 2 ; W3═O
W 1 ═W 2 ═O, W 3 ═CH 2
n 1 =n 2 =1, 2, 3
Y═OMe, CH 2 NH 2 , NH 2 , other hetero and heteroalkyl groups
R═CHMe 2 , alkyl, heteroalkyl and the like.
K═OH, NH 2 , NHMe, NHR, SO 2 , and the like
is described.
In another embodiment, a compound having the formula
W 1 ═W 2 ═W 3 ═O
W 1 ═CH 2 , W 2 ═W 3 ═O
W 1 ═O, W 2 ═CH 2 ; W3═O
W 1 ═W 2 ═O, W 3 ═CH 2
n 1 =n 2 =1, 2, 3
Y═OMe, CH 2 NH 2 , NH 2 , other hetero and heteroalkyl groups
R═CHMe 2 , alkyl, heteroalkyl and the like.
K═OH, NH 2 , NHMe, NHR, SO 2 , and the like
is described.
In another embodiment, a compound having the formula
X═Y═Z═CH2
X═O, NR Y═Z═CH2, where R═H, Me, SO2Me, COMe, CO2Me, and the like
X═Y═CH2, Z═O, NR
X═Z═CH2, Y═O, NR
is described, where Ar=p-PhOMe, p-PhNH2, p-PH—CH2OH, p,m-substituted aromatic, substituted benoxazole, benzoxazole, benzodioxane, benzodioxolane, and the like.
In another embodiment, a compound having the formula
X═Y═Z═CH2
X═O, NR Y═Z═CH2, where R═H, Me, SO2Me, COMe, CO2Me, and the like
X═Y═CH2, Z═O, NR
X═Z═CH2, Y═O, NR
is described, where Ar=p-PhOMe, p-PhNH2, p-PH—CH2OH, p,m-substituted aromatic, substituted benoxazole, benzoxazole, benzodioxane, benzodioxolane, and the like.
In one illustrative example, the compounds described herein are prepared by a method comprising one or more, or all, of the steps shown in the following scheme.
The compounds described herein may contain one or more chiral centers, or may otherwise be capable of existing as multiple stereoisomers. It is to be understood that in one embodiment, the invention described herein is not limited to any particular sterochemical requirement, and that the compounds, and compositions, methods, uses, and medicaments that include them may be optically pure, or may be any of a variety of stereoisomeric mixtures, including racemic and other mixtures of enantiomers, other mixtures of diastereomers, and the like. It is also to be understood that such mixtures of stereoisomers may include a single stereochemical configuration at one or more chiral centers, while including mixtures of stereochemical configuration at one or more other chiral centers.
Similarly, the compounds described herein may include geometric centers, such as cis, trans, E, and Z double bonds. It is to be understood that in another embodiment, the invention described herein is not limited to any particular geometric isomer requirement, and that the compounds, and compositions, methods, uses, and medicaments that include them may be pure, or may be any of a variety of geometric isomer mixtures. It is also to be understood that such mixtures of geometric isomers may include a single configuration at one or more double bonds, while including mixtures of geometry at one or more other double bonds.
It has been discovered herein that the X-ray structures of both DRV-bound and TMC-126-bound HIV-1 protease complexes revealed extensive protein-ligand hydrogen bonding interactions involving the backbone of HIV-1 protease throughout the active site. In particular, it has also been observed herein that both oxygens of the P2-bis-THF ligand are involved in hydrogen bonding with Asp-29 and Asp-30 backbone NHs. In addition, the bicyclic ligand appears to fill in the hydrophobic pocket at the S2-subsite. Without being bound by theory, it is believed that the P2-bis-THF is responsible for the superior drug-resistance properties of DRV. Without being bound by theory, it is believed herein that to counter drug resistance, the inhibitor design strategies could focus on maximizing inhibitor interactions with the HIV-1 protease active site, particularly to promote extensive hydrogen bond interactions with the protein backbone atoms. It has been discovered herein that enhancing backbone binding leads to PIs that maintain full potency against a panel of multidrug-resistant HIV-1 variants. Based upon examination of the protein-ligand X-ray structure of DRV-bound HIV-1 protease, it has been found that the incorporation of another tetrahydrofuran ring on the bis-THF ligand may provide additional ligand-binding site interactions. Particularly, it appears that ligand oxygens may be able to effectively maintain backbone hydrogen bonding with Asp29 and Asp30 as well as fill in the hydrophobic pocket effectively. Without being bound by theory, it is believed that these interactions may further improve drug-resistance properties of the PIs.
Such oxatricyclic ligand could have a number of possible stereochemical motifs, including a syn-syn-syn (SSS-type) and a syn-anti-syn (SAS-type) isomers. Though both are potent compounds, it is discovered herein that the SAS-type ligand-based PIs have higher affinity, when compared to SSS-isomer. That observation is supported by examination of X-ray structure-based preliminary models suggesting that the SAS-type ligand-based PIs make enhanced interactions in the S2-subsite when compared to SSS-isomer.
In another embodiment, novel oxatricyclic [3(R), 3aS, 4aS, 7aR, 8aS] and [3(R), 3aS, 4aR, 7aS, 8aS]-ligands were designed, synthesized, and incorporated into the (R)-hydroxyethyl sulfonamide isostere. Illustratively, compound 33 exhibits remarkable enzyme inhibitory and antiviral potency. The antiviral activity of 33 against a panel of highly PI-resistant clinical HIV-1 variants in vitro was measured. It was found that 33 effectively suppressed all tested clinical HIV-1 variants that are highly resistant to a number of currently available PIs.
Without being bound by theory, it is believed that successful antiviral drugs exert their virus-specific effects by interacting with viral receptors, virally encoded enzymes, viral structural components, viral genes, or their transcripts without disturbing cellular metabolism or function. However, at present, it is believed that current antiretroviral drugs and agents are unlikely to be completely specific for HIV-1 or to be devoid of toxicity or side effects in the therapy of AIDS. Those issues are of special note because patients with AIDS and its related diseases will have to receive antiretroviral therapy for a long period of time, perhaps for the rest of their lives.
Without being bound by theory, it is also suggested that the compounds described herein may exert their utility by the inhibition of proteases encoded by human immunodeficiency virus (HIV), such as HIV-1. It is appreciated that the compounds described herein may inhibit the homodimer form of the HIV-1 protease, or it may inhibit formation of a functional enzyme, e.g. inhibit dimerization of the protein subunits. The compounds or pharmaceutically acceptable salts thereof, are of value in the prevention of infection by HIV, the treatment of infection by HIV and the treatment of the resulting acquired immune deficiency syndrome (AIDS), either as compounds, pharmaceutically acceptable salts, or pharmaceutical composition ingredients.
It is appreciated that the compounds described herein may be used alone or in combination with other compounds useful for treating such diseases, including those compounds that may operate by the same or different modes of action. Further, it is appreciated that the compounds and compositions described herein may be administered alone or with other compounds and compositions, such as other antivirals, immunomodulators, antibiotics, vaccines, and the like.
As used herein, the term “alkyl” includes a chain of carbon atoms, which is optionally branched. As used herein, the term “alkenyl” and “alkynyl” includes a chain of carbon atoms, which is optionally branched, and includes at least one double bond or triple bond, respectively. It is to be understood that alkynyl may also include one or more double bonds. It is to be further understood that alkyl is advantageously of limited length, including C 1 -C 24 , C 1 -C 12 , C 1 -C 8 , C 1 -C 6 , and C 1 -C 4 . It is to be further understood that alkenyl and/or alkynyl may each be advantageously of limited length, including C 2 -C 24 , C 2 -C 12 , C 2 -C 8 , C 2 -C 6 , and C 2 -C 4 . It is appreciated herein that shorter alkyl, alkenyl, and/or alkynyl groups may add less lipophilicity to the compound and accordingly will have different pharmacokinetic behavior.
As used herein, the term “cycloalkyl” includes a chain of carbon atoms, which is optionally branched, where at least a portion of the chain in cyclic. It is to be understood that cycloalkylalkyl is a subset of cycloalkyl. It is to be understood that cycloalkyl may be polycyclic. Illustrative cycloalkyl include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, 2-methylcyclopropyl, cyclopentyleth-2-yl, adamantyl, and the like. As used herein, the term “cycloalkenyl” includes a chain of carbon atoms, which is optionally branched, and includes at least one double bond, where at least a portion of the chain in cyclic. It is to be understood that the one or more double bonds may be in the cyclic portion of cycloalkenyl and/or the non-cyclic portion of cycloalkenyl. It is to be understood that cycloalkenylalkyl and cycloalkylalkenyl are each subsets of cycloalkenyl. It is to be understood that cycloalkyl may be polycyclic. Illustrative cycloalkenyl include, but are not limited to, cyclopentenyl, cyclohexylethen-2-yl, cycloheptenylpropenyl, and the like. It is to be further understood that chain forming cycloalkyl and/or cycloalkenyl is advantageously of limited length, including C 3 -C 24 , C 3 -C 12 , C 3 -C 8 , C 3 -C 6 , and C 5 -C 6 . It is appreciated herein that shorter alkyl and/or alkenyl chains forming cycloalkyl and/or cycloalkenyl, respectively, may add less lipophilicity to the compound and accordingly will have different pharmacokinetic behavior. As used herein the term “alkylene” refers to a divalent alkyl moiety.
As used herein, the term “heteroalkyl” includes a chain of atoms that includes both carbon and at least one heteroatom, and is optionally branched. Illustrative heteroatoms include nitrogen, oxygen, and sulfur. In certain variations, illustrative heteroatoms also include phosphorus, and selenium. As used herein, the term “cycloheteroalkyl” including heterocyclyl and heterocycle, includes a chain of atoms that includes both carbon and at least one heteroatom, such as heteroalkyl, and is optionally branched, where at least a portion of the chain is cyclic. Illustrative heteroatoms include nitrogen, oxygen, and sulfur. In certain variations, illustrative heteroatoms also include phosphorus, and selenium. Illustrative cycloheteroalkyl include, but are not limited to, tetrahydrofuryl, pyrrolidinyl, tetrahydropyranyl, piperidinyl, morpholinyl, piperazinyl, homopiperazinyl, quinuclidinyl, and the like. As used herein the term “heteroalkylene” refers to a divalent heteroalkyl moiety.
As used herein, the term “aryl” includes monocyclic and polycyclic aromatic groups, including aromatic carbocyclic and aromatic heterocyclic groups, each of which may be optionally substituted. As used herein, the term “carbaryl” includes aromatic carbocyclic groups, each of which may be optionally substituted. Illustrative aromatic carbocyclic groups described herein include, but are not limited to, phenyl, naphthyl, and the like. As used herein, the term “heteroaryl” includes aromatic heterocyclic groups, each of which may be optionally substituted. Illustrative aromatic heterocyclic groups include, but are not limited to, pyridinyl, pyrimidinyl, pyrazinyl, triazinyl, tetrazinyl, quinolinyl, quinazolinyl, quinoxalinyl, thienyl, pyrazolyl, imidazolyl, oxazolyl, thiazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, thiadiazolyl, triazolyl, benzimidazolyl, benzoxazolyl, benzthiazolyl, benzisoxazolyl, benzisothiazolyl, and the like.
As used herein, the term “amino” includes the group NH 2 , alkylamino, and dialkylamino, where the two alkyl groups in dialkylamino may be the same or different, i.e. alkylalkylamino. Illustratively, amino includes methylamino, ethylamino, dimethylamino, methylethylamino, and the like. In addition, it is to be understood that when amino modifies or is modified by another term, such as aminoalkyl, or acylamino, the above variations of the term amino are included therein. Illustratively, aminoalkyl includes H 2 N-alkyl, methylaminoalkyl, ethylaminoalkyl, dimethylaminoalkyl, methylethylaminoalkyl, and the like. Illustratively, acylamino includes acylmethylamino, acylethylamino, and the like.
As used herein, the term “amino and derivatives thereof” includes amino as described herein, and alkylamino, alkenylamino, alkynylamino, heteroalkylamino, heteroalkenylamino, heteroalkynylamino, cycloalkylamino, cycloalkenylamino, cycloheteroalkylamino, cycloheteroalkenylamino, arylamino, arylalkylamino, arylalkenylamino, arylalkynylamino, acylamino, and the like, each of which is optionally substituted. The term “amino derivative” also includes urea, carbamate, and the like.
As used herein, the term “hydroxy and derivatives thereof” includes OH, and alkyloxy, alkenyloxy, alkynyloxy, heteroalkyloxy, heteroalkenyloxy, heteroalkynyloxy, cycloalkyloxy, cycloalkenyloxy, cycloheteroalkyloxy, cycloheteroalkenyloxy, aryloxy, arylalkyloxy, arylalkenyloxy, arylalkynyloxy, acyloxy, and the like, each of which is optionally substituted. The term “hydroxy derivative” also includes carbamate, and the like.
As used herein, the term “thio and derivatives thereof” includes SH, and alkylthio, alkenylthio, alkynylthio, heteroalkylthio, heteroalkenylthio, heteroalkynylthio, cycloalkylthio, cycloalkenylthio, cycloheteroalkylthio, cycloheteroalkenylthio, arylthio, arylalkylthio, arylalkenylthio, arylalkynylthio, acylthio, and the like, each of which is optionally substituted. The term “thio derivative” also includes thiocarbamate, and the like.
As used herein, the term “acyl” includes formyl, and alkylcarbonyl, alkenylcarbonyl, alkynylcarbonyl, heteroalkylcarbonyl, heteroalkenylcarbonyl, heteroalkynylcarbonyl, cycloalkylcarbonyl, cycloalkenylcarbonyl, cycloheteroalkylcarbonyl, cycloheteroalkenylcarbonyl, arylcarbonyl, arylalkylcarbonyl, arylalkenylcarbonyl, arylalkynylcarbonyl, acylcarbonyl, and the like, each of which is optionally substituted.
As used herein, the term “carboxylate and derivatives thereof” includes the group CO 2 H and salts thereof, and esters and amides thereof, and CN.
The term “optionally substituted” as used herein includes the replacement of hydrogen atoms with other functional groups on the radical that is optionally substituted. Such other functional groups illustratively include, but are not limited to, amino, hydroxyl, halo, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, nitro, sulfonic acids and derivatives thereof, carboxylic acids and derivatives thereof, and the like. Illustratively, any of amino, hydroxyl, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, and/or sulfonic acid is optionally substituted.
As used herein, the term “optionally substituted aryl” includes the replacement of hydrogen atoms with other functional groups on the aryl that is optionally substituted. Such other functional groups illustratively include, but are not limited to, amino, hydroxyl, halo, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, nitro, sulfonic acids and derivatives thereof, carboxylic acids and derivatives thereof, and the like. Illustratively, any of amino, hydroxyl, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, and/or sulfonic acid is optionally substituted.
Illustrative substituents include, but are not limited to, a radical —(CH 2 ) x Z X , where x is an integer from 0-6 and Z X is selected from halogen, hydroxy, alkanoyloxy, including C 1 -C 6 alkanoyloxy, optionally substituted aroyloxy, alkyl, including C 1 -C 6 alkyl, alkoxy, including C 1 -C 6 alkoxy, cycloalkyl, including C 3 -C 8 cycloalkyl, cycloalkoxy, including C 3 -C 8 cycloalkoxy, alkenyl, including C 2 -C 6 alkenyl, alkynyl, including C 2 -C 6 alkynyl, haloalkyl, including C 1 -C 6 haloalkyl, haloalkoxy, including C 1 -C 6 haloalkoxy, halocycloalkyl, including C 3 -C 8 halocycloalkyl, halocycloalkoxy, including C 3 -C 8 halocycloalkoxy, amino, C 1 -C 6 alkylamino, (C 1 -C 6 alkyl)(C 1 -C 6 alkyl)amino, alkylcarbonylamino, N-(C 1 -C 6 alkyl)alkylcarbonylamino, aminoalkyl, C 1 -C 6 alkylaminoalkyl, (C 1 -C 6 alkyl)(C 1 -C 6 alkyl)aminoalkyl, alkylcarbonylaminoalkyl, N-(C 1 -C 6 alkyl)alkylcarbonylaminoalkyl, cyano, and nitro; or Z X is selected from —CO 2 R 4 and —CONR 5 R 6 , where R 4 , R 5 , and R 6 are each independently selected in each occurrence from hydrogen, C 1 -C 6 alkyl, and aryl-C 1 -C 6 alkyl.
The term “prodrug” as used herein generally refers to any compound that when administered to a biological system generates a biologically active compound as a result of one or more spontaneous chemical reaction(s), enzyme-catalyzed chemical reaction(s), and/or metabolic chemical reaction(s), or a combination thereof. In vivo, the prodrug is typically acted upon by an enzyme (such as esterases, amidases, phosphatases, and the like), simple biological chemistry, or other process in vivo to liberate or regenerate the more pharmacologically active drug. This activation may occur through the action of an endogenous host enzyme or a non-endogenous enzyme that is administered to the host preceding, following, or during administration of the prodrug. Additional details of prodrug use are described in U.S. Pat. No. 5,627,165; and Pathalk et al., Enzymic protecting group techniques in organic synthesis, Stereosel. Biocatal. 775-797 (2000). It is appreciated that the prodrug is advantageously converted to the original drug as soon as the goal, such as targeted delivery, safety, stability, and the like is achieved, followed by the subsequent rapid elimination of the released remains of the group forming the prodrug.
Prodrugs may be prepared from the compounds described herein by attaching groups that ultimately cleave in vivo to one or more functional groups present on the compound, such as —OH—, —SH, —CO 2 H, —NR 2 . Illustrative prodrugs include but are not limited to carboxylate esters where the group is alkyl, aryl, aralkyl, acyloxyalkyl, alkoxycarbonyloxyalkyl as well as esters of hydroxyl, thiol and amines where the group attached is an acyl group, an alkoxycarbonyl, aminocarbonyl, phosphate or sulfate. Illustrative esters, also referred to as active esters, include but are not limited to 1-indanyl, N-oxysuccinimide; acyloxyalkyl groups such as acetoxymethyl, pivaloyloxymethyl, β-acetoxyethyl, β-pivaloyloxyethyl, 1-(cyclohexylcarbonyloxy)prop-1-yl, (1-aminoethyl)carbonyloxymethyl, and the like; alkoxycarbonyloxyalkyl groups, such as ethoxycarbonyloxymethyl, α-ethoxycarbonyloxyethyl, β-ethoxycarbonyloxyethyl, and the like; dialkylaminoalkyl groups, including di-lower alkylamino alkyl groups, such as dimethylaminomethyl, dimethylaminoethyl, diethylaminomethyl, diethylaminoethyl, and the like; 2-(alkoxycarbonyl)-2-alkenyl groups such as 2-(isobutoxycarbonyl) pent-2-enyl, 2-(ethoxycarbonyl)but-2-enyl, and the like; and lactone groups such as phthalidyl, dimethoxyphthalidyl, and the like.
Further illustrative prodrugs contain a chemical moiety, such as an amide or phosphorus group functioning to increase solubility and/or stability of the compounds described herein. Further illustrative prodrugs for amino groups include, but are not limited to, (C 3 -C 20 )alkanoyl; halo-(C 3 -C 20 )alkanoyl; (C 3 -C 20 )alkenoyl; (C 4 -C 7 )cycloalkanoyl; (C 3 -C 6 )-cycloalkyl(C 2 -C 16 )alkanoyl; optionally substituted aroyl, such as unsubstituted aroyl or aroyl substituted by 1 to 3 substituents selected from the group consisting of halogen, cyano, trifluoromethanesulphonyloxy, (C 1 -C 3 )alkyl and (C 1 -C 3 )alkoxy, each of which is optionally further substituted with one or more of 1 to 3 halogen atoms; optionally substituted aryl(C 2 -C 16 )alkanoyl, such as the aryl radical being unsubstituted or substituted by 1 to 3 substituents selected from the group consisting of halogen, (C 1 -C 3 )alkyl and (C 1 -C 3 )alkoxy, each of which is optionally further substituted with 1 to 3 halogen atoms; and optionally substituted heteroarylalkanoyl having one to three heteroatoms selected from O, S and N in the heteroaryl moiety and 2 to 10 carbon atoms in the alkanoyl moiety, such as the heteroaryl radical being unsubstituted or substituted by 1 to 3 substituents selected from the group consisting of halogen, cyano, trifluoromethanesulphonyloxy, (C 1 -C 3 )alkyl, and (C 1 -C 3 )alkoxy, each of which is optionally further substituted with 1 to 3 halogen atoms. The groups illustrated are exemplary, not exhaustive, and may be prepared by conventional processes.
It is understood that the prodrugs themselves may not possess significant biological activity, but instead undergo one or more spontaneous chemical reaction(s), enzyme-catalyzed chemical reaction(s), and/or metabolic chemical reaction(s), or a combination thereof after administration in vivo to produce the compound described herein that is biologically active or is a precursor of the biologically active compound. However, it is appreciated that in some cases, the prodrug is biologically active. It is also appreciated that prodrugs may often serves to improve drug efficacy or safety through improved oral bioavailability, pharmacodynamic half-life, and the like. Prodrugs also refer to derivatives of the compounds described herein that include groups that simply mask undesirable drug properties or improve drug delivery. For example, one or more compounds described herein may exhibit an undesirable property that is advantageously blocked or minimized may become pharmacological, pharmaceutical, or pharmacokinetic barriers in clinical drug application, such as low oral drug absorption, lack of site specificity, chemical instability, toxicity, and poor patient acceptance (bad taste, odor, pain at injection site, and the like), and others. It is appreciated herein that a prodrug, or other strategy using reversible derivatives, can be useful in the optimization of the clinical application of a drug.
The term “therapeutically effective amount” as used herein, refers to that amount of active compound or pharmaceutical agent that elicits the biological or medicinal response in a tissue system, animal or human that is being sought by a researcher, veterinarian, medical doctor or other clinician, which includes alleviation of the symptoms of the disease or disorder being treated. In one aspect, the therapeutically effective amount is that which may treat or alleviate the disease or symptoms of the disease at a reasonable benefit/risk ratio applicable to any medical treatment. However, it is to be understood that the total daily usage of the compounds and compositions described herein may be decided by the attending physician within the scope of sound medical judgment. The specific therapeutically-effective dose level for any particular patient will depend upon a variety of factors, including the disorder being treated and the severity of the disorder; activity of the specific compound employed; the specific composition employed; the age, body weight, general health, gender and diet of the patient: the time of administration, route of administration, and rate of excretion of the specific compound employed; the duration of the treatment; drugs used in combination or coincidentally with the specific compound employed; and like factors well known to the researcher, veterinarian, medical doctor or other clinician of ordinary skill
It is also appreciated that the therapeutically effective amount, whether referring to monotherapy or combination therapy, is advantageously selected with reference to any toxicity, or other undesirable side effect, that might occur during administration of one or more of the compounds described herein. Further, it is appreciated that the co-therapies described herein may allow for the administration of lower doses of compounds that show such toxicity, or other undesirable side effect, where those lower doses are below thresholds of toxicity or lower in the therapeutic window than would otherwise be administered in the absence of a co-therapy.
As used herein, the term “composition” generally refers to any product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combinations of the specified ingredients in the specified amounts. It is to be understood that the compositions described herein may be prepared from isolated compounds described herein or from salts, solutions, hydrates, solvates, and other forms of the compounds described herein. It is also to be understood that the compositions may be prepared from various amorphous, non-amorphous, partially crystalline, crystalline, and/or other morphological forms of the compounds described herein. It is also to be understood that the compositions may be prepared from various hydrates and/or solvates of the compounds described herein. Accordingly, such pharmaceutical compositions that recite compounds described herein are to be understood to include each of, or any combination of, the various morphological forms and/or solvate or hydrate forms of the compounds described herein. Illustratively, compositions may include one or more carriers, diluents, and/or excipients. The compounds described herein, or compositions containing them, may be formulated in a therapeutically effective amount in any conventional dosage forms appropriate for the methods described herein. The compounds described herein, or compositions containing them, including such formulations, may be administered by a wide variety of conventional routes for the methods described herein, and in a wide variety of dosage formats, utilizing known procedures (see generally, Remington: The Science and Practice of Pharmacy, (21 st ed., 2005)).
It is to be understood that in the methods described herein, the individual components of a co-administration or a combination can be administered by any suitable means, contemporaneously, simultaneously, sequentially, separately or in a single pharmaceutical formulation. Where the co-administered compounds or compositions are administered in separate dosage forms, the number of dosages administered per day for each compound may be the same or different. The compounds or compositions may be administered via the same or different routes of administration. The compounds or compositions may be administered according to simultaneous or alternating regimens, at the same or different times during the course of the therapy, concurrently in divided or single forms.
Illustrative routes of oral administration include tablets, capsules, elixirs, syrups, and the like.
Illustrative routes for parenteral administration include intravenous, intraarterial, intraperitoneal, epidural, intraurethral, intrasternal, intramuscular and subcutaneous, as well as any other art recognized route of parenteral administration. Illustrative means of parenteral administration include needle (including microneedle) injectors, needle-free injectors and infusion techniques, as well as any other means of parenteral administration recognized in the art. Parenteral formulations are typically aqueous solutions which may contain excipients such as salts, carbohydrates and buffering agents (preferably at a pH in the range from about 3 to about 9), but, for some applications, they may be more suitably formulated as a sterile non-aqueous solution or as a dried form to be used in conjunction with a suitable vehicle such as sterile, pyrogen-free water. The preparation of parenteral formulations under sterile conditions, for example, by lyophilization, may readily be accomplished using standard pharmaceutical techniques well known to those skilled in the art. Parenteral administration of a compound is illustratively performed in the form of saline solutions or with the compound incorporated into liposomes. In cases where the compound in itself is not sufficiently soluble to be dissolved, a solubilizer such as ethanol can be applied.
The dosage of each compound of the claimed combinations depends on several factors, including: the administration method, the condition to be treated, the severity of the condition, whether the condition is to be treated or prevented, and the age, weight, and health of the person to be treated. Additionally, pharmacogenomic (the effect of genotype on the pharmacokinetic, pharmacodynamic or efficacy profile of a therapeutic) information about a particular patient may affect the dosage used.
In making the pharmaceutical compositions of the compounds described herein, a therapeutically effective amount of one or more compounds in any of the various forms described herein may be mixed with one or more excipients, diluted by one or more excipients, or enclosed within such a carrier which can be in the form of a capsule, sachet, paper, or other container. Excipients may serve as a diluent, and can be solid, semi-solid, or liquid materials, which act as a vehicle, carrier or medium for the active ingredient. Thus, the formulation compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosols (as a solid or in a liquid medium), ointments, soft and hard gelatin capsules, suppositories, sterile injectable solutions, and sterile packaged powders. The compositions may contain anywhere from about 0.1% to about 99.9% active ingredients, depending upon the selected dose and dosage form.
Some examples of suitable excipients include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, water, syrup, and methyl cellulose. The formulations can additionally include: lubricating agents such as talc, magnesium stearate, and mineral oil; wetting agents; emulsifying and suspending agents; preserving agents such as methyl- and propylhydroxybenzoates; sweetening agents; and flavoring agents. The compositions can be formulated so as to provide quick, sustained or delayed release of the active ingredient after administration to the patient by employing procedures known in the art. It is appreciated that the carriers, diluents, and excipients used to prepare the compositions described herein are advantageously GRAS (generally regarded as safe) compounds.
Examples of emulsifying agents are naturally occurring gums (e.g., gum acacia or gum tragacanth) and naturally occurring phosphatides (e.g., soybean lecithin and sorbitan monooleate derivatives). Examples of antioxidants are butylated hydroxy anisole (BHA), ascorbic acid and derivatives thereof, tocopherol and derivatives thereof, butylated hydroxy anisole, and cysteine. Examples of preservatives are parabens, such as methyl or propyl p-hydroxybenzoate, and benzalkonium chloride. Examples of humectants are glycerin, propylene glycol, sorbitol, and urea. Examples of penetration enhancers are propylene glycol, DMSO, triethanolamine, N,N-dimethylacetamide, N,N-dimethylformamide, 2-pyrrolidone and derivatives thereof, tetrahydrofurfuryl alcohol, and AZONE. Examples of chelating agents are sodium EDTA, citric acid, and phosphoric acid. Examples of gel forming agents are CARBOPOL, cellulose derivatives, bentonite, alginates, gelatin and polyvinylpyrrolidone. Examples of ointment bases are beeswax, paraffin, cetyl palmitate, vegetable oils, sorbitan esters of fatty acids (Span), polyethylene glycols, and condensation products between sorbitan esters of fatty acids and ethylene oxide (e.g., polyoxyethylene sorbitan monooleate (TWEEN)).
METHODS AND EXAMPLES
Syn-Syn-Syn (SSS) tris-THF Alcohol
Synthesis of Syn-Syn-Syn (SSS)-type tris-THF Alcohol The fused Syn-Syn-Syn (SSS)-type tris-tetrahydrofuran (tris-THF) ligands 8 and 10 were synthesized as outlined in Scheme 1. The (3R, 3aS, 6aR)-3-hydroxyhexahydrofuro[2,3-b]furan (bis-THF alcohol) 2 was prepared according to the known procedure. The bis-THF alcohol 2 was converted to the corresponding iodide 3 in 90% yield with triphenylphosphine and iodine, which undergoes β-elimination to give the cyclic vinyl ether 4. Compound 4 is very volatile and was directly used for the next reaction in the presence of solvent. Accordingly, cyclic vinyl ether 4 was treated with NIS and propargyl alcohol in CH 2 Cl 2 at 0° C. to afford iodide 5 in 58% yield over three steps. Radical cyclization of 5 initiated by AIBN afforded the corresponding tris-THF alkene 6 which was cleaved by ozonolysis to afford the tris-THF ketone 7 in 68% yield over two steps. The syn-syn-syn configuration of 7 was confirmed by NOESY and X-ray crystal structure (FIG. 1). Reduction of ketone 7 with L-Selectride generated the alcohol 8 in 85% yield as a single isomer. Following the same procedure, the enantiomer 10 was prepared using 1 as the starting material.
Synthesis of Syn-Anti-Syn (SAS)-type tris-THF Alcohol
Commercially available 2,3-dihydrofuran was treated with ethyl diazoacetate and anhydrous CuSO 4 at reflux to provide the tetrahydrafuranyl cyclopropanyl ester 11 (4:1 dr) as shown in Scheme 2. LAH reduction of the resulting ester gave the corresponding primary alcohol 12 in quantitative yield. Oxidation of primary alcohol 12 with IBX generated the corresponding aldehyde, which underwent an in-situ arrangement to afford the racemic cyclic vinyl ether 4. With this route, racemate alkene 4 could be obtained from 2,3-dihydrofuran in three steps in 35% yield. In comparison, it needs six steps to get the same alkene 4 described in Scheme 1.
The synthetic route for tris-THF with SAS ring fusion is depicted in Scheme 3. Alkene 4 was exposed to freshly prepared acetone-free DMDO in CH 2 Cl 2 at −78 ° C. to afford the corresponding epoxide, which was opened by methanol/sodium methoxide to provide the alcohol 13 in 96% yield. Addition of a catalytic amount (10%) of sodium methoxide is critical for this reaction. The stereochemistry was confirmed by 1 H-NMR coupling constant comparison and nOe analysis. Oxidation of the alcohol 13 with Des s-Martin reagent generated the corresponding ketone. L-Selectride reduction of the ketone gave the 3-OH inverted alcohol 14 exclusively in 58% yield over two steps.
The inversion of the stereochemistry was easily confirmed by 1 H-NMR and nOe analysis. Acylation of alcohol 14 and subsequent glycosylation with propargyl alcohol exchange promoted by TMSOTf provided the corresponding acetals 15 and 16 in 4:1 ratio as an inseparable mixture. After removal of the acetyl protecting group, the two diastereomers were readily separated by flash chromatography to provide the corresponding alcohol. Conversion of the resulting alcohol to tricyclic alkene 18 was carried out in a two step sequence: 1) conversion of the hydroxyl group to the thiocarbonyl derivative using 1,1′-thiocarbonyldiimidazole under neutral conditions to the thiocarbonyl derivative 17 in 95% yield) radical cyclization with tri-n-butyltin hydride in refluxing toluene initiated by AIBN to afford tricyclic alkene 18 in 75% yield. Cleavage of the double bond of the resulting alkene 18 with a stream of O 3 in CH 2 Cl 2 /CH 3 OH at −78° C. generated the corresponding tricyclic ketone in 89% yield. L-Selectride reduction of the resulting ketone gave the racemate SAS-type tris-THF alcohol (±)-19 exclusively in 95% yield.
With the racemate SAS-type tris-THF alcohol (±)-19 in hand, herein described are procedures to make enantiopure tris-THF alcohol (Scheme 3.7). Based on the strategy of preparing bis-THF alcohol, an enzyme kinetic resolution was used to separate two enantiomers. Thus, the racemate compound (±)-19 was resolved with immobilized lipase 30, vinyl acetate and DME for 36 h to afford free alcohol (+)-19 in 49% yield and acylated product 20 in 47% yield. Ester 20 was hydrolyzed with K 2 CO 3 and methanol to get the other SAS-type tris-THF enantiomer (−)-19 in 100% yield.
Synthesis THF-Cy-THF P2 Ligand 28 and 30
The synthesis of ligand 28 is depicted in Scheme 3.8. Enantiopure cyclopentenyl alcohol 22 was prepared according to a previously reported procedure. TBS protection and hydrolysis of acetate 22 afforded the alcohol 23 in quantitative yield. It was converted to the corresponding bromo acetal utilizing ethyl vinyl ether and NBS in CH 2 Cl 2 followed by removal of TBS to give alcohol 24 in 85% yield over two steps. Treatment of alcohol 24 with NaH and propargyl bromide in the presence of TBAI gave the cyclization precursor 25 in 90% yield. The cascade cyclization using tri-n-butyltin hydride in refluxing toluene initiated by AIBN generated the tricyclic alkene 26 in 79% yield. Acetal reduction with trifluoroboron diethyl etherate and triethylsilane provided the alkene 27 in 76% yield. Cleavage of the double bond by ozonolysis at −78° C. followed by NaBH 4 reduction at −15 ° C. in a single operation afforded the P2 ligand 28 in 85% yield.
Treatment of alcohol 23 under Mitsunobu condition and the subsequent hydrolysis resulted in the corresponding inverted alcohol 29 in 90% yield over 2 steps. Following the same procedure described earlier, ligand 30 was synthesized.
Synthesis of Inhibitor 31-36
The syntheses of inhibitors 31-36 are outlined in Scheme 6. The ligand alcohols were converted to the corresponding p-nitrophenyl carbonate 37a-f utilizing p-nitrophenyl chloroformate and N-methyl morpholine in various solvents. Commercially available epoxide 38 was opened with isobutylamine in 2-propanol at 65° C. for 3 h. The crude product was subjected to sulfonation to afford isostere 39 in quantitative yield according to a previously reported procedure. Treatment of isostere 39 with trifluoroacetic acid followed by coupling of the amine with the corresponding carbonate 37a-f to gives inhibitors 31-36.
TABLE 1
Enzymatic Inhibitory Activity of Compounds 31-36, and Antiviral
activity of Selected Inhibitors against HIV-1 LAI
Entry
Inhibitor
K i
IC 50
1
+
31
2
+++
32
3
+++
+++
33
4
+
+
34
5
+
+
35
6
+
−
36
7
++
8
+++
+++
9
+++
10
+++
11
++
12
−
13
+++
15
+++
15
+++
16
+++
17
−
18
+++
Ki: >10 nM, −; <10 nM, +; <1 nM, ++; and <0.1 nM, +++
IC 50 : >1 μM, −; <1 μM, +; <0.1 μM, ++; and <0.01 μM, +++
Resistance Profiles for Inhibitors 33, 34
Relative Antiviral activity of 33, and 34 against multi-drug resistant clinical isolates in PHA-PBMs
APV
DRV
Virus
(33)
(34)
(Amprenavir)
(Darunavir)
HIV-1 ERS104pre
1
1
1
1
(wild-type: X4)
HIV-1 MDR/B (X4)
7
2
16
6
HIV-1 MDR/C (X4)
2
1
11
2
HIV-1 MDR/G (X4)
5
2
15
6
HIV-1 MDR/TM (X4)
4
2
15
6
HIV-1 MDR/MM (R5)
5
2
9
3
HIV-1 MDR/JSL (R5)
5
>2
13
5
The amino acid substitutions identified in the protease-encoding region of HIV-1 ERS104pre , HIV-1 B , HIV-1 C , HIV-1 G , HIV-1 TM , HIV-1 MM , HIV-1 JSL compared to the consensus type B sequence cited from the Los Alamos database include L63P; L10I, K14R, L33I, M36I, M46I, F53I, K55R, I62V, L63P, A71V, G73S, V82A, L90M, I93L; L10I, I15V, K20R, L24I, M36I, M46L, I54V, I62V, L63P, K70Q,V82A, L89M; L10I, V11I, T12E, I15V, L19I, R41K, M46L, L63P, A71T, V82A, L90M; L10I, K14R, R41K, M46L, I54V, L63P, A71V, V82A, L90M; I93L; L10I, K43T, M46L, I54V, L63P, A71V, V82A, L90M, Q92K; and L10I, L24I, I33F, E35D, M36I, N37S, M46L, I54V, R57K, I62V, L63P, A71V, G73S, V82A, respectively. HIV-1 ERS104pre served as a source of wild-type HIV-1. The IC 50 values were determined by using PHA-PBMs as target cells and the inhibition of p24 Gag protein production by each drug was used as an endpoint. The numbers in parentheses represent the fold changes of IC 50 values for each isolate compared to the IC 50 values for wild-type HIV-1 ERS104pre . All assays were conducted in duplicate.
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Tricylic ether carbamates that inhibit HIV proteolytic enzymes and processes for preparing the compounds are described. Methods of using the disclosed compounds for treating patients infected with HIV are also described.
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CLAIM OF PRIORITY
This application claims priority to an application entitled “Self-healing passive optical network,” filed in the Korean Intellectual Property Office on Dec. 19, 2003 and assigned Serial No. 2003-93864, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical communication network, and more particularly to a passive optical network (PON).
2. Description of the Related Art
Wavelength division multiplexing passive optical networks (hereinafter, referred to as WDM-PON) provide ultra high-speed broadband communication service using specific wavelengths assigned to each subscriber unit. WDM-PONs can ensure the secrecy of communication, can easily accommodate special communication services required from each subscriber unit or enlargement of channel capacity, and can easily increase the number of subscriber units by adding specific wavelengths to be assigned to new subscribers.
However, in spite of the advantages described above, the WDM-PON has not yet been put to practical use. This is because a central office (CO) and a plurality of optical network units (ONUs) in the WDM-PON require both light sources having specific oscillation wavelengths and additional wavelength stabilization circuits for stabilizing the wavelengths of the light sources. This puts a heavy economic burden on the subscribers. In order to construct an economic WDM-PON, some conventional WDM-PON have tried using a fabry-perot laser wavelength-locked with inherent light or a reflective semiconductor optical amplifier as a WDM light source, which allow a spectrum sliced broadband light source to facilitate wavelength management.
Generally, the conventional WDM-PON uses a double star structure in order to minimize the length of optical line. A central office and a remote node (RN) installed at an area adjacent to optical network units are connected to each other through one main optical fiber (MOF). The remote node and each optical network unit are connected to each other through a separate distribution optical fiber (DOF). Multiplexed downstream optical signals are transmitted to the remote node through the main optical fiber. The multiplexed downstream optical signals are demultiplexed by a wavelength division multiplexer installed in the remote node and the demultiplexed signals are transmitted to the optical network units through the distribution optical fibers. The upstream optical signals output from the optical network units are transmitted to the remote node and multiplexed by the wavelength division multiplexer. The multiplexed signal is transmitted to the central office.
In such WDM-PON, large amounts of data are transmitted at high speed through wavelengths assigned to each optical network unit. Accordingly, when an abnormality (such as malfunction or deterioration) of an upstream light source or a downstream light source or an abnormality (such as cut or deterioration) of a main optical fiber or distribution optical fiber occurs, the transmitted data may be lost even if the abnormality only occurs for a short time. Accordingly, such an abnormality must be quickly detected and be corrected.
However, when the direct optical line between the central office and the optical network units is cut, the central office and the optical network units cannot report the existence or absence of abnormality to each other. For this situation, a separate low speed communication line may be provided. However, in order to install the separate low speed communication line the central office and each optical network unit, additional cost is required and investment is required for continuously managing and supervising the separate low speed communication line. In addition, in order for the central office and each optical network unit to communicate with each other and check the existence or absence of abnormality through the separate low speed communication line, and to report a manager of the abnormality occurrence, a separated time period is required. As a result, a communication interruption state between the central office and each optical network unit is extended by the time period.
It is also necessary to develop a monitoring method, which can quickly detect an abnormality of an upstream light source or a downstream light source, or an abnormality of a main optical fiber or a distribution optical fiber, and directly report the manager of the existence or absence of abnormality, and a correction method.
The abnormality of the downstream light source or the abnormality of the main optical fiber connecting the central office to the remote node can be monitored by the central office which manages the operation state of the downstream light sources and the received state of all upstream optical signals. For example, when it is assumed that an abnormality does not occur at each distribution optical fiber connecting the remote node to each optical network unit, the state of the upstream light source installed at each optical network unit may be monitored from an upstream optical signal received in an upstream optical receiver installed at the central office. However, when an abnormality occurs at one distribution optical fiber, since the central office cannot receive an upstream optical signal progressing to the distribution optical fiber, the state of the upstream light source cannot be monitored.
Accordingly, in the WDM-PON, a method is required, which can monitor an abnormality of the distribution optical fiber. Further, a monitoring method is required, which can distinguish and recognize an abnormality of the upstream light source and an abnormality of the distribution optical fiber. Furthermore, when an abnormality has occurred at the upstream light source or the distribution optical fiber, a method capable of healing the abnormality is required.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a passive optical network capable of monitoring an abnormality of a distribution optical fiber.
Another aspect of the present invention relates to a passive optical network capable of distinguishing and recognizing an abnormality of an upstream light source and abnormality of a distribution optical fiber.
Another aspect of the present invention relates to a passive optical network capable of performing self-healing when an abnormality occurs at an upstream light source or a distribution optical fiber.
One embodiment of the present invention it directed to a self-healing passive optical network including a central office and a remote node connected to the central office through a main optical fiber. The remote node transmits one portion of power of the upstream optical signal, which has input from each of the optical network units, to the central office. A remaining portion of the power of the upstream optical signal to the optical network unit is returned. The network also includes a plurality of optical network units connected to the remote node through a plurality of distribution optical fibers, each of the optical network units transmitting an upstream optical signal to the remote node through the directly connected distribution optical fiber, and detecting abnormality occurrence from a state of the upstream optical signal returning from the remote node.
Another embodiment of the present invention is directed to a passive optical network including a central office and a remote node. The remote node including a wavelength division multiplexer and a plurality of optical distributors. The wavelength division multiplexer has a multiplexing port connected to the central office through a main optical fiber and a plurality of demultiplexing ports connected to a plurality of distribution optical fibers. The wavelength division multiplexer multiplexes a plurality of upstream optical signals input to the demultiplexing ports to output the multiplexed signal to the multiplexing port, and the optical distributors disposed on the distribution optical fibers, having multiple pairs of the optical distributors, passing input upstream optical signals when the upstream optical signals have specific wavelengths assigned to the optical distributors, and transmitting the upstream optical signals to other optical distributors when the upstream optical signals do not have specific wavelengths assigned to the optical distributors. The network also includes a plurality of optical network units connected to the distribution optical fibers, having multiple pairs of the optical network units, and having a first upstream light source for outputting an upstream optical signal and a first optical switch, the first optical switch transmitting the upstream optical signal to a directly connected distribution optical fiber in a normal state. The first optical switch transmits the upstream optical signal through a distribution optical fiber connected to a corresponding optical network wilt when an abnormality occurs at the distribution optical fiber.
Yet another embodiment of the present invention is directed to an optical network unit for an optical network. The unit includes an interface for a distribution optical fiber, an upstream light source for outputting an upstream optical signal and a controller. The optical network units transmits the upstream optical signal via the interface and receives a return signal based upon the upstream optical signal. The control is arranged to detect an abnormality occurrence from a state of the return signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and embodiments of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram showing the construction of a PON according to one embodiment of the present invention;
FIG. 2 is a block diagram illustrating an abnormality position determination process in the PON shown in FIG. 1 ;
FIG. 3 is a block diagram illustrating an optical line switching process in the PON shown in FIG. 1 ; and
FIG. 4 is a block diagram illustrating a light source changing process in the PON shown in FIG. 1 .
DETAILED DESCRIPTION
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the following description of the present invention, a detailed description of known functions and configuration incorporated herein will be omitted when it may obscure the subject matter of the present invention.
FIG. 1 is a diagram showing the construction of a PON according to one embodiment of the present invention. The PON 100 includes a central office 110 , a remote node 130 connected to the central office 110 through an main optical fiber 120 , and a first to an n th optical network unit 180 - 1 to 180 -n connected to the remote node 130 through a first to an n th distribution optical fiber 170 - 1 to 170 -n.
The central office 110 receives multiplexed upstream optical signals through the main optical fiber 120 .
The remote node 130 is connected to the central office 110 through the main optical fiber 120 and includes a reflector 140 , a wavelength division multiplexer (WDM) 150 , and a first to an n th optical distributor (OD) 160 - 1 to 160 -n.
The reflector 140 has one end connected to the main optical fiber 120 and other end connected to a multiplexing port (MP) of the wavelength division multiplexer 150 . The reflector 140 receives upstream optical signals multiplexed by the wavelength division multiplexer 150 , partially transmits the power of the multiplexed upstream optical signals, and partially reflects the power of the multiplexed upstream optical signals to the wavelength division multiplexer 150 . The reflector 140 may also include a multi-layer thin film filter having a predetermined reflection factor in a predetermined wavelength range, at least one fiber Bragg grating (FBG), or a mirror.
The wavelength division multiplexer 150 has the multiplexing port and a first to an n th demultiplexing port (DP). The multiplexing port is connected to the reflector 140 , and the first to the n th demultiplexing port are respectively connected to the first to the n th optical distributor 160 - 1 to 160 -n in a one-to-one fashion. The wavelength division multiplexer 150 multiplexes a first to an n th upstream optical signal input to the first to the n th demultiplexing port to output the multiplexed signal to the multiplexing port. The wavelength division multiplexer 150 may also include an arrayed waveguides grating (AWG).
The first to the n th optical distributor 160 - 1 to 160 -n each have a first to a fourth port. The first port is connected to a corresponding demultiplexing port. The second port is connected to a fourth port of a corresponding optical distributor. The third port is connected to a corresponding distribution optical fiber. The fourth port is connected to a second port of a corresponding optical distributor.
In FIG. 1 , an X th optical distributor corresponds to an (n+1−X) th optical distributor, where, 1≦X ≦(n/2), n and X are natural numbers. For example, the first optical distributor 160 - 1 corresponds to the n th optical distributor 160 -n, the second optical distributor 160 - 2 corresponds to the (n−1) th optical distributor 160 -(n−1), and the third optical distributor 160 - 3 corresponds to the (n−2) th optical distributor 160 -(n−2).
In another embodiment, a correspondence method between two optical distributors may be optionally selected. For example, two optical distributors adjacent to each other may correspond. The first optical distributor 160 - 1 corresponds to the second optical distributor 160 - 2 , and the third optical distributor 160 - 3 corresponds to the fourth optical distributor 160 - 4 .
Each of the first to the n th optical distributor 160 - 1 to 160 -n has a specific wavelength. When a wavelength of an upstream optical signal input to the third port coincides with the specific wavelength, the upstream optical signal is output to the first port. Otherwise, the upstream optical signal is output to the second port. In this way, the n th optical distributor 160 -n outputs the n th upstream optical signal input to the third port to the first port, and outputs the first upstream optical signal input to the third port to the first port. Further, each of the first to the n th optical distributor 160 - 1 to 160 -n outputs an upstream optical signal input to the first port to the third port. The n th optical distributor 160 -n outputs the n th upstream optical signal input to the first port to the third port.
The first to the n th optical network unit 180 - 1 to 180 -n are connected to the remote node 130 through the first to the n th distribution optical fiber 170 - 1 to 170 -n. The n th optical network unit 180 -n includes an n th optical coupler (OC) 190 -n, an n th circulator (CIR) 200 -n,a (n−1) th and a (n−2) th optical switch (OS) 220 -n and 250 -n, an n th optical receiver (RX) 260 -n, an n th beam splitter (BS) 260 -n, a (n−1) th and a (n−2) th upstream light source (LS) 230 -n and 240 -n, and an n th controller (CTRL) 270 -n. An X th optical network unit corresponds to a (n+1−X)th optical network unit. Since the first to the n th optical network unit 180 - 1 to 180 -n have the same constructions, the first optical network unit 180 - 1 will be representatively described hereinafter.
A ( 1 - 1 ) th upstream light source and a ( 1 - 2 ) th upstream light source 230 - 1 and 240 - 1 each output a first upstream optical signal under the control of a first controller 270 - 1 . The ( 1 - 2 ) th upstream light source 240 - 1 is a reserved light source and operates when an abnormality occurs at the ( 1 - 1 ) th upstream light source 230 - 1 .
A ( 1 - 1 ) th optical switch 220 - 1 has a first to a fourth port. The first port is connected to a first beam splitter 210 - 1 . The second port is connected to the n th optical coupler 190 -n of the n th optical network unit 180 -n. The third port is connected to the ( 1 - 1 ) th upstream light source 230 - 1 . The fourth port is connected to the ( 1 - 2 ) th upstream light source 240 - 1 . The ( 1 - 1 ) th optical switch 220 - 1 connects the first port to the third port in a normal state under the control of a first controller 270 - 1 , connects the first port to the fourth port when an abnormality occurs at the ( 1 - 1 ) th upstream light source 230 - 1 , and connects the second port to the third port when an abnormality occurs at the first distribution optical fiber 170 - 1 .
The first beam splitter 210 - 1 has a first to a third port. The first port is connected to a first circulator 200 - 1 . The second port is connected to a ( 1 - 2 ) th optical switch 250 - 1 . The third port is connected to the first port of the ( 1 - 1 ) th optical switch 220 - 1 . The first beam splitter 210 - 1 splits the power of the first upstream optical signal, which is input to the third port, at a predetermined proportion, outputs one portion of the split power to the first port, and outputs the other portion of the split power to the second port.
The first circulator 200 - 1 has a first to a third port. The first port is connected to the first port of the first beam splitter 210 - 1 . The second port is connected to a first optical coupler 190 - 1 . The third port is connected to the ( 1 - 2 ) th optical switch 250 - 1 . The first circulator 200 - 1 outputs the first upstream optical signal input to the first port to the second port, and outputs the first upstream optical signal input to the second port to the third port.
The ( 1 - 2 ) th optical switch 250 - 1 has a first to a third port. The first port is connected to the third port of the first circulator 200 - 1 . The second port is connected to the second port of the first beam splitter 210 - 1 . The third port is connected to a first optical receiver 260 - 1 . The ( 1 - 2 ) th optical switch 250 - 1 connects the first port to the third port in a normal state under the control of the first controller 270 - 1 , and connects the second port to the third port when an abnormality occurs.
The first optical receiver 260 - 1 is connected to the third port of the ( 1 - 2 ) th optical switch 250 - 1 , and converts the received first upstream optical signal into an electrical signal which will be output.
The first controller 270 - 1 detects that an abnormality has occurred at the first distribution optical fiber 170 - 1 or the ( 1 - 1 ) th upstream light source 230 - 1 according to the state of the electrical signal (abnormality occurrence detection stage), and performs an abnormality position determination stage, an optical line switching stage, or a light source changing stage.
The operation of the PON 100 in a normal state will now be described with reference to FIG. 1 .
In the normal state, the first port of the ( 1 - 1 ) th optical switch 220 - 1 is connected to the third port of the ( 1 - 1 ) th optical switch 220 - 1 , and the first port of the ( 1 - 2 ) th optical switch 250 - 1 is connected to the third port of the ( 1 - 2 ) th optical switch 250 - 1 . The first upstream optical signal output from the ( 1 - 1 ) th upstream light source 230 - 1 passes through the ( 1 - 1 ) th optical switch 220 - 1 and is input to the first beam splitter 210 - 1 .
The first beam splitter 210 - 1 splits the power of the first upstream optical signal, outputs one portion of the split power to the first port, and outputs the other portion of the split power to the second port. The first upstream optical signal outputted from the second port of the first beam splitter 210 - 1 is input to the second port of the ( 1 - 2 ) th optical switch 250 - 1 and then disappears. The first upstream optical signal output from the first port of the first beam splitter 210 - 1 is input to the first port of the first circulator 200 - 1 and is output to the second port. The first upstream optical signal then passes through the first optical coupler 190 - 1 , the first distribution optical fiber 170 - 1 , and the first optical distributor 160 - 1 and is input to the first demultiplexing port of the wavelength division multiplexer 150 .
The wavelength division multiplexer 150 multiplexes the first upstream optical signal and the second to the n th upstream optical signal input to the second to the n th demultiplexing port, and outputs the multiplexed upstream optical signals to the multiplexing port. The power of the multiplexed upstream optical signals is split by the reflection of the reflector 140 , one portion of the split power passes through the reflector 140 and is transmitted to the central office 110 through the main optical fiber 120 . The other portion of the split power is input to the multiplexing port of the wavelength division multiplexer 150 . The wavelength division multiplexer 150 demultiplexes the multiplexed upstream optical signals, which are input to the multiplexing port, according to wavelengths to output the demultiplexed signals the first to the n th demultiplexing port.
The first upstream optical signal output from the first demultiplexing port passes through the first optical distributor 160 - 1 , the first distribution optical fiber 170 - 1 , and the first optical coupler 190 - 1 , is input to the second port of the first circulator 200 - 1 and is output to the third port. The first upstream optical signal output from the third port of the first circulator 200 - 1 is input to the first port of the ( 1 - 2 ) th optical switch 250 - 1 , is output to the third port, and is input to the first optical receiver 260 - 1 . The first optical receiver 260 - 1 converts the input first upstream optical signal into an electrical signal which will be output. Since the input electrical signal is in a normal state, the first controller 270 - 1 determines that the first distribution optical fiber 170 - 1 or the ( 1 - 1 ) th upstream light source 230 - 1 is in a normal state.
Abnormality Occurrence Detection Stage
The first controller 270 - 1 detects that an abnormality has occurred at the first distribution optical fiber 170 - 1 or the ( 1 - 1 ) th upstream light source 230 - 1 when the input electrical signal is in an abnormal state (e.g., rapid reduction of power or intermittent interruption of a signal), or an electrical signal is not input.
Abnormality Position Determination Stage
FIG. 2 is a block diagram illustrating an abnormality position determination process in the PON shown in FIG. 1 . Hereinafter, a process in which the first controller 270 - 1 determines an abnormality position when the abnormality has occurred at the first distribution optical fiber 170 - 1 or the ( 1 - 1 ) th upstream light source 230 - 1 will be described with reference to FIG. 2 .
The first controller 270 - 1 detects that the abnormality has occurred and controls the second port of the ( 1 - 2 ) th optical switch 250 - 1 to be connected to the third port of the ( 1 - 1 ) th optical switch 250 - 1 . When the input electrical signal is in a normal state, the first controller 270 - 1 determines that the abnormality has occurred at the first distribution optical fiber 170 - 1 . When the input electrical signal is in an abnormal state or an electrical signal is not input, the first controller 270 - 1 determines that the abnormality has occurred at the ( 1 - 1 ) th upstream light source 230 - 1 .
When the abnormality has occurred at the first distribution optical fiber 170 - 1 , the first controller 270 - 1 performs the optical line switching process which will be described below. When the abnormality has occurred at the ( 1 - 1 ) th upstream light source 230 - 1 , the first controller 270 - 1 performs the light source changing process which will be described below.
Optical Line Switching Stage
FIG. 3 is a block diagram illustrating an optical line switching process in the PON shown in FIG. 1 . Hereinafter, a process in which the first controller 270 - 1 switches the optical line when the abnormality has occurred at the first distribution optical fiber 170 - 1 will be described with reference to FIG. 3 .
The first controller 270 - 1 detects that the abnormality has occurred at the first distribution optical fiber 170 - 1 and controls the second port of the ( 1 - 1 ) th optical switch 220 - 1 to be connected to the third port of the ( 1 - 1 ) th optical switch 220 - 1 .
The first upstream optical signal output from the ( 1 - 1 ) th upstream light source 230 - 1 passes through the ( 1 - 1 ) th optical switch 220 - 1 , is input to the third port of the n th optical coupler 190 -n, and is output to the first port thereof. The first upstream optical signal output from the first port of the n th optical coupler 190 -n passes through the n th distribution optical fiber 170 -n, is input to the third port of the n th optical distributor 160 -n, and is output to the second port thereof. The second port of the n th optical distributor 160 -n is connected to the fourth port of the first optical distributor 160 - 1 , and the first optical distributor 160 - 1 outputs the first upstream optical signal input to the fourth port to the first port. The first upstream optical signal output from the first port of the first optical distributor 160 - 1 is input to the first demultiplexing port of the wavelength division multiplexer 150 .
The wavelength division multiplexer 150 multiplexes the first upstream optical signal and the second to the n th upstream optical signal input to the second to the n th demultiplexing port, and outputs the multiplexed upstream optical signals to the multiplexing port. The power of the multiplexed upstream optical signals is split by the reflection of the reflector 140 . One portion of the split power passes through the reflector 140 and is transmitted to the central office 110 through the main optical fiber 120 . The other portion of the split power is input to the multiplexing port of the wavelength division multiplexer 150 .
Light Source Changing Stage
FIG. 4 is a block diagram illustrating a light source changing process in the PON shown in FIG. 1 . Hereinafter, a process in which the first controller 270 - 1 replaces the ( 1 - 1 ) th upstream light source 230 - 1 with the ( 1 - 2 ) th upstream light source 240 - 1 when the abnormality has occurred at the ( 1 - 1 ) th upstream light source 230 - 1 will be described with reference to FIG. 4 .
The first controller 270 - 1 detects that the abnormality has occurred at the ( 1 - 1 ) th upstream light source 230 - 1 and controls the first port of the ( 1 - 1 ) th optical switch 220 - 1 to be connected to the fourth port of the ( 1 - 1 ) th optical switch 220 - 1 , controls the first port of the ( 1 - 2 ) th optical switch 250 - 1 to be connected to the third port of the ( 1 - 1 ) th optical switch 250 - 1 , and operates the ( 1 - 2 ) th upstream light source 240 - 1 .
The first upstream optical signal output from the ( 1 - 2 ) th upstream light source 240 - 1 passes through the ( 1 - 1 ) th optical switch 220 - 1 , and is input to the first beam splitter 210 - 1 . The first beam splitter 210 - 1 splits the power of the first upstream optical signal, outputs one portion of the split power to the first port thereof, and outputs the other portion of the split power to the second port thereof. The first upstream optical signal output from the second port of the first beam splitter 210 - 1 is input to the second port of the ( 1 - 2 ) th optical switch 250 - 1 and then disappears. The first upstream optical signal output from the first port of the first beam splitter 210 - 1 is input to the first port of the first circulator 200 - 1 and is output to the second port thereof. The first upstream optical signal then passes through the first optical coupler 190 - 1 , the first distribution optical fiber 170 - 1 , and the first optical distributor 160 - 1 and is input to the first demultiplexing port of the wavelength division multiplexer 150 .
The wavelength division multiplexer 150 multiplexes the first upstream optical signal and the second to the n th upstream optical signal input to the second to the n th demultiplexing port, and outputs the multiplexed upstream optical signals to the multiplexing port. The power of the multiplexed upstream optical signals is split by the reflection of the reflector 140 . One portion of the split power passes through the reflector 140 and is transmitted to the central office 110 through the main optical fiber 120 . The other portion of the split power is input to the multiplexing port of the wavelength division multiplexer 150 . The wavelength division multiplexer 150 demultiplexes the multiplexed upstream optical signals, which are input to the multiplexing port, according to wavelengths to output the demultiplexed signals the first to the n th demultiplexing port. The first upstream optical signal output from the first demultiplexing port passes through the first optical distributor 160 - 1 , the first distribution optical fiber 170 - 1 , and the first optical coupler 190 - 1 , is input to the second port of the first circulator 200 - 1 and is output to the third port thereof. The first upstream optical signal output from the third port of the first circulator 200 - 1 is input to the first port of the ( 1 - 2 ) th optical switch 250 - 1 , is output to the third port thereof, and is input to the first optical receiver 260 - 1 .
The first optical receiver 260 - 1 converts the input upstream optical signal into an electrical signal which will be output. Since the input electrical signal is in a normal state, the first controller 270 - 1 determines that the light source changing process has been normally performed.
As described above, abnormality occurrence is detected from a state of a returning upstream optical signal, so that the abnormality occurrence can be quickly detected and instantly processed.
In addition, a state of a distribution optical fiber and a state of an upstream light source located at an optical network unit are respectively monitored. Self-healing can then be performed when an abnormality occurs at the distribution optical fiber or the upstream light source. Therefore, the distribution optical fiber and the upstream light source can be economically and efficiently managed and healed.
While the invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A self-healing passive optical network is disclosed. The network includes a central office and a remote node connected to the central office through a main optical fiber. The remote node transmits one portion of power of the upstream optical signal, which has been input from each of the optical network units, to the central office, and returning a remaining portion of the power of the upstream optical signal to the optical network unit. The network also includes a plurality of optical network units connected to the remote node through a plurality of distribution optical fibers. Each of the optical network units transmits an upstream optical signal to the remote node through the directly connected distribution optical fiber, and detects abnormality occurrences from a state of the upstream optical signal returning from the remote node.
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BACKGROUND OF THE INVENTION
The invention relates to improvements in a liquid encapsulation Czockralaski method (LEC method) for growing a single semiconductor crystal by pulling up a seed crystal covered with a liquid encapsulant such as B 2 O 3 out of a semiconductor compound melt in a heated crucible. The invention also relates to an improved apparatus for crystal growth used in carrying out the LEC method.
Semiconductor compounds produced by the LEC method include compounds of elements of Group III and Group V of the Periodic Table for example, GaAs, GaP, InP, InAs, GaSb, etc. and compounds of elements of Group IV and Group VI of the Periodic Table for example, PbTe, PbSe, SnTe, etc.
Conventional apparatus for growing a single crystal based on a LEC method generally have a single cylindrical crucible heater with a relatively large uniform thickness of heating element structure around a quartz crucible supported by a carbon support.
Another LEC apparatus for growing a single crystal is disclosed in Japanese Patent Publication No. 39787/1977 wherein the inner diameter and outer diameter of a single cylindrical quartz crucible heater vary along the axial line of the crucible adjacent the walls of the crucible.
Another LEC apparatus has two cylindrical crucible heaters where a portion of one heater is positioned near the top of the crucible and a portion of the second heater is positioned near the bottom of the crucible. Such an apparatus is disclosed in Japanese Patent Laying Open No. 11897/1982 wherein a quartz crucible is supported by a carbon support around which the two heaters are installed. The two heaters can be independently moved upwardly or downwardly. The temperature distribution in the crucible is changed by moving the crucible and its carbon support and by moving the two independent heaters upwardly or downwardly.
The above described apparatuses for carrying out an LEC method for producing a single crystal semiconductor are directed to provide a temperature environment in the crucible suitable for crystal growth in the crystal growing region of the crucible. However, a significant problem has not been addressed. In practice, the crystal pulled up from a semiconductor compound melt is cooled rapidly with non-uniform temperature distribution at a cooling zone above the crystal growing region above the crucible.
The rapid and non-uniform cooling of a single crystal semiconductor brings about the following undesirable results.
1. When the single crystal that is pulled up is cooled abruptly and irregularly by convection of highly-pressurized gas at the cooling zone above the crucible, strong thermal stress is generated in the crystal by the non-uniform distribution of temperature. As a result, many dislocations, lineages, and other lattice defects result within the crystal.
2. Even if the temperature gradient between (a) the crystal growing region corresponding to the vicinity of liquid-solid interface and (b) the space in the liquid encapsulant is reduced in order to avoid rapid cooling in the interface region, the generation of thermal stress is not adequately avoided. Large amounts of heat are transmitted vertically in the grown crystal and from the surface of the upper portion of the crystal. This occurs because the upper portion of the crystal is still exposed to a strong convection current of pressurized gas. This mode of heat dissipation causes radial temperature differences between the surface and the center of the crystal in horizontal planes normal to the vertical axis of the crystal. Thus, the grown crystal is fragile and vulnerable. The crystal is susceptible to cracking during cooling. In such a case, when the cooled crystal ingot is sliced into thin wafers, both the ingot and the wafers are apt to crack.
Accordingly, it is an object of the present invention to provide a liquid encapsulation Czockralski method and apparatus for growing single semiconductor crystals wherein control of the thermal environment of the cooling zone above the crystal growing crucible is provided.
SUMMARY OF THE INVENTION
The LEC apparatus of the invention has three independently operated temperature controlling means. The three temperature controlling means are: a heater H1 for heating the melt in the crucible; a heater H2 for controlling the thermal environment of the crystal growing zone; and, a heater H3 or a heat shield 11 for controlling the thermal environment of the cooling zone.
The cooling zone heater H3 operates independently of the first and second heaters H1 and H2 and provides a substantially uniform temperature distribution in the cooling zone. The grown crystal is slowly cooled in a controlled manner with a substantially uniform temperature distribution.
Two kinds of heat shields are applicable. A heat shield having a diameter larger than the diameter of the crucible and which is installed in the space above the crucible or a heat shield with a cylindrical shape having a diameter smaller than the crucible which can be floated in the compound melt and liquid encapsulant in the crucible.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a sectional view of a crucible and heaters of a prior art LEC apparatus;
FIG. 2 is a sectional view of one embodiment of an LEC apparatus of the invention;
FIG. 3 is a sectional view of a second embodiment of the invention and a graph showing the temperature distribution along the axial line at the crystal growing zone and at the cooling zone of the apparatus;
FIG. 4A shows a sectional view of a straightwalled cylindrical device which may be either an active heater or a passive heat shield for controlling the thermal environment of the cooling zone;
FIG. 4B shows a sectional view of a cylinder having a conical top wall inclining inward which may be either an active heater or a passive heat shield for controlling the thermal environment of the cooling zone;
FIG. 4C shows a sectional view of a cylindrical device having a flat top wall which projects inward at a right angle with the cylinder wall and which may be either an active heater or a passive heat shield for controlling the thermal environment of the cooling zone;
FIG. 5 is a sectional view of an embodiment of an LEC apparatus of the invention after a single crystal has been pulled up into the cooling zone;
FIG. 6A is a graph showing the distribution of measured etch pit densities (EPD) on two wafers sliced from the head and tail portions of a GaAs single crystal grown using the method and an embodiment of the apparatus of the invention;
FIG. 6B is a graph showing the distribution of measured EPD's on two wafers sliced from the head and tail portions of a GaAs single crystal grown using a prior art LEC method and apparatus;
FIG. 7 is a sectional view of a third embodiment of the invention in which the heat shield for controlling the temperature of the cooling zone is a cylinder floating on semiconductor compound melt or liquid encapsulant in the crucible; and,
FIG. 8 is a sectional view of an example of a floating cylinder having a hollow cavity within the inner and outer walls of the floating cylinder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 2, crucible assembly 15 is comprised of crucible 1 and crucible support 2. Crucible support 1 contains a semiconductor compound melt 4 and a liquid encapsulant 5. Crucible support 2 supports the crucible 1 on the bottom and side surfaces.
An upper shaft 6 is installed along an axial line from the top of a chamber (not shown) enclosing all the elements shown in FIG. 2. The upper shaft 6 rotates and moves vertically.
A seed crystal 9 is attached to the bottom end of the upper shaft 6. The seed crystal 9 is dipped in the compound melt 4 by lowering the upper shaft 6. The upper shaft 6 then rotates and slowly moves upward. The single crystal 8 is grown on the seed crystal 9.
A lower shaft 7 supports the crucible assembly 15. The lower shaft 7 rotates and moves vertically.
Three independently controlled heaters are provided for three separately controlled thermal zones. Heater H1 is the heater for melting the semiconductor compound in the melting zone and heating the encapsulant liquid. Heater H1 heats the crucible assembly 15 and the liquids 4 and 5 in the crucible 1.
Heater H2 is the heater for heating the liquid-solid crystal interface zone between the liquid encapsulant and the single crystal in the vicinity of the liquid encapsulant. This interface zone is the single crystal growing zone. The thermal environment of the single crystal growing zone can be controlled by controlling the power of the heater H2. The heater H2 is designated as the crystal growing zone heater H2. It is noted that heater H1 also contributes to heating the liquid encapsulant 5.
Heater H3 is a heater for controlling the thermal environment of the cooling zone above the liquid encapsulant 5 and above the crucible 1. The desirable thermal environment of the cooling zone is either of uniform temperature distribution or quasi-uniform temperature distribution with a small temperature gradient. This zone is the zone in which the pulled single crystal is cooled. Thus, heater H3 is designated as the crystal cooling zone heater H3.
All the heaters H1, H2, and H3 are resistance heaters which generate Joule heat in proportion to current and voltage.
The melt-heating zone heater H1 and the crystal growing zone heater H2 jointly determine the temperature of semiconductor compound melt and the thermal environment of the crystal growing zone.
An illustration of the thermal environments in an embodiment of the LEC apparatus of the invention is provided in an example wherein GaAs is the semiconductor compound undergoing single crystal growth, and B 2 O 3 is the liquid encapsulant.
FIG. 3 shows the distribution of temperature along a vertical center axis A. The temperature gradient along the axis in the crystal growing region is 20°-200° C./cm, preferably 50° C./cm, in the liquid B 2 O 3 encapsulant; and, is 5°-50° C./cm, preferably 10° C./cm, in the inert gas above the B 2 O 3 .
As shown in the left-hand figure of FIG. 3, the cooling zone heater H3 controls the thermal environment in which the single crystal is cooled after the crystal growth is ended.
The cooling zone should be a zone having a uniform distribution of temperature or a zone having a quasi-uniform distribution with a small temperature gradient.
Such a preferred thermal cooling environment is realized mainly by controlling the cooling zone heater H3. However, the crystal growing zone heater H2 also has some influence upon the thermal environment of the cooling zone.
The right-hand side figure of FIG. 3 shows a graph of the above mentioned temperature distributions. The slant line area between the two intersecting lines in the cooling zone of the graph in FIG. 3 denotes an allowable temperature range distribution for the cooling zone.
The crystal growing zone heater H2 mainly controls the thermal environment of the liquid-solid interface, liquid encapsulant 5, and the space in the crucible 1 above the liquid encapsulant 5.
In GaAs crystal growth, a satisfactory range of temperature at the cooling zone should be adjusted to be 700° C.-1000° C. preferably at 850° C. The temperature gradient along a vertical direction at the cooling zone should be 0°-20° C./cm.
A single GaAs crystal pulled up to the cooling zone is cooled slowly when the above-mentioned temperature gradient is maintained.
FIGS. 4A, 4B, and 4C show examples of the sectional shape of cooling zone heaters H3. FIG. 4A shows a heater of a simple cylindrical shape. Both inner diameter and outer diameter are uniform along an axial direction. FIG. 4B shows a heater of a tranformed cylindrical shape having a conical top wall which inclines inwardly. FIG. 4C shows another heater of a transformed cylindrical shape having a flat top wall which projects horizontally inward at a right angle with the vertical cylinder wall.
Heaters having the sectional shapes in FIGS. 4B and 4C are preferred over the heater having the shape in FIG. 4A to form a wide zone of uniform temperature in the cooling zone.
Although control of the thermal environment in the cooling zone is preferably brought about by an active cooling zone heater H3, the active heater H3 can be replaced by a passive cylindrical heat shield 11 as shown in FIG. 7. Although heat shield 11 does not actively provide heat by itself, it is heated by heat it absorbs from heat radiating from the other heaters H1 and H2. The heat shield 11 heats the cooling zone by re-radiating the heat absorbed from heaters H1 and H2.
Because the cooling zone heat shield 11 is not a heater, it is unable to control the thermal environment of the cooling zone directly. But the cooling zone heat shield 11 contributes to controlling the thermal environment of the cooling zone in an indirect manner by varying the effective powers of the heaters H1 and H2 upon the cooling zone. In addition, the heat shield 11 effectively prevents convection of inert gases present in the cooling zone. Therefore, a cooling zone heat shield 11 can replace heater H3 and can keep the thermal environment of the cooling zone uniform or quasi-uniform.
The sectional shapes shown in FIGS. 4A, 4B, and 4C for cooling zone heaters H3 are also suitable shapes for cooling zone heat shield 11.
The cooling zone heat shield 11 can be fixed upon the heater H2 and can have a diameter which is nearly equal to that of the crystal growing zone heater H2.
Alternatively, a smaller heat shield of a cylindrical shape is also suitable as a cooling zone heat shield 11. As shown in FIG. 7, the smaller heat shield 11 is placed in a crucible 1 in order to enclose a single crystal 8. The heat shield 11 in FIG. 7 floats in the semiconductor compound melt 4 and the liquid encapsulant 5. For proper operation, the bottom of the heat shield 11 must not touch the bottom of the crucible 1 so as not to prevent the circulation of the semiconductor compound melt.
Because it is floating and has cylindrical shape, the smaller heat shield 11 is called a floating cylinder 11. The floating cylinder 11 in FIG. 7 has a cylindrical sectional shape, the top portion of which inclines inward. This shape is very effective to suppress inert gas circulating between the space inside and the space outside of the floating cylinder 11 and to reduce heat dissipation by gaseous convection.
Suitable materials for fabricating for the heat shield 11 are carbon, carbon coated with BN or AlN, SiO 2 , Al 2 O 3 , BN, Si 3 N 4 , and PBN, among others. Because of the high heat conductivity, carbon is the preferred material for a fixed heat shield. For a floating cylinder 11, the preferred material for fabrication is carbon coated with BN or AlN. The nitride coating protects the semiconductor compound melt and the single semiconductor crystal from contamination by carbon powder.
The floating cylinder 11 must float in the liquid melt. The top end of the floating cylinder must enclose the single crystal therein until crystal growth has proceeded to a considerable extent. Therefore, the effective specific gravity of the floating cylinder 11 must be lower than that of the melt in order that it float. A floating cylinder 11 with a hollow cavity shown in FIG. 8 provides a low effective specific gravity and is preferred.
Floating cylinders 11 can have various shapes--a cylinder with a step part on the inner wall, a cylinder having a widening conical upper wall with a bigger top opening, or a cylinder having a narrowing conical upper wall with a smaller top opening. The shape and the size of the floating cylinder are selected to bring about the desired thermal environment and the desired thermal conditions for pulling up the single crystal.
Various sizes of floating cylinders are suitable. But the upper limits and lower limits of sizes are determined according to the following inequalities:
0.9D<d 2 <D
0.4D<d 1 <0.9D
0.4H<h<1.5H
where d l is the inner diameter of the floating cylinder; d 2 is the outer diameter; h is the height of the floating cylinder 11; D is the inner diameter of the crucible 1; and, H is the height of the crucible.
A specific example of the dimensions of a suitable floating cylinder 11 and a crucible 1 is provided. Reference is made to FIG. 7 which is not drawn to scale. The height H of the crucible is 150 mm, and the inner diameter D is 150 mm. The inner diameter d l of the floating cylinder is 102 mm, and the outer diameter d 2 is 149 mm. The distance K from the bottom end of the floating cylinder to the liquid-solid crystal interface is 5 mm.
Numerous advantages are obtained by employing the method and apparatus of the invention. By employing the apparatus and method of the invention, a novel semiconductor crystal product is obtained. In carrying out the method of the invention, a single semiconductor crystal is pulled through the crystal growing zone having a small temperature gradient; and, the grown crystal is slowly cooled in the cooling zone having a uniform or quasi-uniform temperature distribution.
Because the temperature difference in the crystal is small, the occurrence of thermal stress in the crystal is relatively low. It is theorized that this aspect results in the following advantages observed in the semiconductor crystal product produced by the process of the invention.
(1) Dislocations, lineages and other lattice defects in the crystal are reduced in comparison with crystals produced by other methods. Distribution of etch pit density (EPD) is more uniform in a wafer produced in accordance with the invention.
(2) A reduction in the occurrence of cracks in the crystal during cooling and during a slicing operation is realized.
(3) Because the generation of thermal stress is reduced, an annealing process is unnecessary. Conventional LEC methods require an annealing process to reduce the occurrence of cracks in crystal wafers. Thus, by following the principles of the invention, a reduction in the overall amount of work to produce crystal wafers is realized.
An example of a semiconductor crystal product of the invention produced by a process of the invention is described. A GaAs crystal is pulled up in the embodiment of the LEC apparatus of the invention shown in FIG. 2. In the example, a cooling zone heater H3 is used.
EXAMPLE
______________________________________Charge of GaAs 4 KGCrucible made of PBN 6 inches (inner diameter)Inert gas nitrogen gasLiquid encapsulant B.sub.2 O.sub.3______________________________________
In the example, the melt heating zone heater H1, the crystal growing zone heater H2, and the cooling zone heater H3 are turned on; and, the temperatures of the heaters rise to predetermined values.
The 4KG of solid GaAs semiconductor compound is melted in the crucible. The compound melt is covered with the liquid encapsulant. Nitrogen gas at 2-50 atm. pressure fills the chamber (not shown in Figures). The actual gas pressure required depends on the thickness of the B 2 O 3 encapsulant layer. When the B 2 O 3 layer is relatively thick, only 3 atm. of pressure of nitrogen gas is sufficient to adequately pressurize the B 2 O 3 layer. In general, however, the optimum range of gas pressure is 15-20 atm.
The GaAs semiconductor compound starting material can be either polycrystalline GaAs or may be directly synthesized from pure Ga and pure As. The technique for raising the temperature of a polycrystalline GaAs starting material differs from the technique for raising the temperature in the case where a GaAs starting compound is directly synthesized from pure Ga and pure As.
When the starting material is polycrystalline GaAs, the melt-heating heater H1, the crystal growing zone heater H2, and the cooling zone heater H3 are turned on at the same time. The temperatures of the three heaters rise simultaneously in a predetermined proportion to one another. Preferably, raising the temperature of the cooling zone heater 3 is stopped when the temperature at a measuring point on the outer surface of the cooling zone heater 3 attains 870° C.
When the temperature at a measuring point at the outer surface of the melt heating heater H1 is about 1200° C., the temperature at the measuring point at the outer surface of the crystal growing zone heater H2 is about 1000° C. At this time, the melt heating heater H1 is still kept turned on. When the polycrystalline GaAs melts in the crucible, the heating of the heater H1 is stopped. The temperature of the crystal growing zone heater H2 is adjusted to be 900° C. to 1100° C. at that time. By an adequate choice of the adjusted temperature in the crystal growing zone, preselected temperature gradients in the liquid-solid interface, the B 2 O 3 liquid, and the gaseous space in the vicinity of B 2 O 3 are realized.
Alternatively, when a GaAs compound is directly synthesized from Ga and As in the crucible, different temperature parameters are employed. As the temperature of the heater is raised, a chemical reaction between Ga and As occurs at a high pressure (higher than 60 atm.). Thus, GaAs compound is synthesized by the chemical reaction in a direct manner.
After the direct synthesis of GaAs is completed, the pressure of the nitrogen gas is reduced. The process of raising the temperatures of heaters H1, H2, and H3 is started again and proceeds until the GaAs is molten thus providing a semiconductor compound melt.
To grow a single semiconductor crystal from a semiconductor melt, seeding with a seed semiconductor crystal is done about 30 minutes after the semiconductor compound of GaAs is melted. A seed crystal is dipped into the compound melt, and then crystal growth begins.
The preferred conditions of crystal growth are: pulling speed of seed crystal in range of 4-20 mm/hr. (preferably lO mm/hr.); rotating rate of crucible in the range of 2-40 rpm. (preferably 12 rpm.); rotating rate of crystal in the range of 2-40 rpm. (preferably 10 rpm.); and, diameter of crystal grown preferably 3 inches.
When crystal growth is terminated, the temperature distribution in the crystal is in the range from 820°-880° C. After the crystal growth is terminated, the newly grown crystal is pulled upward into the cooling zone and is stopped there as shown in FIG. 5.
In the crystal cooling zone, the crystal is slowly cooled in a uniform or quasi-uniform temperature distribution which is maintained uniform by adjusting the electric power sent to the heaters H1, H2, and H3.
After the single semiconductor crystal is cooled to room temperature, it is detached from the LEC apparatus.
The crystal is 3 inches in diameter. The weight of the crystal is 3820 grams. The length is 19 cm. The crystal is a high quality GaAs single crystal without cracks.
The single GaAs crystal is sliced into wafers and the distributions of etch pit density (EPD) in the wafers are measured.
FIG. 6A is a graph showing the distribution of measured EPD on two wafers prepared in accordance with the invention, one sliced from the head portion and one sliced from the tail portion of the crystal. The abscissa denotes the distances from the center of the wafers. The ordinate denotes EPD on a logarithmic scale. The distributions of EPD on both the tail wafer and the head wafer are lower than 3×10 4 cm -2 .
FIG. 6B is a graph showing the distributions of measured EPD on two wafers sliced from the head and tail portions of a GaAs single crystal grown by a conventional prior art LEC method and apparatus having only a single heater. The distributions of EPD on head and tail crystal wafers is about 10 5 cm -2 .
A comparison of the EPD data in FIGS. 6A and 6B reveals that by employing the method and apparatus of the invention a reduction of EPD levels occurs to about 1/3 to 1/6 the levels of EPD that occur with a conventional LEC method.
The single crystals made in accordance with the invention have not cracked during the cooling process.
After the single crystal is produced, it is subsequently subjected to grinding of the outer surface to adjust the diameter to a prescribed value. In addition, it undergoes marking of orientation flats which denote the crystallographic axes.
The single semiconductor crystals made in accordance with the invention do not crack during the grinding and marking steps. The yield of usable wafers after both the grinding of the outer surface to adjust the diameter in the allowable range from 3 inches minus 1 mm to 3 inches plus 1 mm and after marking orientation flats is about 60% with the invention. This is in sharp contrast to a crystal yield of usable wafer of about only 33% when a conventional LEC method is employed.
With the invention, an annealing treatment after cooling becomes unnecessary because the single crystals made by the invention do not crack. Thus, the overall amount of work required for processing is decreased.
Still greater decreases in the EPD occur reducing it to nearly 1/10 of the EPD in the embodiment graphically depicted in FIG. 6A by doping more than 10 19 /cm 3 of In or Sb into the crystal.
The method and apparatus of the invention have a wide scope of application for the growth of crystals of Group III and Group V semiconductor compounds such as GaAs, GaP, InP, InAs, GaSe, etc. and of Group IV and Group VI compounds such as PbTe, PbSe, SnTe, etc.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various alterations in form and detail may be made therein without departing from the spirit and scope of the invention.
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A liquid encapsulation Czockralski method for growing a single crystal of a semiconductor compound which comprises: melting a semiconductor compound in the presence of a B 2 O 3 liquid encapsulant to form a two phase liquid; dipping a semiconductor seed crystal into the compound melt covered with the B 2 O 3 encapsulant; growing the crystal from the compound melt by pulling up and rotating the seed crystal; and, cooling the crystal in a cooling zone above a crucible. The cooling zone is maintained at a substantially uniform temperature distribution with a small temperature gradient by using primarily an independently controlled crystal cooling zone heater H3. In addition, an independently controlled melt heater H1 and an independently controlled crystal growing heater H2 are employed. Also, a crystal cooling zone heat shield 11 can be provided to aid in slowly cooling the grown crystal in the substantially uniform temperature distribution. Preferably, a crystal cooling zone heater H3 is employed to control the temperature distribution in the cooling zone. The semiconductor crystals produced by employing the process and apparatus of the invention are substantially crack-free both before and after grinding and cutting. Also the etch pitch density (EPD) of the semiconductor crystal material is significantly lower than conventionally produced material.
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BACKGROUND OF THE INVENTION
The present invention relates to video record/playback systems and, more particularly, to a system wherein multiple views are simultaneously recorded and are selectable and changeable at playback time.
Continuous loop record and playback devices are well known in the art. For example, as shown in FIG. 1, the so-called "8-Track" cartridge, generally indicated as 10, which is used for audio recording/playback, comprises a housing 12, having an extended loop of magnetic tape 14 therein. As shown by the arrows, in use, the tape 14 is pulled out of the center of a coiled portion 16 across readheads 18 and is wound back onto the outside of the coiled portion 16.
One of the more recent video record/playback devices is the laser video disk such as that shown simplified in FIG. 2. The disk is recorded in a studio and played back with, for example, a home television set and disk player. In the video disk system, generally indicated as 20, at playback time, the video disk 22 is rotated on shaft 24 by motor 26. A laser beam 28 from source 30 passes through the disk 22 to strike a photodetector 32. Information within the disk 22 as recorded therein modulates the laser beam 28 as it passes therethrough such that the electrical signal on lines 34 is a reflection of the information on the disk 22 and can be used to drive a video display.
In both of the aforementioned devices, a sequencing system is provided to move the reading apparatus from track to track. As shown in FIG. 3, the tape 14 of the 8-track cartridge 10 is divided into four major tracks 36 across the width of the tape 14. Each track 36 is subdivided into two subtracks comprising the "A" and "B" channels of the stereo system. Readheads 18 comprise a side-by-side pair of identical heads 38 and 40 assigned to the A and B channels, respectively. As shown in FIG. 3(a), the heads 18 are initially positioned at track number 1. As the tape 14 is moved past the heads 18, head 38 reads the channel A information on track number 1, and head 38 reads the channel B information and electrical signals reflecting that data are developed on lines 42 and 44, respectively, which can be amplified and output as stereo music reflecting the contents of track number 1. Upon track number 1 arriving at a point thereon with an "end of track" marker (not shown), the heads 18 are skipped one track to the position of FIG. 3(b) where they are reading the data from track number 2. Upon reaching the "end of track" on track number 2, the heads 18 are skipped one more track to track number 3 as shown in FIG. 3(c). Similarly, at the "end of track" of track 3, the heads 18 are shifted to track 4 as shown in FIG. 3(d). At the end of track 4, the heads 18 are again skipped one track from track 4 to track 1 which, physically, involves skipping back over tracks 2 and 3 to the track number 1 position. Typically, a user "skip" button is provided which, when pushed, causes the heads 18 to skip to the next track 36 as if the "end of track" signal had been read. In addition to the more commonly known stereo players, such a system was also used in a robot toy game manufactured and sold by MEGO under the name "2XL".
Turning to FIG. 4, the disk 22 of the video disk system 20 of FIG. 2 is shown in plan view with a typical data track layout shown and numbered. In this particular instance, the tracks 46 comprise consecutive rings on the disk 22. Each track 46 begins and ends at the same point. As the disk 22 rotates between the laser source 30 and the photodetector 32, an appropriate sensing mechanism (not shown) senses the end of track, i.e. vertical intervals, (indicated by the dashed line 48) and causes an appropriate mechanism (also not shown for simplicity) to skip the laser source 30 and photodetector 32 in combination inward towards the shaft 24 in the direction of the arrows 50 one track 46. Typically, for convenience, each track 46 represents one "frame" on the video display. Thus, for example, if 30 frames are shown each second as with standard NTSC television to prevent flicker, a typical one and one-half hour television motion picture would occupy approximately 181,000 tracks 46 on each of two sides of disk 22.
Basic prior art switching logic for a video disk system such as that shown as 20 in FIG. 2 and as described with respect to FIG. 4 is shown in FIG. 5. At decision block 5.1 the logic checks for the end of track 48. If it is the end of track, at action block 5.2 the logic skips the laser source 30 and photodetector 32 in combination one track as just described. In either case, the logic next checks at decision block 5.3 as to whether a "skip" has been requested. This feature is typically provided in the manner of the skip button described with respect to FIG. 3 whereby the heads 18 could be jumped from track to track. Quite often, a video disk system will have a "fast forward" button wherein the viewer can repeatedly skip over tracks to find a desired portion of the disk. When video disks are applied to such applications as video games, the logic of FIG. 5 is quite often produced wherein the mechanism can be skipped on request by the program to a particular track on the disk in order to display known action recorded at that point. Thus, if a skip is requested at decision block 5.3, at action block 5.4 the logic picks up the new track number, at action block 5.5, it skips one track towards the new track, and at decision block 5.6, it checks to see if it is at the new track; if it is, it returns to the beginning of the loop to check for end of track and, if not, it returns to action block 5.5 to skip one more track.
Easily implemented additional features are often provided in conjunction with the "skip to next track" block 5.2 in a disk system. These are shown in the additional logic of FIG. 6. Having found the end of track at decision block 5.1, as duplicated in FIG. 6, at decision block 6.1 the logic next checks to see if "stop action" has been selected. If it has, the viewer is simply requesting that the action not proceed. This is easily done by by-passing the "skip to the next track" and allowing the same track to repeat over and over until the stop action has been deleted. If stop action has not been selected, at decision block 6.2 the logic checks to see if "slow motion" has been selected. If it has, a simple delay, as implemented at action block 6.3, before skipping to the next track will cause the motion to be slowed down.
While the foregoing features of the prior art record and playback systems are desirable and provided obvious benefits, they are unable to provide selection of multiple views as would be desirable in certain applications. For example, in a self-study program implemented on a video disk system, a student surgeon (or practicing surgeon looking for self-improvement) might watch a particular surgical technique on a video disk. At various points in the procedure, the student might desire and also receive benefit of a view of the procedure from a different angle than that presently on the screen. In prior art systems, there is no ability for him to see that view unless it is the view originally selected at the time of the video recording of the surgical procedure; or, unless several views are serially recorded, say a minute or two per view, and then viewed successively. The latter approach may present all the desirable views, but cannot do so in real time and, therefore, destroys the continuity required for learning a complex surgical procedure or the like. Wherefore, it is the object of the present invention to provide a video recording and playback system wherein multiple simultaneous views are recorded which can be individually selectable and changeable at the time of viewing.
SUMMARY
The foregoing objective has been achieved by the video record and playback system of the present invention comprising a plurality of video cameras for simultaneously receiving light inputs and generating input electrical video signals at respective outputs thereof reflecting the received light from multiple views; a recording medium in the form of a disk having a plurality of recording tracks thereon for recording video signals; interleaving writing means connected to respective ones of the outputs of the cameras for receiving and writing the input electrical video signals onto the recording track in a pre-established interleaved addressing pattern so that each addressable "track" is comprised of a plurality of "subtracks" which are respective ones of the recording tracks with one of the subtracks for each video signal from each camera; reading means for subsequently reading the recorded signal on a one of the subtracks sequentially from respective ones of the tracks and for generating an output electrical video signal reflecting the read signal; video display means operably connected to receive the output video signal for displaying a visual representation thereof; and, view changing means for selectively changing the one of the subtracks being read by the reading means.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified plan view of an 8-track cassette system.
FIG. 2 is a simplified elevation view of a video disk system.
FIG. 3, consisting of (a)-(e), is a simplified drawing showing the track sequencing performed in playing the 8-track cartridge of FIG. 1.
FIG. 4 is a plan view showing the track layout of the video disk of FIG. 2.
FIG. 5 is a simplified logic diagram showing the tracking logic employed with the video disk of FIGS. 2 and 4.
FIG. 6 is a simplified block diagram showing additional features which have been added in the prior art to the video disk system of FIGS. 2 and 4.
FIG. 7 is a plan view showing the track layout according to one embodiment of the present invention.
FIG. 8 is a simplified elevation of an object being recorded according to the method and with the apparatus of the present invention.
FIG. 9 is a simplified block diagram of a record and playback video system according to the present invention.
FIG. 10 is a simplified logic diagram showing the track switching logic employed in the system of FIG. 9 to accomplish the objectives of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The system of the present invention and its method of operation are depicted in FIGS. 7-10. In the description which follows, four simultaneous views are employed. Those skilled in the art will recognize that more views or less views could be employed by increasing or decreasing the number of cameras and tracks as appropriate.
In FIG. 8, an engine 52 is shown on a workbench 54. Assume that a mechanic (not shown) is to perform a repair procedure on the engine 52 according to the present invention. In such case, a plurality of cameras 56 are placed to simultaneously view the engine 52 and repair procedure from different angles. In FIG. 8, the cameras 56 are labeled "A", "B", "C", and "D", respectively. As can be seen, each of the cameras 56 has been marked in a different manner to correspond to the track designations in FIG. 7 for ease of identification. As can be seen in FIG. 7, each of the individual tracks 46 on the disk 22 is a "subtrack" in the present system. Four contiguous subtracks 46, as designated 58, comprise an addressable "track" within the present system. It should be recognized that track 58, #1, comprises the first frame of the view from camera "A" followed by the first frame from camera "B", then the view from camera "C", and finally the view from camera "D". This then repeats for the second frame, et sequence. Those skilled in the art will recognize that while the four views at each frame are consecutive in the track layout of FIG. 7, different patterning and interleaving of the data on the tracks 46 of the disk 22 could be employed within the scope and spirit of the present invention. For example, all the view A's subtracks 1-n could be consecutively recorded followed by all the view B's, then the C's, and finally the D's. All that is required is a pre-established addressing pattern wherein each addressable "track" is comprised of a plurality of "subtracks", with one addressable subtrack designation for each video signal from each camera 56.
The system of the present invention is shown in simplified block diagram form in FIG. 9 and exemplary logic as could be employed therein to accomplish the purposes of the present invention is shown in FIG. 10. As shown in FIG. 9, the electrical outputs 60 from the cameras 56 are controlled by input and write apparatus 62 to record the electrical signals from the cameras 56 onto the disk 22. To create a disk 22 configured in the manner of FIG. 7, four laser sources 30 could be disposed side-by-side in the manner of the two heads 18 of FIG. 3, to write four tracks 46 on the disk 22 simultaneously. If a different addressing pattern is employed, the input and write apparatus 62 would, of course, have to be modified accordingly. The manner of accomplishing this should be obvious to those skilled in the art and, accordingly, no greater detail thereof is provided to prevent redundancy. Those skilled in the art will recognize that this is a simplified description showing only the critical changes in equipment and approach. In the more usual approach of a commercial production of the video disk and subsequent playback by the viewer on equipment designed for playback only, the initial recording would most likely be done on four one-inch video tape recorders. The four tapes would then be interleaved, by fours, onto a new master one-inch tape in a frame-by-frame automatic editing system. Finally, the master tape would be used to create master disks (laser, LED, etc.) used to make the production disks which are bought by the viewer. This should be kept in mind with respect to this specification and the claims appended thereto.
Once the disk 22 has been recorded, whether in a combination playback and recording machine or on typical video disk production equipment used to prerecord video disks, the contents thereof can be read and displayed subsequently by the remaining components of FIG. 9 according to the logic of FIG. 10. Block 64 labeled as "TRACK SELECT" represents the physical apparatus for moving the laser sources 30 and photodetectors 32 with relationship to the tracks 46 on the disk 22. With four subtracks 46 comprising each major address able track 58, four laser sources 30 and four photodetectors 32 disposed adjacent one another would be employed. Block 66 labeled "READ LOGIC" represents the logic of FIG. 10 which will be described shortly. "VIEW SELECT" block 68 and operably attached selector switch 70 represents the interface to the viewer whereby the viewer can continuously and instantaneously select which one of the views A, B, C, or D he wishes to watch at any moment. Block 72 labeled "USER" represents any additional functions and is also connected to drive the display 74 which receives the selected subchannel video signal and displays it as a visual representation thereof. There again, the USER function 72 and display 74 are all well known to those skilled in the art and, to conserve space and avoid redundancy, further explanation thereof is not incorporated as part of this specification.
With particular reference to FIG. 10, the READ LOGIC 62 in combination with the TRACK SELECT apparatus 64 at decision block 10.01 first checks for an end of track condition. If the end of track has been achieved, at action block 10.02 the logic causes TRACK SELECT apparatus 64 to skip to the same subtrack of the next track group. Thus, for example, if the end of track 48 for view D of frame #1 (the cross-hatched track) had been sensed, the read function would be skipped across four tracks 46 (being four subtracks of the main addressable "track" 58) to the view D track 46 of frame #2. That is, having read the fourth track from the edge as FIG. 7 is viewed, the read function would be skipped to the eighth track as the figure is viewed.
At decision block 10.03, the logic checks to see if a skip has been requested in the manner of the logic of FIG. 5. If it has, in a similar manner to the logic contained therein, the logic at action block 10.04 picks up the new track number, at action block 10.05, it skips one track group towards the new track; that is, skips from a subtrack 46 for a given view to the next same view subtrack 46 in the direction towards the new track 58 or four subtracks 46. At decision block 10.06, the logic checks to see if the new track has been arrived at. If it has, the logic proceeds back to the starting point and if not, returns to action block 10.05.
To this point, the logic of FIG. 10 is very similar to that of FIG. 5, except that the skipping is by major addressable "tracks" 58 as opposed to single tracks (now subtracks) 46. To accomplish the major objective of view selectability, however, additional logic is provided. At decision block 10.07, the logic next checks to see if a view change has been requested; that is, has the viewer changed the position of selector switch 70. If he has not, the logic returns back to the beginning of the loop at START. If a change of view has been requested, at action block 10.08 the logic picks up the new subtrack number; that is, the number of the subtrack 46 within the track grouping 58 corresponding to the position of the selector switch 70. At action block 10.09 the logic next skips one subtrack 46 within the track grouping 58 towards the new subtrack. At decision block 10.10 the logic next checks to see if the new subtrack is now the subtrack now being read. If it is, the change in view has been completed and the logic returns to START. If not, it returns to action block 10.09.
Thus, from the foregoing description, it can be seen that the method and apparatus of the present invention provides an improvement to video record/playback systems, as desired, wherein a viewer watching action in progress can instantaneously select between a number of views of that same action to suit his own desires and wishes as opposed to being limited to with a single view sequence as originally provided.
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A video recorder and playback system adapted to provide the viewer with selectable views of the action in progress. During recording, a plurality of cameras simultaneously record the action in progress on addressable subtracks of a multi-track loop recording medium such as a laser disk or magnetic surfaced disk. At playback time, the playback and display portion of the system is adapted to read from the same subtract on sequential tracks beginning at a selected starting point. Means are provided for the viewer to change on demand the one of the subtracks being read whereby the view can be instantaneously changed by selecting the one of the subtracks containing the desired view.
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[0001] This application claims the benefit of priority under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application Ser. No. 60/820,714, filed Jul. 28, 2006, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to crystalline erlotinib, including anhydrous as well as hydrated forms, processes for preparing them, pharmaceutical compositions thereof and their use in preparing erlotinib or pharmaceutical acceptable salts of erlotinib.
[0003] Erlotinib, chemically [6,7-bis(2-methoxyethoxy)-quinazolin-4-yl]-(3-ethynylphenyl)amine of formula 1
is a compound that inhibits the human epidermal growth factor receptor tyrosine kinase, also known as EGFR-TK, that is critical for growth of malignant cells. EGFR overexpression is associated with disease progression, and reduced survival. Erlotinib acts by blocking tyrosine kinase activity of EGFR-TK, resulting in inhibition of signaling pathway, and decreased growth of malignant tumors. Erlotinib is thus useful for the treatment of proliferative disorders such as cancers in humans. Erlotinib is marketed as its hydrochloride salt under such brand names as TARCEVA® (OSI Pharmaceuticals, Inc.) for treatment of certain lung cancers and pancreatic cancer.
[0004] WO 96/30347 and U.S. Pat. No. 5,747,498 teach quinazoline derivatives for treating hyperproliferative diseases such as cancers. Example 20 shows the formation of erlotinib free base and the subsequent conversion to the hydrochloride salt. Before the conversion to the salt, an organic phase containing the erlotinib was concentrated and the residue flash chromatographed on silica to obtain the free base as a pate yellow solid. This solid was then dissolved in a solvent and reacted with HCl to form the hydrochloride salt. There is no report of whether the solid erlotinib was crystalline.
[0005] European patent application EP 1044969 discloses processes for making erlotinib, its salts, and related compounds. Several examples make the hydrochloride salt (see examples 4, 7 and 9-11) and several make the mesylate salt (see examples 8 and 12). No mention is made in the examples of forming a solid erlotinib free base. Rather the solid forms are obtained by precipitation of the erlotinib salts.
[0006] Several patent publications disclose the existence of polymorphic forms of erlotinib salts. For example, WO 01/34574 discloses the existence of two polymorphic Forms of erlotinib hydrochloride which were designated as Form A and B. Form B is thermodynamically more stable than Form A. More recently WO 2004/072049 discloses the existence of another polymorph of erlotinib hydrochloride, designated as Form E, which is thought to have similar stability as Form B but with a higher solubility. The mesylate salt of erlotinib, with enhanced solubility compared to the hydrochloride, and its preparation is disclosed in WO 99/55683. Anhydrous erlotinib mesylate exists in three different polymorphic Forms designated Form A, B and C. Also a monohydrate of erlotinib mesylate and its use in the preparation of anhydrous mesylate Forms is disclosed.
[0007] While crystalline salts of erlotinib have been studied, it would be advantageous to be able to provide erlotinib in a solid, crystalline form.
SUMMARY OF THE INVENTION
[0008] The present invention is based on the discovery that erlotinib free base can be formed as a crystalline solid material and, more particularly, to the discovery of three specific crystalline forms. Accordingly, a first aspect of the invention relates to crystalline erlotinib free base which is substantially Form I, Form II, or Form III. The crystalline erlotinib can be an anhydrous crystal or a hydrated crystal. The crystalline erlotinib can be a stable solid material suitable for making a pharmaceutical dosage form and is thus also useful for treating hyperproliferative diseases such as cancer. Alternatively, the crystalline erlotinib can be useful in forming salts of erlotinib. For example, crystalline erlotinib free base according to the invention can be precipitated from a solution and then converted to a pharmaceutically acceptable salt such as the aforementioned hydrochloride or methanesulfonate salts. The formation of the crystalline free base can provide a useful pathway for purifying erlotinib or an erlotinib salt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is a representative XRPD pattern of erlotinib free base Form II.
[0010] FIG. 1B is a representative DSC spectra of erlotinib free base Form II.
[0011] FIG. 1C is a representative FT-IR spectra of erlotinib free base Form II.
[0012] FIG. 2A is a representative XRPD pattern of erlotinib monohydrate Form I.
[0013] FIG. 2B is a representative DSC spectra of erlotinib monohydrate Form I.
[0014] FIG. 2C is a representative FT-IR spectra of erlotinib monohydrate Form I.
[0015] FIG. 3A is a representative XRPD pattern of erlotinib monohydrate Form III.
[0016] FIG. 3B is a representative DSC spectra of erlotinib monohydrate Form III.
[0017] FIG. 3C is a representative FT-IR spectra of erlotinib monohydrate Form III.
[0018] FIG. 4 is a XRPD pattern of the product of the Comparative Example
[0019] The XRPD patterns were recorded according to the following settings:
Start angle (2θ): 2.0° End angle (2θ): 35.0-50° Scan step width: 0.02° Scan step time: between 1-6 seconds Radiation type: Cu Radiation wavelengths: 1.54060 Å (Kα 1 ), primary monochromator used Exit slit: 6.0 mm Focus slit: 2 mm Divergence slit: Variable (V20) Antiscatter slit: 3.37 or 6.17 mm Receiving slit: 5.25 or 10.39 mm
[0020] The DSC spectra were obtained according to the temperature schedule given below and the samples were measured in an aluminum pan with a pierced lit:
Start temperature: 25° C. End temperature: 260° C. Heating rate: 10° C./min
[0021] The FT-IR spectra were obtained according to the KBr-method. The FT-IR spectra were recorded from 600 cm −1 to 4000 cm −1 . From each FT-IR spectrum a blank FT-IR spectrum of KBr was subtracted. That blank IR spectrum was recorded prior to the measurements of the samples.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention relates to the discovery of crystalline Forms of erlotinib free base. As used herein, “crystalline erlotinib” and “crystalline erlotinib free base” are used broadly to include solvates/hydrates of erlotinib as well as anhydrous forms. The crystal need not be morphologically pure but does substantially comprise one of the Forms I, II, or III. Thus the erlotinib crystalline material is “substantially” one of the Forms I, II, or III, e.g., one Form accounts for at least 80%, more typically at least 85%, and usually at least 90% of the crystalline erlotinib. A “pure” Form is substantially free of any other crystalline Forms having less than 5%, typically less than 2%, and more preferably no XRPD-detectable amount of any other crystal Form. While none of the above-mentioned prior art describes a crystalline erlotinib free base, it appears that Example 20 of WO 96/30347 may be capable of producing a type of crystalline erlotinib free base. As shown in the Comparative Example hereinafter, a similar experiment to the Example produced a material having some crystallinity as demonstrated by the XRPD shown in FIG. 4 . The material has several strong peaks below 10° 2θ and may have a significant amorphous content. The crystalline portion of the material is either a different crystal From than Forms I, II and III of the present invention or is a mixture of forms; in the latter event, the crystalline erlotinib is not substantially one of Forms I, II, or III. Being able to reliably form a solid, crystalline form of erlotinib can provide useful ways of administering erlotinib. Additionally, the crystallization of the free base can serve as a useful purification step for the erlotinib base or a salt thereof, e.g., using crystalline erlotinib as the starting material for the salt formation reaction.
[0023] In general, the crystalline erlotinib free base Forms of the present invention can be formed by crystallizing erlotinib from an erlotinib solution. The solvent is generally an alcohol such as methanol, ethanol or isopropanol; acetone; acetonitrile, chloroform; 1,4-dioxane; toluene; or a mixture of two or more of these solvents. The crystallization can be induced/caused by cooling and/or adding a contrasolvent such as water or an alkane such as heptane. Other crystallization techniques may also be used, including reducing the volume of the solution by evaporation, and/or seeding.
[0024] Three specific crystalline forms have been found useful and are designated Forms I, II, and III, respectively. Forms I and III are hydrates while Form II is an anhydrate. The three forms, beginning with the anhydrous Form II, are hereafter described in more detail.
[0025] Crystalline erlotinib free base Form II of the present invention is an anhydrous crystalline form. It can generally be identified or distinguished from other erlotinib crystalline forms by the following characteristic XRPD peaks at 2θ: 6.4, 12.8, 15.6, 18.2, 22.3, 23.2, 23.6, and 25.8±0.2 degrees, and/or FT-IR peaks v max (KBr) cm −1 : 772, 851, 1033, 1131, 1218, 1256, 1334, 1430, 1502, 1576, 1619, and 3251±4 cm −1 . As used herein, the ±0.2 degrees for the XRPD peaks and the 4 cm −1 for the FT-IR peaks applies to each peak listed, respectively. Also, the listed peaks for each Form are not intended to represent an exhaustive list. Generally crystalline Form II erlotinib, in a relatively pure state, has an XRPD that substantially corresponds to FIG. 1A and/or an FT-IR that substantially corresponds to FIG. 1C . The expression “substantially corresponds” means that a pattern or spectra does not have to be superimposable over the recited figure but rather can have minor variations of the type caused by differences in sample preparation, conditions of measurement, purity of the sample to other compounds, polymorphic purity, etc., as understood by a worker skilled in the art. For example, the increase or decrease in a peak in an FT-IR spectrum corresponding to the presence of the amount of carbon dioxide gas would not indicate a different crystalline form, even though the spectra would not be superimposable.
[0026] The DSC scan of Form II shows a melting peak around 154-158° C. TGA shows only little mass loss below 180° C. Form II may be present as needles or thin plates.
[0027] When Form II is melted and cooled, no recrystallization takes place, regardless of the cooling rate or rate upon reheating. While not entirely clear, probably a stable glass is formed that does not recrystallize. Another explanation may be degradation.
[0028] XRPD under non-ambient conditions (30° C./10-90% RH and 50° C./75% RH) showed that Form II does not undergo polymorphic transitions under humid conditions at elevated temperatures. TGA confirmed that Form II can be considered non-hygroscopic.
[0029] Erlotinib base Form II can be formed by precipitating from a solution. Typically the solvent is an alcohol, especially isopropanol, or acetone. Co-solvents such as ethanol or toluene may also be present. The presence of water is generally avoided in the solution. Specific techniques include:
(i) (re)crystallization of erlotinib base from an alcoholic solvent, typically from 2-propanol; or (ii) precipitation by adding n-heptane to a solution of erlotinib in acetone at room temperature (R.T.).
[0032] Recrystallization from 2-propanol may initially give Form II with a small amount of another Form. However, prolonged stirring results in pure Form II. This indicates that Form II is the thermodynamically more stable Form.
[0033] Mixtures of Form I and Form II were obtained by recrystallization from ethanol, toluene, 2-propanol/n-heptane (1:10 V/V), or by adding a solution of erlotinib in 2-propanol to n-heptane at 0° C. Such mixtures may be recrystallized to yield pure Form II by processes a) or b) above, if desired. Pure Form II should be understood as substantially free of any other crystalline Forms of erlotinib.
[0034] Crystalline Form I is a monohydrated form of erlotinib free base that can generally be identified by the following characteristic XRPD peaks at 2θ: 7.4, 10.9, 14.6, 14.9, 18.3, 20.1, 20.5, 20.8, 22.4, 24.6, 27.6, 30.0, and 30.3±0.2 degrees, and/or FT-IR peaks; vmax (KBr) cm − : 791, 883, 897, 1030, 1128, 1208, 1243, 1293, 1429, 1482, 1533, 1629, and 3569±4 cm −1 . Generally a relatively pure crystalline Form I erlotinib has an XRPD that substantially corresponds to FIG. 2A and/or an FT-IR that substantially corresponds to FIG. 2C . As used herein a “monohydrate” means that the crystalline material contains approximately 1 mole of water for each mole of erlotinib. It can vary typically by up to about 15% from a perfect 1:1 ratio. As is well known in the art, this water is bound to the crystal lattice and is not simply a wet material.
[0035] A DSC scan of Form I shows a complex evaporation endotherm below 145 C with an embedded (melting) peak around 126-129° C. Melting can be observed around 155-157° C. TGA shows evaporation of about 1 equivalent of water below 140-170° C. The crystals are well defined prisms and bars.
[0036] Crystalline Form III is a monohydrated Form of erlotinib free base that can generally be identified by the following characteristic XRPD peaks at 2θ: 6.8, 13.1, 14.7, 20.4, 21.1, and 24.5±0.2 degrees and/or FT-IR peaks; vmax (KBr) cm −1 : 871, 1118, 1131, 1212, 1249, 1434, 1517, 1536, 1629, 3274, and 3536±4 cm −1 . Generally relatively pure crystalline Form III erlotinib has an XRPD that substantially corresponds to FIG. 3A and/or an FT-IR that substantially corresponds to FIG. 3C .
[0037] A DSC scan of Form III shows overlapping evaporation effects and melting around 154-156° C. TGA clearly showed a single step, corresponding to about 1 equivalent of water. Form III may be present as rectangular or square-like thin plates.
[0038] The hydrated crystalline erlotinib free base may be crystallized from a solvent comprising water. Preferably a water/ethanol/acetone mixture (2:1:1 V/V/V) at ambient temperature may be used which results in the hydrated Form I, preferably in pure Form I. Pure Form I should be understood as substantially free of any other crystalline forms of erlotinib. Pure Form III can be obtained by crystallizing from acetone/water (3:10 V/V) at ambient temperature. Pure Form III should be understood as substantially free of any other crystalline form of erlotinib.
[0039] The starting erlotinib used to prepare the crystalline erlotinib free base of the invention, can be obtained by any suitable or known means. The erlotinib can be obtained as an oil, an amorphous solid or as a crystalline material (such as a mixture of crystalline Forms) directly from the erlotinib synthesis and then dissolved into an appropriate solvent for (re)crystallization. Alternatively, the erlotinib free base can be liberated from an acid salt of erlotinib such as a hydrochloric acid or methanesulfonic acid salt of erlotinib, under aqueous basic conditions followed by an extraction of the free base with a water immiscible organic solvent, for instance ethyl acetate. The free base can be recovered as an oil or solid and then, if necessary, dissolved into a suitable solvent for (re)crystallization
[0040] The hydrates of the invention can be converted into anhydrous forms and vice versa. For instance, any of the hydrates provides for the erlotinib free base Form II by heating.
[0041] The transition of hydrate Form I into Form II proceeds via melting of Form I after which the melt recrystallizes to Form II. The transition of Form III into Form II occurs via the solid-solid transformation. Form II appears to be the thermodynamically most stable form.
[0042] Another way to convert the hydrates to Form II includes recrystallization in a suitable solvent, preferably with some provision for removing water; e.g. by a Dean-Stark trap. Suitable solvents are for instance 2-propanol, chloroform, 1,4-dioxane, and mixtures thereof. Seeding can be used to speed up the crystallization rate.
[0043] Crystalline Forms I, II, and III are stable crystalline Forms which make them suitable for formulation of pharmaceutical compositions and for handling and storage, either individually or in combinations, e.g. a mixture of crystalline forms. Form II is generally considered the preferred form for making a pharmaceutical dosage form.
[0044] The invention also relates to the use of crystalline erlotinib free base, especially Form I, II, and/or III and their pharmaceutical compositions as a medicament. Generally the compound is used for the treatment of a hyperproliferative disease, especially a cancer. Specific cancers include brain, squamous cell, bladder, gastric, pancreatic, hepatic, glioblastoma multiform, head, neck, esophageal, prostate, colorectal, lung especially non-small cell lung cancer (NSCLC), renal, kidney, ovarian, gynecological, thyroid, and refractory cancers. Suitable dosage regimens comprise from 0.001 to 100 mg/kg/day.
[0045] The pharmaceutical composition can be in the form for enteral, parenteral or transdermal administration. The composition can be administered orally in the form of tablets, capsules, solutions, suspensions or emulsions. The composition can also be administered in the form of an injection solution or suspension or infusion solution, or transdermally with for instance a patch. Pharmaceutical compositions can be obtained in a way which is common for a person skilled in the art.
[0046] The compositions comprise a crystalline erlotinib and at least one pharmaceutically acceptable excipient. Finished dosage forms, such as tablets or capsules, generally contain at least a therapeutically effective amount of crystalline erlotinib and a suitable carrier.
[0047] Suitable carriers are for instance solid inert diluents or fillers or liquids such as water, alcohols, etc. Examples of common types of carriers/diluents include various polymers, waxes, calcium phosphates, sugars, etc. Polymers include cellulose and cellulose derivatives such as HPMC, hydroxypropyl cellulose, hydroxyethyl cellulose, microcrystalline cellulose, carboxymethylcellulose, sodium carboxymethylcellulose, calcium carboxymethylcellulose, and ethylcellulose; polyvinylpyrrolidones; polyethylenoxides; polyalkylene glycols such as polyethylene glycol and polypropylene glycol; and polyacrylic acids including their copolymers and crosslinked polymers thereof, e.g., Carbopol® (B.F. Goodrich), Eudragit® (Rohm), polycarbophil, and chitosan polymers. Waxes include white beeswax, microcrystalline wax, carnauba wax, hydrogenated castor oil, glyceryl behenate, glycerylpalmito stearate, and saturated polyglycolyzed glycerate. Calcium phosphates include dibasic calcium phosphate, anhydrous dibasic calcium phosphate, and tribasic calcium phosphate. Sugars include simple sugars, such as lactose, maltose, mannitol, fructose, sorbitol, saccharose, xylitol, isomaltose, and glucose, as well as complex sugars (polysaccharides), such as maltodextrin, amylodextrin, starches, and modified starches.
[0048] Furthermore the compositions may contain additional additives including stabilizers, preservatives, flavoring agents, colorants, lubricants, emulsifiers or other additives which will be apparent for the skilled persons in the art of preparing pharmaceutical compositions.
[0049] Crystalline erlotinib free base can also be used for the synthesis of a pharmaceutical acceptable salt of erlotinib. The compound may react in a solvent with an organic or inorganic acid followed by isolation of the pharmaceutical acceptable salt of erlotinib, generally by precipitation from the reaction mixture.
[0050] Suitable organic acids are methanesulfonic acid, naphthalene sulfonic acid, maleic acid, acetic acid, malic acid, fumaric acid, and citric acid. Suitable inorganic acids are hydrobromic and hydrochloric acid. Preferably the acid is methanesulfonic acid or hydrochloric acid. The salts of erlotinib may be obtained in anhydrous, hydrated or solvated forms. Preferably the erlotinib salts are obtained in solid form. More preferably the erlotinib salts are obtained in crystalline form.
[0051] The following examples are illustrative to the present invention. They are not intended to limit the scope of the invention in any manner.
EXAMPLES
Example 1 erlotinib Form II
[0052] 0.2 g of erlotinib monohydrate Form I was dissolved in 5 ml of 2-propanol at reflux. The solution was allowed to cool to R.T. and stirred at R.T. for about 19 hours; crystallization already occurred within the first hour of stirring. The solid was isolated by filtration over a P3-glass filter (reduced pressure) and air dried at R.T. and under ambient conditions for a few hours. An off-white powder with a yield of 140 mg was obtained. (analytical data in FIG. 1A, 1B , and 1 C)
Example II erlotinib monohydrate Form I
[0053] 3.0 g of erlotinib hydrochloride was suspended in 400 ml of demi-water/ethyl acetate (1:1 V/V) at R.T. To the suspension/emulsion, vigorously stirred at R.T., 300 mg of NaOH dissolved in 50 ml of demi-water was added very slowly (dropwise, >1 equivalent of OH − ). As a result of this, the HCl was removed from the drug substance and the drug substance was extracted into the organic phase. Some extra NaOH was added as the water-layer proved to be hardly basic afterwards and to ensure complete removal of HCl from the drug substance. The organic phase was twice washed with water and filtered over a P3-glass filter (reduced pressure), packed with prewashed Celite 545. The filtrate was dried with sodium sulphate for 15-30 minutes. The solution was filtered over a P3-glass filter (reduced pressure) to remove the sodium sulphate. Then, the solvent was evaporated under vacuum to dryness, yielding a pale beige, crystalline solid with a yield of approximately 1.85 g. (analytical data in FIG. 2A, 2B , and 2 C)
Example 3 erlotinib monohydrate Form III
[0054] 0.2 g of erlotinib was dissolved in 15 ml of acetone at R.T. The solution was filtered over a P3-glass filter (reduced pressure) to remove foreign particles. To the clear filtrate, stirred at R.T., 50 ml of demi-water was added dropwise. During addition of water, fast crystallization occurred. The suspension was stirred at R.T. for about 2 minutes. The solid was isolated by filtration over a P3-glass filter (reduced pressure) and air dried overnight at R.T. and under ambient conditions. An off-white, fluffy to foamy powder mass was obtained. The yield was 150 mg. (analytical data in FIG. 3A, 3B , and 3 C)
Example 4 erlotinib monohydrate Form I
[0055] 0.2 g of erlotinib form II was mixed together with 20 ml of demi-water. The suspension was refluxed, but the drug substance did not dissolve. To the hot suspension, 10 ml of ethanol was added, but no clear solution was obtained upon reflux. 10 ml of acetone was added to the suspension. After additional reflux, a clear solution was obtained. The solution was allowed to cool to R.T. and stirred at R.T. for about 23 hours; crystallization occurred. The suspension was stirred for a few minutes at 0° C. The solid was isolated by filtration over a P3-glass filter (reduced pressure) and air dried at R.T. and under ambient conditions for about 3 days. An off-white, nicely flowable powder of small and shiny crystals was obtained. The yield was 160 mg.
Example 5 erlotinib Form II
[0056] 1.5 g of erlotinib hydrochloride was suspended in 100 ml of demi-water/dichloromethane (1:1 V/V) at R.T. To the suspension/emulsion, vigorously stirred at R.T., 300 mg of NaOH dissolved in about 10 ml of demi-water was added slowly. As a result of this, the HCl was removed from the drug substance and the drug substance was extracted into the organic phase. Some extra 1M NaOH (few ml) and 50 ml of dichloromethane were added as extraction appeared to be far incomplete (solid material remained in the water phase).
[0057] After vigorous stirring at R.T. for 1 hour, both liquid layers appeared to be more or less clear. The organic layer was separated. Possible remaining drug substance in the water phase was extracted with an additional 50 ml of dichloromethane. The combined organic phases were filtered over a P3-glass filter (reduced pressure, packed with Celite 545), washed with 50 ml of fresh demi-water and filtered over the same filter again. The clear filtrate was dried with sodium sulphate for 1.5 hours (stirring). The solution was filtered over a P3-glass filter (reduced pressure) to remove the sodium sulphate. Then, the solvent was slowly evaporated under vacuum to dryness, yielding an off-white to pale beige, crystalline solid. No yield was determined.
Example 6
[0058] 0.2 g of erlotinib monohydrate Form I was dissolved in 10 ml of acetone at R.T. and by means of stirring. To the solution, 150 μl of 2-propanol with 5-6 N HCl was added (>1 equivalent of HCl), while stirring was continued. As a result of this, immediate precipitation took place. The suspension was stirred at R.T. for an additional few minutes. The solid was isolated by filtration over a P3-glass filter (reduced pressure, rapid) and air dried overnight at R.T. and under ambient conditions. Lumps of off-white, sticky powder were obtained. The yield was 150mg.
[0059] Erlotinib hydrochloride was obtained as a mixture of Form A and Form B.
Comparative Example (Based on Example 20 of WO 96/30347)
[0060] 37 mg of 3-ethynylaniline and 90 mg of 4-chloro-6,7-bis-(2-methoxy-ethoxy)quinazoline were added to a mixture of 1.5 ml of isopropanol and 25 μl pyridine. The resulting mixture was refluxed for 4 hours under an atmosphere of dry nitrogen. During reflux the color changed from pale yellow to orange-pink. The solvent was removed in vacuo on a rotavap (water bath 40° C.) The residue was partitioned between 5 ml 10% methanol in chloroform and 5 ml saturated aqueous NaHCO 3 . The organic layer was dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was dissolved in a mixture of 2.5 ml of acetone and 2.5 ml hexane and flash chromatographed on silica using 30% acetone in hexane, concentrated in vacuo on a rotavap (water bath 40° C.) About 90 mg of a sticky pale yellow solid was obtained (attached to the wall of the flask) The solid was analyzed on XRPD and the results shown in FIG. 4 .
[0061] Each of the patents, patent applications, and journal articles mentioned above are incorporated herein by reference. The invention having been described it will be obvious that the same may be varied in many ways and all such modifications are contemplated as being within the scope of the invention as defined by the following claims.
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Crystalline Forms of erlotinib are made. The crystalline materials are useful as pharmaceutical active agents in treating various cancers as well as in forming erlotinib salts.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The priority of Korean patent application No. 10-2014-0164498 filed on Nov. 24, 2014, the disclosure of which is hereby incorporated by reference in its entirety, is claimed.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate to a technology for controlling various parking assistance systems developed for parking convenience of a driver.
BACKGROUND
[0003] In general, various systems for parking assistance such as, for example, a Parking Assist System (PAS), an Around View Monitoring (AVM) system, and Reverse-gear tilt-down outside mirrors, detect the driver's parking intention using an R (reverse)-gear switch signal of a shift lever or a direct switch-on/off action, or the like, so that the above-mentioned parking assistance systems can be activated. In this case, respective input signals are different from each other. For example, the R-gear switch signal is not received as input during a front view parking mode, and therefore it is difficult for individual parking assistance systems to be effectively turned on or off at an appropriate time. Therefore, there is a need to determine whether each parking assistance system will be turned on or off prior to execution of the parking mode.
[0004] In addition, the auto hold function of the vehicle needs to simultaneously control on/off functions of each parking assistance system during the parking mode. If the auto hold function is activated, the auto hold function can be conveniently used in a general city driving mode. However, when a driver attempts to park a vehicle during the auto hold function activation, a vehicle halt state is continuously maintained after the driver steps on the brake pedal. This can cause inconvenience to the driver during parking. In that case, when the driver reattempts to park the vehicle, the driver has to turn off the auto hold function by stepping on the accelerator pedal. The driver may feel uneasy doing this, resulting in reduction of vehicle safety. In order to address the above-mentioned problem, the driver has to turn off the auto hold function when attempting to park a vehicle, and also has to turn on the auto hold function when the driver does not park the vehicle, resulting in greater inconvenience of use.
SUMMARY
[0005] Various embodiments of the present invention are directed to providing a parking assistance system and a method for controlling the same that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0006] An embodiment of the present invention relates to a technology for simultaneously controlling the on/off actions of not only the parking assistance system configured to receive the driver's parking intention using a single button (i.e., a parking-mode button) so as to affect the parking action, but also other driving convenience systems, so that the driver can more effectively and conveniently park his or her vehicle in a parking space.
[0007] In accordance with an aspect of the embodiment, a parking assistance system includes a parking-mode input unit, a parking-associated functioning unit having a set of parking-associated systems, a setting unit for selecting parking-associated systems that are operated, and a controller configured to control the respective parking-associated systems by receiving an input signal through the parking-mode input unit.
[0008] The parking-mode input unit may be implemented as one button installed in a vehicle.
[0009] The setting unit may be predetermined through a user setting menu and changeable by a driver.
[0010] The parking assistance system may further include a display unit configured to display a parking image indicating a parking state on a vehicle cluster when an input signal is applied to the parking-mode input unit.
[0011] The parking-associated functioning unit may include a parking assist system (PAS), a rear parking assist system (RPAS), an around view monitoring system (AVM), a reverse-gear tilt-down outside mirrors function, an auto hold function, and other parking-associated functions.
[0012] In accordance with another aspect of the embodiment, a method for controlling a parking assistance system includes transmitting a parking-mode input signal by turning on a parking-mode input unit, recognizing that a parking action is ready to be executed through the parking-mode input signal, and controlling a plurality of parking-associated functioning units according to a predetermined condition stored in a setting unit.
[0013] The predetermined condition may be changeable through a user setting menu.
[0014] The method may further include, upon controlling the parking-associated functioning units, switching off the parking-mode input unit.
[0015] The method may further include, upon transmission of the parking-mode input signal, displaying a parking image indicating a parking state on a vehicle cluster.
[0016] The parking-associated functioning unit may include a parking assist system (PAS), a rear parking assist system (RPAS), an around view monitoring system (AVM), a reverse-gear tilt-down outside mirrors function, an auto hold function, and other parking-associated functions.
[0017] It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a block diagram illustrating a parking assistance system according to an embodiment of the present invention.
[0019] FIG. 2 is a flowchart illustrating a method for controlling a parking assistance system according to an embodiment of the present invention.
[0020] FIGS. 3 and 4 are enlarged views illustrating some constituent parts of a parking assistance system according to an embodiment of the present invention.
[0021] FIGS. 5A to 5D illustrate a method for employing a parking assistance system according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0022] Reference will now be made in detail to the 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.
[0023] FIG. 1 is a block diagram illustrating a parking assistance system according to an embodiment of the present invention.
[0024] Referring to FIG. 1 , the parking assistance system includes a parking-mode input unit 107 , a parking-associated functioning unit 130 , a setting unit 110 , a controller 120 , and a display unit 190 .
[0025] The parking-mode input unit 107 may directly receive the driver's parking intention through a parking-mode input button 300 (shown in FIG. 3 ). The parking-mode input button 300 may be arranged near a shift lever as shown in FIG. 3 . For example, a drive mode button (DRIVE MODE) and an auto hold (AUTO HOLD) button may also be located below the shift lever, as shown in FIG. 3 . The parking-mode input button (P) 300 implemented as a push button may be located adjacent to the two buttons (i.e., DRIVE MODE and AUTO HOLD). Therefore, the driver can easily access the parking-mode input button 300 when attempting to park the vehicle.
[0026] When the parking-mode input unit 107 receives the parking mode input signal and the parking mode starts, the parking-mode input button 300 (of FIG. 3 ) is lighted on and at the same time the letter “P” indicating the parking is displayed on a vehicle cluster screen 400 (shown in FIG. 4 ) of the display unit 190 . Since the letter “P” is displayed on the display unit 190 , the driver who pushes the parking-mode input button 300 can easily recognize whether a current mode normally enters the parking mode.
[0027] The parking-associated functioning unit 130 may include multiple parking-associated systems. The parking-associated systems may include a parking assist system (PAS) 140 , a rear parking assist system (RPAS) 150 , an around view monitoring system (AVM) 160 , a reverse-gear tilt-down outside mirrors function 170 , an auto hold function system 180 , or the like.
[0028] The PAS 140 includes a front-view sensor and a rear-view sensor, and detects the presence or absence of other vehicles in the front and rear directions using the front-view sensor and the rear-view sensor. When the presence of vehicles in the front and rear directions is determined, the PAS 140 may warn the driver of this dangerous situation.
[0029] When the reverse (R) gear of the shift lever is activated, the RPAS 150 may detect the presence or absence of a vehicle in a rear-view dead zone using the rear-view sensor.
[0030] The AVM 160 may provide various view modes using a front-view camera, a rear-view camera, and both side-view cameras of the vehicle.
[0031] When the AVM 160 is not turned on, the front-view mode or the rear-view mode is activated according to a predetermined condition.
[0032] Assuming that the shift lever is shifted to a drive (D) gear, the vehicle starts driving, and the vehicle speed is less than 20 kilometers per hour (kph), the front-view mode starts operation.
[0033] In addition, when the shift lever is shifted to the reverse (R) gear, the rear-view mode starts operation.
[0034] The reverse-gear tilt-down outside mirror function 170 may allow a reflective surface of the outside mirror to move downward, so that it can allow the driver to view a rear-downward view image.
[0035] Assuming that the auto hold function 180 is activated, after the driver steps on a brake pedal to brake the vehicle on the condition that the shift lever is located at the D-gear mode, the R-gear mode, the N (neutral)-gear mode, or the manual mode, although the driver takes a foot off the brake pedal after the vehicle comes to a halt, the vehicle halt state is continuously maintained. Otherwise, if the driver steps on the accelerator pedal, the auto hold function 180 is automatically released, so that the vehicle can start driving.
[0036] Among several parking-associated systems contained in the parking-associated functioning unit 130 , information regarding driver parking habits or information regarding some parts needed for such parking can be selectively turned on or off by the setting unit 110 in such a manner that information regarding the selective on/off states is established in the setting unit 110 . The setting unit 110 may be established by a user setting menu 105 . The setting unit 110 may establish multiple functions to be turned on/off when the parking mode button is pushed, and this establishing condition may be directly changed by a driver.
[0037] For example, assuming that the driver wants to turn on the PAS 140 and the AVM 160 during the vehicle parking and also wants to turn off the R-gear tilt-down outside mirrors function 170 and the auto hold function 180 , the setting condition may be changed by the user setting menu 105 .
[0038] The controller 120 may receive an input signal through the parking-mode input unit 107 , and may control individual systems contained in the parking-associated functioning unit 130 according to the setting information of the setting unit 110 .
[0039] As described above, the on/off actions of various systems embedded in the vehicle can be properly established before the driver parks the vehicle, so that the driver can easily control the systems without the necessity of independently operating each switch of the respective system.
[0040] FIG. 2 is a flowchart illustrating a method for controlling the parking assistance system according to an embodiment of the present invention. A method for controlling the parking assistance system will hereinafter be described with reference to FIG. 2 .
[0041] Referring to FIG. 2 , the vehicle starting key or button is turned on in step S 200 .
[0042] Thereafter, the on/off states of the parking-mode button are confirmed in step S 300 . If the parking-mode button is turned on, the parking mode signal is input to the parking-mode input unit 107 shown in FIG. 1 .
[0043] If the parking mode signal is input to the parking-mode input unit 107 , predetermined user setting menus of the setting unit 110 shown in FIG. 1 may be confirmed in step S 400 .
[0044] Thereafter, the letter “P” is displayed on a vehicle cluster screen 400 (shown in FIG. 4 ) of the vehicle in such a manner that the driver can recognize that the current mode has entered the parking mode, in step S 430 .
[0045] The above-mentioned parking-associated functioning unit 130 of FIG. 1 may be controlled according to a condition of the predetermined user setting menus.
[0046] For example, the PAS 140 of FIG. 1 is transitioned from an OFF state to an ON state in step S 432 . The R-gear tilt-down outside mirrors function 170 of FIG. 1 remains turned on in step S 435 . In addition, the AVM 160 of FIG. 1 starts operation in step S 437 . Moreover, the auto hold function system 180 of FIG. 1 is transitioned from the ON state to the OFF state in step S 439 . In this case, the condition for controlling each parking-associated functioning unit 130 may be changed by the user setting menu 105 shown in FIG. 1 .
[0047] Meanwhile, if in step S 300 the parking mode button is turned off according to the parking mode button confirmation result, the shift lever is confirmed in steps S 410 and S 420 .
[0048] When it is determined that the shift lever is located at the D-gear mode (i.e., D mode) in step S 410 , the PAS 140 and the AVM 160 are operated when the switch is turned on in steps S 440 and S 445 , respectively.
[0049] When it is determined that the shift lever is located at the R-gear mode (i.e., R mode) in step S 420 , the PAS 140 is automatically operated in step S 450 . The R-gear tilt-down outside mirrors function 170 is operated when the switch is turned on. The AVM 160 is automatically operated. In this case, the front-view mode or the rear-view mode may be established in step S 457 . Although the parking mode button of the vehicle is not pushed by the driver, the shift gear is confirmed so that respective systems can be operated according to basic operation conditions of the individual parking assistance functions of the vehicle.
[0050] FIGS. 5A to 5D illustrate a method for employing the parking assistance system according to an embodiment of the present invention.
[0051] Referring to FIG. 5A , the driver may pre-establish functions to be turned on or off when the parking mode button is established through the user setting menu 105 .
[0052] Referring to FIG. 5B , if the vehicle enters the parking lot upon completion of vehicle travel, the driver pushes the parking mode button P ( 300 ) prior to execution of the parking.
[0053] Thereafter, if the driver pushes the parking mode button, the letter “P” indicating entering the parking mode may be displayed on the cluster screen 400 as shown in FIG. 5C . If a screen image indicating the parking mode starting is displayed, an alarm sound indicating the parking mode starting state may also be generated as necessary. If the parking mode is started, respective parking assistance functioning units may be simultaneously shifted according to a predetermined condition as shown in FIG. 5A .
[0054] For example, when the driver attempts to park the vehicle, the PAS 140 and the AVM 160 may be turned on, the R-gear tilt-down outside mirrors function 170 and the auto hold function 180 may be turned off. The above-mentioned condition may be changed through the user setting menu 105 .
[0055] Thereafter, after the driver parks the vehicle, the driver pushes the parking mode button once more so that the parking mode is turned off. After the shift lever is shifted to the parking (P) gear by the driver, the driver can exit the vehicle as shown in FIG. 5D .
[0056] As is apparent from the above description, if the driver pushes the parking mode button embedded in the vehicle before parking the vehicle so that the parking mode is started, the on/off actions of the parking assistance function embedded in the vehicle can be properly established, and the driver can easily control individual systems using only one button without the necessity of independently operating each switch of the respective systems.
[0057] In addition, the embodiments can simultaneously retrieve predetermined on/off information of respective parking assistance systems before the driver parks the vehicle, so that the environment appropriate for the parking mode can be achieved or released by turning on or off the parking mode button. In addition, the parking mode button is located near the shift lever, resulting in greater driver convenience.
[0058] Therefore, the embodiments can correctly receive the driver's parking intention using only one button (i.e., the parking mode button), and can simultaneously control the on/off actions of not only the parking assistance system, but also other driving convenience systems capable of affecting the parking, so that the driver can more effectively and conveniently park his or her vehicle.
[0059] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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A parking assistance system and a method for controlling the same are disclosed. The parking assistance system includes a parking-mode input unit, a parking-associated functioning unit having a plurality of parking-associated systems, a setting unit for selecting parking-associated systems that are operated, and a controller configured to control the respective parking-associated systems by receiving an input signal through the parking-mode input unit. The method for controlling the parking assistance system includes transmitting a parking-mode input signal by turning on a parking-mode input unit, recognizing that a parking action is ready to be executed through the parking-mode input signal, and controlling a set of parking-associated functioning units according to a predetermined condition stored in a setting unit.
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CROSS REFERENCE
This application claims priority to German Patent Application No. 10 2011 055597.8, filed Nov. 22, 2011, which is expressly incorporated in its entirety by reference herein.
TECHNICAL FIELD OF THE INVENTION
The invention relates to a device for determining control parameters to adjust the light distribution of a right headlight (SR) and/or a left headlight (SL) of a vehicle (F) when driving through a curve, with the control parameters determined from a first angle in reference to a longitudinal vehicle axis and/or a second angle in reference to the longitudinal axis of a vehicle (F), the first angle determined from first information and the second angle determined from second information comprising at least one interface for obtaining the first information, namely measurements and/or parameters to be adjusted via actuators of the vehicle, such as the speed, the steering angle, the yaw rate, the steering angle of the front wheels, the distance from a vehicle driving ahead and/or an oncoming vehicle, and for obtaining the second information regarding the road progression ahead of the vehicle, such as the radius of the curve being driven through, the distance from a striking point of the road progression, such as a start of a curve, an end of a curve, an inflexion point of the curve, the start or end of a road, a surface condition of a road, an interstate, a road within or outside city limits, with a control means to determine a first angle from the first information and a second angle from the second information, with one of the angles selectable via the control means for each headlight, with an interface to connect the device equipped with actuators to adjust the light distribution of the headlights or parts of the headlights, at which control parameter-signals can be provided, and with means to convert the angle selected by the control means for the right headlight and the angle selected by the control means for the left headlight into control parameter-signals.
BACKGROUND OF THE INVENTION
In prior art, devices are known to control the pivoting of the light beam of a right head-light and a left headlight of a vehicle, based on first information, such as based on the speed, the yaw rate, and the angle of the steering wheel (dynamic curve light). These devices improve both the illumination as well as visibility in roads with many curves. The use of first information, also called vehicle information, has proven disadvantageous, particularly when driving through curves and exits, because the pivotal angle of the headlights is only dynamically adjusted when the vehicle is already driving through curves or an exit.
In order to improve this situation, the so-called predictive curve light has been developed, in which the second information is used to adjust the light beam of the head-lights in a predictive fashion. The predictive headlight solves the problem of the dynamic curve light, which may develop for example when driving through curves or exits, because the headlights of the predictive curve light are always adjusted to the predictive pivotal angle.
Methods known today may lead to a maximum faulty adjustment of the predictive pivoted headlights in case of faulty information regarding the road progression. The consequences are an increased risk of blinding oncoming traffic, an illumination of the road traveled, which is not ideal, and a rising risk for accidents because the driver may be unnecessarily irritated and distracted by severely maladjusted headlights.
Furthermore, in methods known from prior art it is possible that at the transition between purely dynamic pivoting and purely predictive pivoting a (“cross-eyed”) interference of the light beams can occur on the road. This effect is undesirable for optic reasons.
Another disadvantage in methods of prior art comprises that the driver, unlike in dynamic curve light, cannot influence the direction of pivoting of the headlights in the predictive pivoting. In practice this may lead to the predictive pivoted headlight reaching its maximally possible pivotal angle before the driver starts driving through the curve. This means, at the moment the driver moves the steering wheel no reaction occurs in the illumination because the headlights have already reached their maximally possible pivotal angle by the predictive adjustment. This is unusual for the driver and may reduce the acceptance of the system.
Further, devices are known by which both a dynamic as well as a predictive pivotal angle can be adjusted. Such a device is known for example from the document DE 10 2005 036 948 A1. From the document DE10 2005 036 948 A1 second information is used, such as curvature and/or curve radius and/or curve direction in addition to first information, for example the present speed and/or the present angle of the steering wheel, in order to determine the predictive and dynamic pivotal angle. Additionally, static and/or distance-related and/or speed-related start and end points of curves are required as control aids for the activation/deactivation and/or transitions between the adjustment of the dynamic and/or the predictive pivoting angle. The document DE 10 2005 036 948 shows, among other things, several options of how various predictive and dynamic pivotal angles can be selected for headlights. In one option a predictive pivotal angle is initially set without limits. When the dynamic pivotal angle fails to reach the predictive pivotal angle, e.g. after a predetermined period of time, the predictive pivotal angle is successively reduced to the dynamic pivotal angle, i.e. limited. The successively limited predictive pivotal angle is sent as a control parameter to the headlights.
Disadvantages of this method as well as other methods and devices for combining dynamic and predictive curve light are:
When the predictive pivotal angle is flawed, the predictive pivotal angle is always selected initially with the potentially maximum error and converted into a control parameter for the headlight. The correction then only occurs when the dynamic pivotal angle fails to approach the predictive pivotal angle within a de-fined period of time. Until this correction is made, the driver is provided with less light than possible, particularly in case of maximum errors. The driver has no option, in selected predictive pivotal angles, particularly when entering a curve and/or leaving a curve as well as during corrective motions (e.g. when avoiding an obstacle) inside a curve to move the adjusted pivotal angle further into and/or out of the curve via steering motions. Thus, the driver has no influence upon the light on the road in front of him/her and particularly in dangerous situations in which the driver must deviate from the predicted road progression the light is not provided where the driver needs it, but in the predicted driving direction.
SUMMARY OF THE INVENTION
The present invention is based on the problem to improve the predictive adjustment of the light distribution of the headlights of a motor vehicle such that on the one hand errors of the prediction cannot lead to unlimited consequences and on the other hand the driver can influence the adjustment of light distribution, particularly in special driving situations.
The adjustment of the light distribution can occur, on the one hand, by the pivoting of a headlight or a portion of the headlight. Light diodes may be provided as the lighting means in headlights, which are switched to a so-called array of light diodes. By switching on or off individual light diodes or groups of light diodes of such an array of light diodes the light distribution of light emitted by such headlights can be modified. No pivoting occurs, here. The invention extends both to headlights with conventional lighting means as well as to headlights with arrays of light diodes. With regards to the invention here the pivoting of headlights or parts of headlights is not discussed. Any direction of pivoting or a pivoting angle is not discussed either in the context of the present invention, because these terms may be misleading in reference to headlights with arrays of light diodes.
The problem underlying the invention is attained according to the invention such that via the control means the second angle p can be limited to a limited second angle p L when an amount |a| of a deviation a=p−d between the second angle p and the first angle d is greater than a maximally permitted deviation a max .
The directions and algebraic signs of angles, pivotal motions are equivalent to the definitions given in DIN ISO 4130. Accordingly, angles towards the left in reference to the longitudinal axis of the vehicle are marked with a negative algebraic sign and angles towards the right in reference to the longitudinal axis of the vehicle with a positive algebraic sign.
The limitation of the second angle p occurs according to the invention always when an excessive deviation a max of the determined second angle p from the first angle is given. Major deviations are frequently given when the second angle has been determined erroneously, because the second information was partially or entirely false. The error of the determination may not lead to unlimited consequences according to the invention and it remains ensured that the limited second angle used for determining the control parameter remains in context with the actual driving situation. Further, the driver can obtain increased influence upon the adjustment of the light distribution not predictable by the road progression because, for example by strong steering movements as a consequence of evasive maneuvers, the deviation of the second angle from the first angle is increased and thus a striking influence of the first angle can be achieved upon the angle to adjust the headlight, as explained in greater detail in the following.
The first and second angles represent interim parameters or variables which initially serve for calculation purposes within the control means. Only in conventional headlights the first angle and the second angle, (forming) adjustable angles in reference to the longitudinal axis of the vehicle, can commonly be called dynamic pivotal angles or predictive pivotal angles. The first angle and the second angle are not required to be allocated to units for any calculation within the control means. The naming of the first angle and the second angle as angles was selected only due to the proximity to dynamic pivotal angles and/or predictive pivotal angles. Here, a first value or a second value or the like could be used just as well.
The limited second angle p L may be equivalent to the first angle d plus the maximally permitted deviation a max , when the second angle p is greater than the first angle d. However, when the second angle p is smaller than the first angle d, the limited second angle p L is advantageously equivalent to the first angle d minus the maximally permitted deviation a max . In both cases, the first angle d shows a dominating influence upon the second angle.
Here, the maximally permitted deviation may be a constant value. It is also possible that the maximally permitted deviation a max is dependent on first information and/or second information. This way, an adjustment to the maximally permitted deviation to the driving situation and the predicted road progression is possible.
Using the control means of a device according to the invention for the right and the left headlight the second angle p and/or, in case of a limitation of the second angle p, the limited second angle p L can be selected as the angle used to determine the control parameters. If the (device) according to the invention is used to determine control parameters to adjust the light distribution of conventional headlights, here at both headlights the predictive pivotal angle p and/or the limited predictive pivotal angle p L are adjusted.
Using the control means of a device according to the invention the first angle d can be selected for the right headlight and the second angle for the left headlight, and/or in case of a limitation of the second angle p, the limited second angle p L , when the second angle p is smaller than the first angle d. Alternatively, using the control means of a device according to the invention, for the left headlight the first angle d can be selected and for the right headlight the second angle p and/or, in case of a limitation of the second angle p, the limited second angle p L , when the second angle p is greater than the first angle d. It is also possible that in one of the two headlights the first angle is adjusted and at the other of the two headlights the second and/or the limited second angle is adjusted. This may lead to a wider illumination of the area ahead of the vehicle, particularly when driving through curves.
The control means of a device according to the invention may be suitable and implemented such that it can be alternated between the selection of the first angle d for one of the headlights and the selection of the second angle p and/or the limited second angle p L for the same headlight, when the first angle d is equivalent to the second angle p.
These aspects are merely illustrative of the innumerable aspects associated with the present invention and should not be deemed as limiting in any manner. These and other aspects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the referenced drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.
FIG. 1 a schematic illustration of a vehicle with a device according to the invention and a right and a left headlight.
FIG. 2 a flow chart of a method performed by a device according to the invention, in which a first angle is adjusted at a headlight and a second and/or limited second angle is adjusted at another (headlight), and
FIG. 3 a flow chart of a method that can be performed according to a device according to the invention, in which a second and/or second limited angle is adjusted at both headlights.
DETAILED DESCRIPTION
In the following detailed description numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. For example, the invention is not limited in scope to the particular type of industry application depicted in the figures. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
The vehicle F shown in FIG. 1 as a block shows a right headlight S R and a left headlight S L . Both headlight preferably comprise engines as actuators, by which the headlights can be horizontally pivoted in order to horizontally pivot the beam direction of the headlights. This represents conventional headlights, not headlights with a LED array. This way it is possible to pivot the headlights S R , S L such that they illuminate the road in the direction ahead of the vehicle. The vehicle is therefore equipped with so-called curve lighting.
As already explained at the outset, it is distinguished between the so-called dynamic curve lighting and the so-called predictive curve lighting.
The dynamic curve lighting only considers for the determination of the pivotal direction of the headlights information regarding the actual condition of the vehicle, described by first information, which can be provided by sensors S and/or control devices EC in the vehicle. It has already been stated in detail at the outset, which information may be included here. A pivotal angle determined based on first information is called the first angle. Due to the fact that this angle is actually adjusted at the headlights of the exemplary embodiment in the following the first angle shall be called the dynamic pivotal angle d.
When determining the direction of pivoting of the headlights the predictive curve lighting considers the information regarding the road ahead of the vehicle, particularly the road progression. This second information may for example be provided by a navigation system and/or by a camera system K. It has also already been stated what this second information may include. A pivotal angle determined based on the second information is called the second angle. Due to the fact that in the exemplary embodiment this angle is actually adjusted at the headlights in the following the second angle is called the predictive pivotal angle p.
In order to determine the dynamic pivotal angle d and the predictive pivotal angle p in the vehicle F the device according to the invention is provided to control the pivoting of a right headlight S R and a left headlight S L of a vehicle F.
The device V according to the invention comprises an interface I, by which the device V is connected to a camera system K and various control devices EC and sensors S. Via the interface I the first information and/or the second information provided by the control devices EC and/or sensors S and/or by a camera system may be obtained by the device V.
A control means C is provided in the device, which processes the first information and the second information and which determines the dynamic pivotal angle d from the first information and the predictive pivotal angle p from the second information. Using the control means C, it is additionally selected if the dynamic pivotal angle d or the predictive pivotal angle p shall be adjusted at the right and/or the left headlight S R , S L .
In the device, further a means is provided to convert the pivotal angle d, p selected from the control means C for the right headlight S R and the pivotal angle d, p selected by the control means C for the left headlight S L in the control parameter-signal. The control parameter-signals may be transmitted via another interface I to the actuators of the headlights S R , S L . The actuators process the control parameter-signals to pivot or to displace the pendentive e.g., in LED systems according to the selected pivotal angle d, p.
The selection of the pivotal angle occurs e.g., according to the method shown in FIG. 2 or in FIG. 3 .
After the dynamic pivotal angle and the predictive pivotal angle have been determined, it is selected according to the method shown in FIGS. 2 and 3 which pivotal angle shall be adjusted at the headlights S R , S L . Additionally, a limitation of the predictive pivotal angle is set, if applicable.
After the method shown in FIG. 2 has been initiated, in a step 1 first it is checked if the predictive pivotal angle p is smaller than the dynamic pivotal angle. If that is the case, in a step 2 the dynamic pivotal angle is selected as the pivotal angle to be set for the right headlight S R . If this is not the case, in step 3 the dynamic pivotal angle is selected for the left headlight S L .
After step 2 has occurred, in step 4 it is checked if the amount |a| of the deviation a=p−d of the predictive pivotal angle p from the dynamic pivotal angle d is smaller or equivalent to a maximally permitted deviation a max . If this is the case, in step 5 a pivotal angle is selected to be adjusted for the left headlight of the predictive pivotal angle. If this is not the case, in step 6 a limited predictive pivotal angle p L is determined for the left headlight, which is equivalent to the difference d−a max from the dynamic pivotal angle d and the maximally permitted deviation a max .
After step 3 has occurred, it is checked in step 7 similar to step 4 if the amount |a| of the deviation a=p−d of the predictive pivotal angle p from the dynamic pivotal angle d is smaller or equivalent to a maximally permitted deviation a max . If this is the case, in step 8 the predictive pivotal angle is selected as the pivotal angle to be adjusted for the right headlight. If this is not the case, in step 9 a limited predictive pivotal angle p L is determined and selected for the right headlight, which is equivalent to the total d+a max from the dynamic pivotal angle d and the maximally permitted deviation a max .
According to a method shown in FIG. 2 , here for a headlight SR, SL always the dynamic pivotal angle is selected, while for the other headlight S L , S R either the predictive pivotal angle p or the limited predicted pivotal angle p L is selected.
After the start of the method shown in FIG. 3 , in a step 11 it is first checked if the amount |a| of the deviation a=p−d of the predictive pivotal angle p of the dynamic pivotal angle d is smaller or equivalent to the maximally permitted deviation a max . If this is the case, in step 12 the predictive pivotal angle p is selected as the pivotal angle to be adjusted for the right headlight S R and the left headlight S L . If this is not the case, it is checked in step 13 if the predictive pivotal angle p is greater than the dynamic pivotal angle. If this is the case, in a step 14 , for the right headlight S R and the left headlight S L a limited predictive pivotal angle p L is determined and selected, which is equivalent to the total d+a max from the dynamic pivotal angle d and the maximally permitted deviation a max . If after the review in step 13 it shows that the predictive pivotal angle p is smaller or equivalent to the dynamic pivotal angle d, in a step 15 for the right headlight S R and the left headlight S L a limited predictive pivotal angle p L is determined and selected, which is equivalent to the difference d−a max from the dynamic pivotal angle d and the maximally permitted deviation a max .
The above explanations of the present invention shall be understood as examples only and are not restrictive to the scope of the present invention. The teaching of the present invention can easily be transferred to other applications. The description of the exemplary embodiments is provided for illustration purposes only, and shall not limit the scope of protection of the claims. Many alternative, modifications, and variants are obvious for one trained in the art without here the scope of protection of the present invention being exceeded, which is defined in the following claims.
The preferred embodiments of the invention have been described above to explain the principles of the invention and its practical application to thereby enable others skilled in the art to utilize the invention in the best mode known to the inventors. However, as various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by the above-described exemplary embodiment, but should be defined only in accordance with the following claims appended hereto and their equivalents.
LIST OF REFERENCE CHARACTERS
F Vehicle
SR Right headlight
SL Left headlight
S Sensors
V Device according to the invention
EC Control devices
K Camera system
I Interface
C Control means
D Means for conversion
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A device for determining control parameters to adjust the light distribution of a vehicle headlight when driving through a curve from a first or second angle relative to a longitudinal axis of the vehicle, the first angle determined from first information,
namely measurements and/or parameters to be adjusted via actuators of the vehicle, such as speed, steering angle, yaw rate, steering angle of the front wheels, distance from a second vehicle, or road progression ahead of the vehicle, with a control means to determine the first angle the second angle, with an interface to connect the device with actuators to adjust the light distribution of the headlight, where control parameter-signals can be provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application No. 07/756,295, filed Sep. 6, 1991, which is a continuation in part of copending U.S. application No. 07/705,295, filed May 24, 1991, and U.S. application No. 07/714,642, filed Jun. 13, 1991 all applications still pending.
FIELD OF THE INVENTION
This invention relates to vascular catheters (such as angioplasty catheters) specially adapted for rapid exchange of both the guidewire and the catheter during use. It also relates to the method of using those catheters.
BACKGROUND OF THE INVENTION
Percutaneous transluminal coronary angioplasty (PTCA) has emerged as the major viable present alternative to bypass surgery for revascularization of stenotic and occluded coronary arteries. Although transluminal angioplasty has application in peripheral artery disease, it is most widely used in the treatment of coronary artery disease. Unlike bypass surgery, percutaneous angioplasty does not require general anesthesia, cutting of the chest wall, extracorporeal perfusion, or transfusion of blood. Percutaneous coronary angioplasty is not only less invasive and less traumatic to the patient, it is also less expensive because the angioplasty patient will have a shorter hospital stay and shorter post-procedure recovery time.
Percutaneous transluminal angioplasty is performed by making a skin puncture with a specially-designed needle in one of the groins, and then introducing a guiding catheter (typically 8 or 9 French size) into the aorta and coronary artery orifice. A smaller caliber catheter which has a built-in inflatable and deflatable balloon of predetermined size and diameter is passed through the guiding catheter which is positioned in the opening of a target artery. This balloon catheter (with the balloon totally deflated by negative pressure) is advanced inside the target artery toward the point of obstruction that needs to be dilated. The guidewire plays an essential role in leading the balloon catheter to the target coronary artery in safety and non-traumatic fashion. With the balloon portion of the catheter properly positioned inside the obstructed segment of the artery, under X-ray fluoroscopic observation, the balloon is inflated by injecting contrast media mixed with saline at a pressure sufficient to overcome the resistance of the arteriosclerotic plaque of the obstructed segment.
By inflating the balloon in the stenosis multiple times over a period of between 10-30 seconds and one or two minutes (allowing blood flow between inflations), the desired dilation of the obstructed segment of the artery can be achieved. When the desired results have been obtained by balloon inflations, the guiding catheter, the balloon catheter (with the balloon completely deflated with negative pressure) and the guidewire are withdrawn from the artery and the patient and the procedure is successfully terminated.
The size and diameter of the balloon to be used in a transluminal angioplasty should be approximately matched to the size and native diameter of the obstructed segment of the artery to be dilated. If the balloon size and diameter is smaller than the native artery, the results of balloon angioplasty are suboptimal, requiring a second dilation with a larger-sized balloon, and if balloon size is too large for the native artery, complications may occur due to arterial wall damage.
During the angioplasty procedure, a guidewire is first advanced into the desired location, after which the angioplasty catheter is advanced over the guidewire. It is sometimes necessary to replace (or exchange) either the guidewire or the balloon catheter during the procedure.
If the balloon is undersized, for example, the catheter must be withdrawn and replaced with a larger balloon catheter in order to permit adequate dilatation of the lesion. With conventional over-the-wire catheters, in which the guidewire lumen extends the entire length of the catheter shaft, a guidewire extension (e.g., 145 cm long) must first be attached to the regular guidewire (e.g. 175 cm long) being used outside the patient before the catheter is withdrawn. This permits the distal end of guidewire to be held in position while the catheter is removed and a new catheter is exchanged. Usually, two to three operators are needed to effect such a catheter exchange.
The catheter disclosed in U.S. Pat. No. 4,762,129 avoids the necessity for extending the guidewire or exchange guidewire (e.g. 300 cm in length) by having a short guidewire lumen that extends substantially only through the distal end of the catheter. This type of catheter is referred to herein as a rapid-exchange catheter. Thus, the guidewire is outside the catheter shaft for much of the catheter length, and is inside the catheter at only the distal end. The catheter can be exchanged without extending the 175 cm regular guidewire, and the exchange can be effected by one or two operators. However, this catheter has a serious drawback of not being able to permit ready exchange of guidewires. In clinical practice, the need for guidewire exchange is more common.
Conventional over-the-wire angioplasty catheters, with a guidewire lumen extending their entire length, permit simple guidewire exchange. During angioplasty procedures, the guidewire tip may become damaged, may be needed of a different type of guidewire or may need to be reshaped to complement the patient's vasculature. The guidewire exchange procedure is readily accomplished with such a conventional over-the-wire catheter. However, with the rapid-exchange type catheter of U.S. Pat. No. 4,762,129, guidewire exchange requires complete removal and reinsertion of both the guidewire and the angioplasty catheter; thus, defeating the original goal of expedient advantage of the rapid-exchange catheter.
Another disadvantage of the rapid-exchange catheter is back bleeding. While the guidewire is being manipulated to select the target vessel or to cross the culprit lesion, the Tuohy-Borst adapter must be loosened. This, in turn, permits backbleeding to occur.
Accordingly, there is a need for an angioplasty catheter that permits rapid-exchange of both the catheter and the guidewire. There is also a need for a catheter that will permit the user to select the mode of usage between the rapid-exchange and the over-the-wire system.
SUMMARY OF THE INVENTION
The present invention includes a multi-lumen vascular catheter for use with a guidewire, comprising a longitudinally extending catheter shaft having a proximal end and a distal end and having at least first and second lumens extending distally from the proximal end, each of the lumens having a proximal opening, wherein the first lumen is adapted to receive a guidewire, and a first connector at the proximal end of the catheter providing a first channel communicating with the interior of the first lumen for insertion of a guidewire therethrough, the connector including means for permitting a guidewire extending longitudinally through the first channel into the first lumen to be moved laterally out of the first channel through the first connector. In one embodiment, the first connector is adapted to separate into first and second parts to permit the lateral movement of the guidewire out of the first channel through the first connector. The catheter may include a second connector at the proximal end of the catheter providing a second channel communicating with the interior of the second lumen. The second connector may be located distally or proximally of the first connector. In one embodiment, the first and second connectors are joined together in the form of a "Y". The catheter may further include guidewire removing means in the outside wall of the first lumen extending distally from the proximal opening for permitting a guidewire in the first lumen to be moved laterally from the first lumen though the outside wall of the guidewire lumen. The guidewire removing means can be a slit, a weakened area of the outside wall of the guidewire lumen, or a removable strip. The slit may be continuous from the proximal opening to a point normally inside the patient during use, or may be discontinuous (e.g., a perforated line). The guidewire removing means can be a weakened area of the wall of the first lumen adapted to be severed for removal of the guidewire therethrough. The catheter may also include a side port located at a point normally inside the patient during use, the side port extending through the outside wall of the guidewire lumen and adapted to permit insertion of a guidewire therethrough. The catheter may still further include an angioplasty balloon located at the distal end of the catheter, the interior of the balloon in fluid communication with the second lumen.
Also contemplated by the present invention is an intravascular catheter comprising a catheter shaft having a proximal end and a distal end, wherein a portion of the catheter including the distal end is normally inside a patient during use and the proximal end is normally outside the patient, a guidewire lumen extending through the shaft for receiving a steerable guidewire, wherein the guidewire lumen has and outside wall, and a proximal opening at the proximal end of the shaft for insertion of a guidewire into the lumen, and means formed in the outside wall of the guidewire lumen extending distally from the proximal opening to a point normally inside the patient during use of the catheter for permitting a guidewire in the guidewire lumen to be moved laterally from the guidewire lumen though the outside wall of the guidewire lumen. The catheter of claim 14, wherein the guidewire removing means is a slit. The catheter may also include a side port through the outside wall of the guidewire lumen for passage of a guidewire into the lumen through the side of the catheter shaft, the side port located distally of the proximal opening and normally inside of a patient during use of the catheter. As before, the guidewire removing means can be a slit. The slit may be continuous from the proximal opening to the side port. Alternatively, it can be discontinuous, forming a perforated line from the proximal opening to the side port. Moreover, as above, the guidewire removing means can be a weakened area of the wall of the guidewire lumen adapted to be severed for removal of the guidewire therethrough. The catheter may further include a second side port communicating with the interior of the guidewire lumen. The proximal opening may be formed in the side of the catheter at a point distal of the proximal end of the catheter, and the catheter may further comprise a guidewire adapter at the proximal end of the catheter communicating with the guidewire lumen, so that a guidewire can be inserted into the guidewire lumen at the proximal portion of the catheter either through the guidewire adapter or through the proximal opening.
Another embodiment of the present invention is a guidewire connector for a catheter, comprising a connector body adapted to connect to a catheter shaft and having a channel therethrough adapted to receive a guidewire and direct the guidewire into the catheter shaft, and means for permitting a guidewire in place in the connector and the catheter shaft to be moved laterally out of the connector. The permitting means may comprise a longitudinally extending slot in the connector. Alternatively, it may comprise a longitudinally severable segment of the connector that can be removed from the connector. Preferably, the slit or guidewire removing means in the side wall of the catheter extends proximally to the guidewire connector, and preferably begins at the very proximal end of the catheter.
Yet another embodiment of the invention is a catheter for use with a guidewire in an invasive medical procedure, comprising a catheter shaft having a guidewire lumen therethrough, the catheter having a proximal end and a distal end and including an outside wall of the guidewire lumen, and a longitudinally removable strip forming part of the outside wall of the guidewire lumen and extending distally from the proximal end of the catheter, the strip adapted to be removed from the catheter to permit lateral removal of the guidewire from the guidewire lumen while maintaining the longitudinal positioning of the guidewire. In this catheter, the strip may be defined by two longitudinally extending weakened areas of the outside wall. Alternatively, the strip may be made of a material different from the remainder of the catheter shaft. The catheter may also have a strip that includes a longitudinally extending reinforcing member.
In accordance with still another aspect of the present invention, there is provided an angioplasty catheter comprising a catheter shaft having a proximal portion and a distal end, an angioplasty balloon attached to the shaft at the distal end, a balloon inflation lumen extending through the shaft and communicating with the interior of the balloon, a guidewire lumen extending through the shaft and through the balloon for receiving a steerable guidewire, the guidewire lumen having an outside wall, wherein the guidewire lumen has a proximal opening located at a point normally outside of the patient during use of the catheter for insertion of a guidewire into the lumen, and a side port adapted to permit passage of a guidewire into the lumen through the outside wall of the guidewire lumen, the side port located distally of the proximal opening and at a point normally inside of the patient during use, and guidewire removing means in the outside wall of the guidewire lumen extending from the proximal opening to the side port for permitting a guidewire in the guidewire lumen to be moved laterally from the guidewire lumen though the outside wall of the guidewire lumen. In one embodiment, the side port is located adjacent to and proximally of the balloon, preferably within about 35 cm of the balloon. One embodiment of the guidewire removing means is a slit through the outside wall of the catheter shaft. This slit may be continuous from the proximal opening to the side port, or may be discontinuous, forming a perforated line from the proximal opening to the side port. In another embodiment, the guidewire removing means is a weakened area of the wall of the guidewire lumen adapted to be severed for removal of the guidewire therethrough. One variation of the invention provides a second side port communicating with the interior of the guidewire lumen. Another provides a perfusion opening communicating with the interior of the guidewire lumen, the perfusion opening located between the side port and the balloon. Still another embodiment includes a "Y" connector at the proximal opening having an axial portion through which the balloon inflation lumen extends and a side portion through which the guidewire may be inserted into the guidewire lumen, wherein at least a portion of the connector can be removed from the catheter shaft to permit a guidewire extending through the connector and into the guidewire lumen to be removed through the guidewire removing means. The connector is advantageously adapted to be separated longitudinally and at least a portion thereof removed from the catheter shaft. In one variation, the connector comprises two longitudinally separable portions having first and second longitudinal sides on different sides of the catheter shaft, the portions being hingedly joined at the first longitudinal side and separably joined at the second longitudinal side.
Another embodiment of the present invention comprises an intravascular catheter comprising a catheter shaft having a proximal end and a distal end, wherein a portion of the catheter including the distal end is normally inside a patient during use and the proximal end is normally outside the patient or outside the guiding catheter, a guidewire lumen extending through the shaft for receiving a steerable guidewire, wherein the guidewire lumen has and outside wall, and a proximal opening at the proximal end of the shaft for insertion of a guidewire into the lumen, and means formed in the outside wall of the guidewire lumen extending distally from the proximal opening to a point normally inside the patient during use of the catheter for permitting a guidewire in the guidewire lumen to be moved laterally from the guidewire lumen though the outside wall of the guidewire lumen. The guidewire removing means may be a slit, fully formed or inchoate. The catheter preferably includes a side port through the outside wall of the guidewire lumen for passage of a guidewire into the lumen through the side of the catheter shaft, the side port located distally of the proximal opening and normally inside of a patient during use of the catheter. In one embodiment of the catheter, the guidewire removing means is a slit and the slit is continuous from the proximal opening to the side port. In another, the guidewire removing means is a slit and the slit is discontinuous, forming a perforated line from the proximal opening to the side port. In still another embodiment, the guidewire removing means is a weakened area of the wall of the guidewire lumen adapted to be severed for removal of the guidewire therethrough. According to one modification, the catheter may further comprise a second side port (such as a perfusion port) communicating with the interior of the guidewire lumen.
The present invention also includes a catheter for use in an animal body with a guidewire, comprising a catheter shaft having a proximal end and a distal end with at least two lumens extending therethrough, and a "Y" connector surrounding at least a portion of the proximal end of the catheter shaft and having at least two arms, one arm providing an access channel into one of the lumens and another arm providing an access channel into another of the lumens, wherein the "Y" connector has at least two segments joined together in a separable manner along a longitudinal line so that upon separation of the segments, the "Y" connector no longer surrounds the portion of the proximal end of the catheter shaft. In one embodiment, upon separation of the segments, one of the segments is completely removable from the catheter shaft. In another embodiment, upon separation of the segments, the connector is completely removable from the catheter shaft in such a manner that an elongate object extending through one arm of the connector into a lumen of the catheter shaft can remain in the lumen during such removal of the connector.
The invention further includes a method of removing a catheter during a procedure involving vascular catheterization, comprising the steps of providing a catheter of the type described above having a guidewire passing through the guidewire lumen from the proximal opening to the distal opening thereof and positioning the catheter in a patient with the proximal end of the guidewire extending out of the proximal opening, holding the proximal and of the guidewire to maintain the positioning of the guidewire in the patient while removing the catheter from the patient by moving the guidewire laterally out of the guidewire lumen through the guidewire removing means until the entire catheter is outside the patient and outside the guiding catheter and a portion of the guidewire is exposed at the distal end of the catheter, and then holding the exposed portion of the guidewire and removing the catheter off of the proximal end of the guidewire. The method may also include inserting another catheter, with the guidewire in the guidewire lumen at the distal portion of the catheter and either remaining in the guidewire lumen for the entire length of the catheter that is inside the patient during use, or extending out through the side of the catheter and running parallel to the catheter proximal of the distal portion of the catheter.
Another embodiment of the invention includes a catheter for vascular use, comprising a catheter shaft with a proximal end and a distal end and having first and second lumens therethrough, the first lumen having an outside wall and being adapted to receive a guidewire extending through the first lumen, a guidewire connector attached to the proximal end of the catheter communicating with the first lumen and adapted to direct a guidewire into the first lumen, and means for permitting the guidewire to be removed laterally through the outside wall of the first lumen while maintaining the longitudinal positioning of the guidewire in the patient. The catheter may further include means for removing at least a portion of the guidewire connector from the guidewire. In one embodiment, the guidewire connector is adapted to be removed, at least in part, from the catheter shaft. In another, a portion of the guidewire connector is adapted to be removed longitudinally off of the proximal end of the catheter shaft and off of the proximal end of the guidewire. Optionally, another portion of the guidewire connector is adapted to remain on the catheter shaft while the guidewire is removed laterally out of the guidewire connector through the outside wall of the guidewire lumen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a foreshortened plan view of a catheter according to the present invention.
FIG. 1A is a transverse cross section of the catheter of FIG. 1, taken along the line A--A.
FIG. 1B is a transverse cross section of the catheter of FIG. 1, taken along the line B--B.
FIG. 1C is a transverse cross section of the catheter of FIG. 1 corresponding to FIG. 1B, but illustrating the opening of the guidewire removing means.
FIG. 2 is a fragmentary view of a portion of the catheter shaft of the FIG. 1 catheter surrounding the proximal opening, illustrating one variation of the guidewire removing means.
FIG. 3 is a longitudinal cross section of the catheter of FIG. 1 taken along the line 3--3, illustrating the guidewire in place and the function of the guidewire removing means.
FIG. 4 is a cross sectional fragmentary perspective view of the catheter of FIG. 1, taken along the line B--B, illustrating another variation of the guidewire removing means.
FIG. 5 is a longitudinal cross section corresponding to FIG. 3, illustrating movement of the guidewire laterally out of the guidewire removing means.
FIG. 6 is a foreshortened longitudinal cross section of the proximal end of one embodiment of the catheter of the present invention.
FIG. 7 is a perspective view of a removable "Y" connector at the proximal end of the catheter shaft.
FIG. 8 is a detailed perspective view of a locking mechanism on the "Y" connector of FIG. 7.
FIG. 9 is a transverse cross section taken along the line 9--9 in FIG. 7.
FIG. 10 is a detailed perspective view of another locking mechanism on the "Y" connector of FIG. 7.
FIG. 11 is an exploded transverse cross section corresponding to FIG. 9, illustrating removal of the "Y" connector from the catheter shaft.
FIG. 12 is a perspective view of the distal end of the catheter shaft after removal of the "Y" connector, illustrating a sealing member.
FIG. 13 is a longitudinal cross section of the removable "Y" connector, taken along the line 13--13 in FIG. 7.
FIG. 14 is a longitudinal cross section of the entire catheter, taken along the line 13--13 in FIG. 7.
FIG. 15 corresponds to FIG. 14, except that the guidewire is illustrated in place in the guidewire lumen.
FIG. 16 is a foreshortened side elevation of another embodiment of the catheter of the present invention.
FIG. 17 is a longitudinal cross-section of the catheter of FIG. 16, taken along the line 17--17.
FIG. 18 corresponds to FIG. 17, except a removable breakaway portion is shown in phantom.
FIG. 19 corresponds to FIG. 18, and illustrates lateral removal of a guidewire through a breakaway "Y" connector.
FIG. 20 corresponds to FIG. 19, further illustrating removal of the guidewire through the sidewall of the guidewire lumen.
FIG. 21 is an exploded view of the breakaway "Y" connector of the present invention.
FIG. 22 is a sectional view taken along the line 22--22 in FIG. 21.
FIG. 23 is a sectional view taken along the line 23--23 in FIG. 21.
FIG. 24 is a sectional view taken along the line 24--24 in FIG. 21.
FIG. 25 is a sectional view taken along the line 25--25 in FIG. 21.
FIG. 26 corresponds to FIG. 21, except that the breakaway portion of the "Y" connector is assembled with the remainder of the "Y" connector.
FIG. 27 is a cross-section taken along the line 27--27 in FIG. 26.
FIG. 28 corresponds to FIG. 27, except that the breakaway portion of the "Y" connector has been removed and is illustrated in phantom.
FIG. 29 is a partial transverse cross-section of one embodiment of the catheter shaft illustrating a removable longitudinal strip.
FIG. 30 corresponds to FIG. 29, illustrating a different kind of removable strip.
FIG. 31 corresponds to FIG. 29, further illustrating yet another type of removable strip.
FIG. 32 is a side elevation of one embodiment of the side port.
FIG. 33 is a side elevation of another embodiment of the side port.
DETAILED DESCRIPTION OF THE INVENTION
A basic embodiment of the catheter of the present invention is illustrated in FIG. 1. A catheter 10 is provided with a catheter shaft 12 extending from a proximal end 14 to a distal end 16. As shown more clearly in FIG. 1B, the interior of the catheter shaft 12 has a guidewire lumen 20 and a balloon inflation lumen 22 extending through the catheter shaft 12.
The catheter 10 has an angioplasty balloon 24 at the distal end 16 thereof. At the proximal end 14 of the catheter shaft 12, a balloon inflation connector 26 is provided in fluid communication with the balloon lumen 22. Fluid introduced into the proximal end of the balloon inflation connector 26 can travel through the balloon lumen 22 and into the interior of the balloon 24 to inflate and deflate the balloon 24 during an angioplasty procedure. The balloon inflation lumen 22 terminates inside the balloon 24. The opposite end of the balloon inflation lumen 22 terminates inside the balloon inflation connector 26.
The guidewire lumen 20 is adapted to receive a steerable guidewire and has an outside wall 30 (shown in FIG. 1B).
A proximal opening 32 is provided through the outside wall 30 of the guidewire lumen 20. This proximal opening 32 is situated in the proximal portion of the catheter shaft 12 at a location sufficiently close to the proximal end 14 that it is normally outside of the patient during the angioplasty (or other vascular procedure). Typically, the proximal opening 32 will be within 60 cm, preferably within about 40 cm, more preferable within about 30 cm of the proximal end 14 of the catheter 10.
The balloon 24 is made in accordance with conventional techniques for fabricating angioplasty balloons. Preferably, it is either blown from the distal end 16 of the catheter shaft 12, or is blown or formed of a separate piece of material which is bonded to the distal end of 16 of the catheter shaft 12. The balloon 24 may advantageously be formed of relative inelastic polymer material, such as polyethylene, polypropylene, polyvinylchloride, polyethylene terephthalate, and the like.
The catheter shaft 12 is also provided with a side port 34 which extends through the outside wall 30 of the guidewire lumen 20. The side port 34 is located distally of the proximal opening 32, and is located at a point normally inside of the patient when the catheter is properly place for performance of angioplasty procedure. Preferably, the side port 34 is located proximally of the balloon 24 and within 80 cm, preferably 60 cm, and more preferably about 40 cm of the balloon 24.
The catheter 10 of the present invention is provided with a means for removing a guidewire that is inside of the guidewire lumen out of the guidewire lumen 20 through the outside wall 30 of the guidewire lumen 20. If the catheter shaft 12 or the guidewire is considered to extend in a longitudinal or axial direction, this movement of the guidewire out of the guidewire lumen 20 can be considered as a sideways, radial, or transverse motion of the guidewire. The guidewire removing means 40 is adapted to form a slit through the outside wall 30 of the guidewire lumen 20 through which the guidewire may be removed from inside the guidewire lumen 20. The guidewire removing means 40 may be an actual slit cut entirely through the side wall 30 of the guidewire lumen 20. Alternatively, it may be an inchoate slit such as the weakened area illustrated in FIG. 1B. The guidewire removing means 40 may be cut entirely through the outside wall 30 of the guidewire lumen 20 only in certain sections, leaving other section at least partially intact, to form a sort of perforated line. It may be formed of a different material than the remainder of the catheter shaft 12 and even of a different material than the adjacent portions of the outside wall 30 of the guidewire lumen 20. Combinations of fully formed slits and weakened areas or inchoate slits are also contemplated, such as having an inchoate slit in portions of the catheter normally outside the patient during use (eliminating backbleeding through the slit) and a fully formed slit in a portion of the catheter normally inside the patient during use.
One advantage of having only an inchoate slit is that it prevents backbleeding out of the guidewire removing means 40 during performance of the procedure. It is possible, however, to use an inchoate slit for only the portion of the guidewire removing means 40 that is outside of the guiding catheter in use. The remainder of the guidewire removing means 40 that is outside the patient and outside the guiding catheter can be a fully formed slit or a perforated slit without creating backbleeding problems.
As illustrated in FIG. 2, the guidewire removing means 40 may comprise a removable tear strip 42 defined by a pair of weakened lines 44, 46 extending distally from the proximal opening 32.
The guidewire removing means 40 extends from the proximal opening 32 distally along the length of the catheter shaft 12 to a point that is ordinarily inside the patient when the catheter 10 is properly placed for performance of an angioplasty procedure. Thus, the guidewire removing means 40 begins at a point ordinarily outside the patient and outside the guiding catheter upon proper placement of the catheter 10 and extends distally to a point ordinarily inside the patient upon such placement. From another perspective, it can be said that the guidewire removing means 40 extends distally for at least 40 cm, preferably at least 60 or 70 cm, and more preferably at least 80, 90 or 100 cm.
The guidewire removing means 40 may advantageously extend distally to the side port 34, and in one embodiment of the invention, may extend an additional distance distally beyond the side port 34. The guidewire removing means 40 preferably terminates proximally of the balloon 24, and may be immediately adjacent the balloon 24 or may be 5 cm, 10 cm, or more proximally of the balloon 24.
If the guidewire removing means 40 is not a slit prior to its use, it becomes a slit or opening after use, an illustrated in FIG. 1C.
The use of the catheter 10 of the present invention is illustrated in FIG. 3. In this longitudinal cross sectional view, the catheter 10 is illustrated with a guidewire 50 in place in the guidewire lumen 20. The proximal portion of the guidewire 50 is outside of the catheter 10. The guidewire 50 passes through the proximal opening 32 into the guidewire lumen 20, and is inside the guidewire lumen 20 for the entire length of the catheter shaft 12 that extends distally from the proximal opening 32. The distal end of the guidewire 50 extends out of the distal end 16 of the catheter shaft 12.
When the guide wire is to be removed radially or laterally out of the guidewire lumen 20, the guidewire removing means 40 provides a slit or opening in the outside wall 30 of the guidewire lumen 20 through which the guidewire 50 may be removed from the guidewire lumen 20. This slit or opening, if not fully formed, may be completed by cutting the outside wall 30 of the guidewire lumen 20, by tearing or rupturing a weakened area in the outside wall 30, or by tearing loose a removable strip (as illustrated in FIG. 2). In a preferred embodiment the guidewire removing means 40 is a weakened area that is fully opened only when the guidewire 50 is removed through the guidewire removing means 40. In one embodiment, the guidewire 50 is simply pulled through the outside wall 30 of the guidewire lumen 20. Alternatively, as illustrated in FIG. 4, the catheter shaft 12 may be provided with a filament 52 in association with the guidewire removing means 40. The filament 52 may be a continuous fiber or strand extending along the length of the guidewire removing means and inside at least a portion of the outside wall 30 of the guide wire lumen 20. When the filament 52 is pulled outwardly, it tears a slit into the outside wall 30 of the guidewire lumen 20.
In FIG. 3, the initial removal of the guidewire 50 through the guidewire removing means 40 is illustrated in phantom. In that figure, an phantom guidewire 50 is illustrated extending through the outside wall 30 of the guidewire lumen 20 at a point distally of the proximal opening 32.
As illustrated in FIG. 5, the phantom guidewire 50 is pulled through the outside wall 30 of the guidewire lumen 20 until the guidewire 50 has been removed through the outside wall 30 up to the side port 32. It will be understood, of course, that in accordance with the present invention, the guidewire 50 may be removed through the outside wall 30 to a point proximal of or distal of the side port 34; however, in a preferred embodiment, the lateral removal out of the guidewire lumen 20 continues up to the side port 34.
It should be noted that the removal of the guidewire 50 through the outside wall 30 can be accomplished without longitudinal or axial movement of the guidewire 50. Thus, in FIG. 3, the distal tip of the guidewire 50 is in the same position as in FIG. 5; however, in FIG. 5, the guidewire has been removed laterally through the guidewire removing means along a portion of the length of the catheter shaft 12.
In the simplest embodiment of the present invention the guidewire lumen 20 may be provided simply with a proximal opening 32, a side port 34, and guidewire removing means 40 extending distally of the proximal opening 32 at least to the side port 34, and perhaps beyond.
However, more sophisticated versions of the present invention are also contemplated. In one such embodiment, a distal side opening 54 may be provided through the outside wall 30 of the guidewire lumen 20 to provide access into the guidewire lumen 20 at a point distal of the sideport 34. The distal side opening 54 may be open in normal use; however, the distal side opening 54 is preferably covered with a removable patch 56, as best seen in FIGS. 3 and 5. The removable patch 56 is preferably made of foil, mylar, aluminized or metalized mylar, or other suitable material, and may be held in place with an adhesive. The removable patch 56 may be removed from the catheter shaft 12 to open up the distal side opening to permit extension of the guidewire 50 through the distal side opening or to permit use of the distal side opening 54 as a perfusion opening. In one embodiment of the invention, the guidewire removing means 40 extends distally to the distal side of opening 54.
The portion of the guidewire lumen 20 located proximally of the proximal opening 32 is preferably closed, and may be filled with a filler 60 such as a polymers material formed in place or a stylet inserted in a waterproof manner into a guidewire lumen 20, as illustrated in FIGS. 3 and 5.
In an alternative embodiment of the invention, the catheter of FIG. 1 is modified at its proximal end as illustrated in FIG. 6. Specifically, this particular catheter has a conventional "Y" connector 62 at the proximal end 14 of the catheter shaft 12 having a balloon inflation connector 26 and a guidewire connector 64 at the two "branches" of the "Y". The guidewire lumen 20 extends from the proximal end 14 of the catheter shaft 10 through the guidewire connector 64 and the "Y" connector 62 and extends distally the length of the catheter shaft 12.
The proximal opening 32 is located distally of the "Y" connecter. The catheter 10 is provided with a sliding cover 66 that is axially movable to cover or uncover the proximal opening 32. The sliding cover 66 is preferably an annular sleeve circling the catheter shaft 12 and axially movable with respect thereto. The sliding cover 66 preferably has a soft sealing material 70 (such as a pliable closed cell polymer foam, a silicone elastomer, or other suitable material) on its inside surface to provide a seal against the catheter shaft 12. Ordinarily, the sliding cover 66 is over the proximal opening 32, closing and sealing the proximal opening 32.
In an alternative embodiment, the sliding cover 66 may be replaced by a removable covering (not illustrated) similar to the removable patch 56 to close the proximal opening 32 until it is used.
In ordinary use, the guidewire 50 extends distally through the guidewire connector 64, the remainder of the "Y" connector 62, inside the guidewire lumen 20, past the proximal opening 32, and out of the distal end 16 of the catheter 10. When required (as will be explained in more detail hereafter), the sliding cover 66 or other seal covering the proximal opening 32 is removed, the catheter 10 is maintained in place in the patient while the guidewire 50 is removed proximally out of the guidewire connector 64, and the guidewire 50 is then inserted through the proximal opening 32 until it is in the desired position. Then the guidewire 50 is removed out through the outside wall 30 of the guidewire lumen 20 as explained in more detail elsewhere. Removal of the guidewire 50 through the outside wall of the catheter shaft 12 permits conversion of the catheter from an over-the-wire catheter to a rapid exchange catheter that can be removed from the patient without extension of the guidewire 50.
In the embodiment illustrated in FIG. 6, because a conventional guidewire connector 64 is ordinarily used, back bleeding during use is eliminated by tightening the Tuohy-Borst adapter (not shown) except when manipulating the guidewire 50. This is in contrast to the embodiment illustrated in FIG. 1, where some back bleeding might be expected.
In yet another embodiment of the invention, the guidewire removal and reinsertion explained in connection with FIG. 6 is eliminated by providing a removable "Y" connector 80, illustrated in FIGS. 7-13.
The particular embodiment of removable "Y" connector illustrated in FIG. 7 provides an axially separable "Y" connector 80. The "Y" connector 80 is preferably molded of a relatively hard thermoplastic material, and is adapted to fit concentrically around the catheter shaft. The removable "Y" connector 80 is formed of 2 (or more) pieces which are joined together along lines extending in the axial or longitudinal direction of the catheter shaft 12. In the illustrated embodiment, the removable "Y" connector has an axial portion 82 through which the balloon lumen 22 (and preferably the catheter shaft 12) extends. The removable "Y" connector 80 further has a guidewire connector 64 extending proximally and at an angle outwardly from the axial portion 82 of the removable "Y" connector 80.
The guidewire connector 64 of the removable "Y" connector 80 is cylindrical in shape and has a guidewire bore 84 extending therethrough. The guidewire bore 84 connects through the proximal opening 32 into the guidewire lumen 20, as best illustrated in FIG. 13.
The removable "Y" connector 80 is preferably formed of a first half 86 and second half 90. The first half 86 and the second half 90 each have a semi cylindrical recess 92, 94 extending axially along the length of each half 86, 90 of the removable "Y" connector 80. The semi cylindrical recesses 92,94 are best illustrated in FIG. 11. When the first and second halves 86, 90 are joined together, the semi cylindrical recesses 92, 94 together form a cylindrical recess through which the catheter shaft 12 extends.
When the first and second halves 86, 90 are joined together on the catheter shaft 12, they are joined at a first edge 96 and a second edge 100 on opposite sides of the catheter shaft 12. The first and second edges 96, 100 of each half 86, 90 extend axially parallel to the axis of the catheter shaft 12.
In a preferred embodiment of the invention, the first edges 96 of the first and second halves 86, 90 are joined by a hinge 102. Preferably, the hinge 102 is a "live" hinge; that is, a hinge formed of a thin portion of the polymer material of which the removable "Y" connector 80 is formed. In a preferred embodiment, the hinge 102 extends axially the entire length of the first edge 96.
The second edges 100 of the first and second halves 86, 90 are separably joined together by any appropriate connecting mechanism. The illustrated mechanism is but one possibility. In the illustrated mechanism, the second edge 100 of the first and second halves 86, 90, comprises on each half a radially extending tab 104 running the length of the second edge 100. At the outside radial edge of the tabs 104 is a flange 106 formed so that when the first and second halves 86, 90 are mated together at their second edges 100, the flanges 106 extend in opposite directions on the first and second halves 86, 90, forming a "T" shape in radial cross section as shown in FIG. 9.
An edge connector 110 is provided to hold the second edges 100 of the first and second halves 86, 90 together. The edge connector 110 preferably extends the entire length of the second edges 100 and is formed with a "T" channel inside to lock together the tabs 104 and flanges 106 of the second edges 100 of the first an second halves 86, 90. Thus, the "T" of the mated second edges of the first second edges 100 of the first and second halves 86, 90 is adapted to slide inside the "T" channel of the edge connector 110. Once the connector 110 is placed on the "T" of the second edges, it may be locked in place using any appropriate mechanism. In one embodiment, a first end 112 of the connector is permanently closed to prevent movement of the edge connector 110 in one direction. The second end 114 of the edge connector 110 may have a breakaway end 116, as illustrated in FIGS. 7 and 8. The breakaway end 116 is glued or otherwise connected to the remainder of the connector 110 in such a manners that it may be readily severed from the edge connector 110. This may be done by a rocking motion applied to the breakaway end 116 as illustrated in by the arrows 120 in FIG. 7. Once the breakaway end 116 is removed as illustrated in FIG. 8, the connector 110 may be moved axially in the direction indicated by arrow 122 until the edge connector 110 is removed from the remainder of the removable "Y" connector 80.
Another method for locking the edge connector 110 onto the removable "Y" connector 80 is by use of a locking pin 124 as illustrated in FIG. 10. The locking pin may extend through the edge connector 110 and the second edges 100 of the first and second halves 86, 90, to lock the edge connector 100 in place. When the pin 124 is removed, the edge connector 110 may also be removed.
Although the pin 124 illustrated in FIG. 10 is circular, any other suitable pin or locking device may similarly be used.
After the removal of the edge connector 110, the first and second halves 86, 90 may be removed from the catheter shaft 12 as illustrated in FIG. 11 by pivoting the second edges 100 away from each other. The removable "Y" connector 80 may then be slid proximally off the proximal end of the guidewire 50.
In a preferred embodiment of the invention, a seal 126 is provided around the catheter shaft 12 as illustrated in FIG. 12. The seal 126 prevents leakage between the removable "Y" connector 80 and the catheter shaft 12, and is preferably formed of annular polymer material such as elastomeric material or closed cell foam. The seal 126 is preferably provided with an index feature 130 for preventing rotational or longitudinal movement of the in-place "Y" connector 80 with respect to the catheter shaft 12. In the illustrated embodiment, the index feature 130 is an outwardly extending tab; however, the index feature 130 could alternatively be a groove, a recess, a flange, or the like. The outwardly-extending index feature 130 illustrated in FIGS. 12 and 11 can cooperate with a complimentary index receptacle 132 on the axial portion 82 of the removable "Y" connector 80.
The use of the removable "Y" connector is further illustrated in FIGS. 14 and 15. The catheter 10 without the "Y" connector 80 in place is illustrated in FIG. 14. A guidewire 50 is inserted into the proximal opening 32 through the guidewire adapter 64, as seen in FIG. 15. The guidewire 50 extends the length of the catheter shaft 12 and out of the distal end 16 of the catheter 10.
When the removable "Y" connector 80 is removed from the catheter shaft 12, the catheter 10 is properly illustrated in FIG. 3, and the guidewire 50 can be removed laterally through the outside wall 30 of the guidewire lumen 20 as illustrated in FIGS. 3 and 5, and as previously explained.
Although the removable "Y" connector 80 has been discussed in the context of a particular preferred embodiment, will be understood that equivalent removable "Y" connectors can be provided in which only a portion (such as a strip) of the "Y" connector is removed from the catheter shaft 12; or where there are more than 2 separably pieces of the "Y" connector; where alternative latches or locking mechanisms are utilized to hold the removable "Y" connector together until removal is desired. Further, other mechanical features having equivalent function can be substituted for other of the various described elements.
A catheter according to the invention having another version of the "Y" connector is illustrated in FIGS. 16 and 17. This embodiment of the invention is referred to as the "universal mode" vascular catheter.
In this embodiment of the invention, a catheter 210 is provided with a catheter shaft 212 having a proximal end 214 and a distal end 216. The catheter shaft 212 is provided with a guidewire lumen 220 and a balloon lumen 222 extending the length of the catheter shaft 212. A conventional angioplasty balloon 224 is provided at the distal end 216 of the catheter shaft 212. The balloon 224 is inflated by introducing pressurized fluid through the balloon inflation connector 226 located at the proximal end 214 of the catheter shaft 212. Such pressurized fluid travels distally from the balloon inflation connector 226 through the balloon inflation lumen 222 which communicates with the interior of the balloon 224.
The guidewire lumen 220 has an outside wall 230, and a proximal opening 232.
The catheter 210 is also provided with a side port 234 providing an opening through the outside wall 230 of the guidewire lumen 220.
The side port 234 corresponds to the side port 34 previously described, and is adapted to permit insertion or removal of a guidewire therethrough. Preferably, the side port 234 is configured such that a guidewire passing through the side port 234 may easily extend distally through the guidewire lumen 220, but is adapted to discourage a guidewire passing through the side port 234 from extending proximally through the guidewire lumen 220 from the side port 234. The location of the side port 234 is as previously described in connection with the side port 34.
The guidewire lumen 220 extends substantially the entire length of the catheter shaft 212 from the proximal opening 232 through the balloon 234 to a distal opening 236 located distally of the balloon 224.
Located at the proximal end 214 of the catheter 210 is a guidewire connector 240 adapted to provide access to the guidewire lumen 220. The proximal opening 232 of the guidewire lumen 220 is a channel extending through the guidewire connector 240. The guidewire connector 240 may advantageously be located proximally of the balloon inflation connector 226; however, it is also contemplated that the guidewire connector 240 may be located distally of the balloon inflation connector 226.
In one preferred embodiment of the invention, the guidewire connector 240 and the balloon inflation connector 226 together comprise a "Y" connector 242 as illustrated in FIG. 17. In the preferred embodiment of the "Y" connector 242, the guidewire connector 240 and the balloon inflation connector 226 are connected together and are formed of an appropriate material such as a molded polymer material. The guidewire connector 240, for example, may be coaxial with the guidewire lumen 220, while the balloon inflation connector 226 may extend at an angle from the balloon inflation lumen 222. In this manner, the connectors 226, 240 together form a "Y".
As illustrated in FIG. 18, one preferred embodiment of the universal mode catheter 210 includes a "Y" connector 242 having a breakaway piece 246. The breakaway piece 246 is illustrated in FIG. 18 in phantom. As illustrated, when the breakaway piece of the "Y" connector 242 is removed, the outside wall 230 of the guidewire lumen 220 is exposed for its entire length. The breakaway piece 246 can be completely removed from the remainder of the "Y" connector, or it may be hinged to simply pivot away from the remaining portion of the connector.
The outside wall 230 of the guidewire lumen 220 in this embodiment of the invention is provided with guidewire removing means 250. The guidewire removing means 250 corresponds to the guidewire removing means 40 previously discussed. As illustrated in FIG. 19, when a guidewire 252 is in place in the guidewire lumen 220, the breakaway piece 246 can be removed from the guidewire connector 240 so that the guidewire 252 can be moved laterally through the guidewire removing means 250 through the outside wall 230 of the guidewire lumen 220. (The guidewire extending through the guidewire lumen 220 from the proximal end 214 is illustrated in phantom; the solid guidewire 252 is illustrated after lateral removal from the portion of the guidewire lumen 220 out of the guidewire connector 240 and the "Y" connector 242.)
FIG. 20 illustrates further removal of the guidewire 252 laterally through the outside wall 230 of the guidewire lumen 220 by means of the guidewire removing means 250. In FIG. 20, the guidewire 252 is illustrated in a phantom starting position corresponding to the guidewire in FIG. 19, and in solid illustrating further removal laterally through the guidewire removing means 250 until the guidewire 252 is extending through the side port 234. Removal of the guidewire 252 through the guidewire removing means 250 is accomplished in the same manner as previously discussed.
The breakaway connector 242 of this embodiment of the invention is illustrated in more detail in FIGS. 20-25.
FIG. 21 is a perspective view of the "Y" connector 242 from the side opposite the balloon inflation connector 226 (which is hidden in FIG. 21). In FIG. 21, the guidewire connector 240 is provided with a removable breakaway piece 246 on the side of the guidewire connector 240 opposite the balloon connector 226. The guidewire connector 240 is preferably formed of injection-molded thermo plastic material. In a preferred embodiment, it is formed integrally with the remainder of the "Y" connector 242. At the distal end of the "Y" connector 242 (where it meets the catheter shaft 212) a stress relief sleeve 254 may advantageously be provided. The stress relief sleeve 254 may be formed of flexible polymer material. It advantageously encircles the catheter shaft 212 from a point inside the distal end of the "Y" connector 242 extending a short distance (e.g. 1-2 cm) distally of the "Y" connector 242 to prevent buckling of the catheter shaft 212.
The removable breakaway piece 246 preferably overlays a portion of the outside wall 230 of the guidewire lumen 220. In radial cross-section the breakaway piece 246 may, for example, comprise from about 5° to about 180° of arc. In the embodiment illustrated in FIG. 21, the breakaway piece 246 encircles the catheter shaft 212 for about 90° to 120° of arc. Although the longitudinally extending breakaway piece 246 is shown extending the entire length of the "Y" connector 242, it should be understood that a "Y" connector having an axially removable proximal portion (outlined by dashed line "A" in FIG. 27) that entirely encircles a guidewire and a longitudinally extending, radially removable portion (outlined by dashed line "B" in FIG. 27) is also contemplated. To use this embodiment, the encircling proximal portion "A" is removed axially, and the longitudinally extending portion "B" is removed radially. In another variation of this embodiment, the portion "B" may simply be eliminated, leaving a slot, and the lateral or radial removal of the guidewire 252 from the "Y" connector can be accomplished after removing portion "A" (as by unscrewing it from the remainder of the "Y" connector 242 and sliding it off of the proximal end of the guidewire 252).
The breakaway piece 246 may advantageously be formed from the same material as the remainder of the "Y" connector 242. It may be molded separately from the remainder of the "Y" connector 242; alternatively, the "Y" connector may be molded in one piece, and then the breakaway piece 246 may be cut form the "Y" connector 242. The catheter may even be provided with the breakaway piece 246 entirely missing. In this embodiment, a narrow longitudinal slot is provided along the side of the "Y" connector at all times. The proximal end of the guidewire connector 240 may then be removable and may completely encircle the guidewire.
In any event, means (not illustrated) for holding the breakaway piece 246 in place until removal is desired should be provided. These means may include a relatively weak adhesive or weld joining the edges of the breakaway piece 246 to the corresponding edges of the remainder of the "Y" connector 242. Alternately, the breakaway piece 246 may be incompletely cut from the remainder of the "Y" connector 242. In another embodiment, the breakaway piece 246 may be held in place by tape encircling the breakaway piece 246 and all or part of the guidewire connector 240 and/or the "Y" connector 242.
The guidewire connector 240 preferably has a circular flange encircling the proximal end thereof to facilitate connection of adapters and the like.
When the breakaway piece 246 is removed from the guidewire connector 240 and/or the "Y" connector 242, the guidewire removing means 250 will be exposed. As previously discussed, the guidewire removing means may be a slit, a weakened line, a tear-away strip, or other equivalent means for removing the guidewire 252 laterally through the outside wall 230 of the guidewire lumen 220.
In addition to removing the breakaway piece 246, at least a portion of the stress relief sleeve 254 must also be removed, as also illustrated in FIG. 21. The stress relief sleeve 254 may be slit or cut and the removable portion may be connected to the breakaway piece 246. Alternatively, the stress relief sleeve 254 may simply be slit and not removed from the outside wall 230 of the guidewire lumen 220.
The construction of the breakaway "Y" connector is further illustrated in cross-section in FIGS. 22-24.
In FIG. 22, the proximal end of the guidewire connector 240 is illustrated, showing the unitary polymer construction thereof. In FIG. 23, the unitary guidewire connector 240 is shown encircling only the guidewire lumen 220 of the catheter shaft 212.
In FIG. 24, the balloon inflation connector 226 is shown extending from the far side of the "Y" connector 242. The guidewire connector portion of the "Y" connector 242 is shown encircling both the guidewire lumen 220 and the balloon inflation lumen 222. The stress relief sleeve 254 is shown between the guidewire connector 240 and the catheter shaft 212.
Finally, in FIG. 25, the catheter shaft distal of the "Y" connector 242 is illustrated, showing the guidewire wire 220, the balloon inflation lumen 222, and the outside wall 230 of the catheter shaft 212.
FIG. 26 is an illustration of the "Y" connectors 242 assembled together with the breakaway piece 246. The stress relief sleeve 254 is illustrated partially cut away. This partial cut-away of the portion of the stress relief sleeve 254 may represent the actual finished product. In other words, the finished product may have the portion of the stress relief sleeve 254 overlying the guidewire removing means 250 removed. Alternatively, that portion of the stress relief sleeve 254 may be removable when the breakaway piece 246 is removed.
FIG. 27 is a longitudinal cross-section of the "Y" connector 242. It illustrates the placement of the stress relief sleeve 254 partially inside the "Y" connector 242. Connector flanges 256 are provided on both the guidewire connector 240 and the balloon inflation connector 226. In order to facilitate insertion of the guidewire 252 and connection to appropriate connectors and adapters, the proximal opening 232 of the guidewire lumen is preferably flared so that the channel extending through the guidewire connector is wider at its proximal end 214.
FIG. 28 corresponds to FIG. 27, except that the breakaway piece 246 has been removed and is illustrated in phantom.
FIG. 29 illustrates yet another embodiment of the guidewire removing means 250. In this illustrated embodiment, the outside wall 230 of the guidewire lumen 220 is provided with two weakened areas 260, 262 extending parallel and longitudinally along the outside wall 230 of the guidewire lumen 220. In a preferred embodiment, the weakened areas 260, 262 each comprise a juxtaposed pair of continuous or interrupted grooves formed in the outside wall 230, one inside the wall and the other outside the wall 230. An optional reinforcing filament 264 is provided in the segment of the outside wall 230 located between the weakened areas 260, 262. The reinforcing filament 264 may advantageously comprise a high tensile strength thread or filament, such as nylon or polyaramid (e.g., the material sold by du Pont under the trademark KEVLAR). Alternatively, it may be formed of metal.
The portion of the outside wall 230 bounded by the weakened areas 260, 262 comprises a tear-away strip 266. This strip 266 may be the same thickness as the remainder of the catheter shaft wall; it may be thinner; or it may be thicker. In use, the tear-away strip may be removed by grasping it at the proximal end and tearing distally. Alternatively, it may be removed simply by pulling the guidewire laterally through the outside wall 230 of the guidewire lumen, pulling the tear-away strip 266 in the process.
Another version of the tear-away strip 266 is illustrated in FIG. 30. In this embodiment, the tear-away strip 266 is formed of a different material than the remainder of the outside wall 230 of the guidewire lumen 220. This particular tear-away strip 266 may be formed, for example, by co-extruding a second material with the catheter shaft 212. The portions of the outside wall 230 adjacent to the guidewire removing means 250 are separated by the width of the tear-away strip 266, and the tear-away strip 266 overlaps the outside wall 230 on both the inside and outside of the outside wall 230. This overlapping, interlocking feature anchors the tear-away strip 266 to the outside wall 230 until removal is desired.
Still another embodiment of the tear-away strip 266 is illustrated in FIG. 31. In this embodiment, the tear-away strip 266 (which is advantageously formed of a separate or different material from the outside wall 230) is adhesively attached to the outside wall 230. It may be removed in a manner similar to that discussed in connection with FIGS. 28 and 29.
Whether the catheters of the present invention include a tear-away strip or a slit (formed or inchoate) as the guidewire removing means, it should be understood that the side port is optional when the catheter is used as an over the wire catheter. The side port is useful, however, when one inserts the catheter in rapid exchange mode, with the guidewire passing through the outside wall of the guidewire lumen into the guidewire lumen at a point on the catheter that is ordinarily inside the patient during use of the catheter.
There are many alternative geometries that can be used for the side ports 34, 234, which are applicable to all of the catheters described herein. For example, with reference to FIG. 32, the side port 234 may not comprise an actual opening, but rather a slit. One configuration of a slit that is adapted for easy insertion and removal of a guidewire is a "Y" shape, where the stem of the "Y" is a guidewire removing means slit or strip 250 and the two arms of the "Y" extend at divergent angles from the stem. As shown in FIG. 23, the slits may be fully formed; alternatively, they can be interrupted slits or weakened areas. It will be appreciated that there is no opening or hole in the outside wall of the guidewire lumen; rather, the edges of the slits are closed until a guidewire is passed through this version of the "side port" 34, 234.
Another embodiment of the side port 34, 234 is illustrated in FIG. 33. Here, the side port 234 is initially closed, and is part of the outside wall 230 of the guidewire lumen 220. Until then, the side port 234 is inchoate. When one desires to use the side port 234, the material closing the side port 234 is removed to open that side port. Thus, the side port 234 may be defined by a perforated line (interrupted slit), a weakened area, or the like. It can be connected to a single slit guidewire removing means 250, or to any of the other guidewire removing means disclosed herein. Where the guidewire removing means is a tear-away strip, the side port 234 can be connected to and a part of that strip, and may either be the same size as or an enlarged portion of that strip.
METHODS OF USING THE CATHETER
The catheter of the present invention may be used as a rapid exchange catheter with the guidewire 50, 252 extending through the side port 34, 234 and out of the distal end 16, 216 of the guidewire lumen 20, 220. Alternatively, it may be used as a conventional over the wire catheter with the guidewire 50, 252 extending substantially the entire length of the catheter shaft 12, 212 from the proximal end (either through a "Y" connector 62, 80, or 242 or through the to proximal opening 32, 232) distally through the entire length of the catheter shaft and out of the distal end thereof.
A revolutionary aspect of the catheter of the present invention is that it may readily and rapidly be converted from one mode of use to the other. Thus, it can be used first as a rapid exchange catheter, with the guidewire extending in the guidewire lumen 20, 220 only from the side port 34, 234 to the distal end of the catheter. It can be converted from this rapid exchange mode of use to conventional over-the-wire use simply by removing the guidewire and, while maintaining the catheter 10, 210 in place in the patient, inserting a new guidewire 50, 252 into the proximal end of the guidewire lumen 20, 220 (through a "Y" connector or through the proximal opening 32, 232) and extending the guidewire 50, 252 out of the distal end of the catheter.
When the catheter of FIG. 4 is being used as a conventional over the wire catheter, it can be converted into a rapid exchange catheter by removing the removable "Y" connector 80 (if used), and, with the guidewire extending proximally out of the proximal opening 32, maintaining the guidewire 50 in position in the patient while moving the guidewire laterally out of the outside wall 30 of the guidewire lumen 20 through the guidewire removing means 40 and simultaneously withdrawing the catheter 10 proximally until the distal end 16 of the catheter 10 is outside of the patient. During this portion of the procedure, the guidewire 50 is held by grasping it at the proximal end. Then the operator may hold the guidewire 50 by grasping the portion of the guidewire 50 exposed at the distal end 16 of the catheter 10, remove the catheter 10 off of the proximal end of the guidewire 50, and insert a new catheter 10 over the guidewire 50 while maintaining the position of the guidewire 50 in the patient. The insertion of the new catheter 10 may be accomplished in rapid exchange mode by retrograde insertion of the proximal end of the guidewire 50 through the distal end of the catheter and out of the sideport 34. The proximal end of the guidewire is then held while the catheter 10 is advanced back into position in the patient. The catheter can then be used as a rapid exchange catheter. Alternatively, if desired, the guidewire 50 may be removed with the catheter maintained in position, and in a matter of seconds the guidewire may be reinserted through the proximal opening 32 or through the proximal end 14 of the catheter shaft 12 to convert the mode of use to conventional over the wire use.
Thus, it will be appreciated that the catheter of the present invention can easily be used in either a rapid exchange mode or an over the wire mode; that conversion between modes of use may be readily accomplished; that guidewire exchange may be accomplished in either mode of use, and that catheter exchange when in either mode of use can be accomplished without use of an extension guidewire; and that all of the forgoing conversions and modes of use can be accomplished while maintaining the positioning of either the guidewire or the catheter in the patient.
Thus, one method of the present invention comprises inserting the catheter of FIG. 1 into the patient with the guidewire 50 going through the proximal opening 32 and extending from that point distally through the entire remaining length of the catheter shaft 12 and out of the distal end 16. The guidewire 50 can then be exchanged by removing it and reinserting it through the proximal opening 32. The catheter can be exchanged by holding the guidewire as explained above while peeling away the catheter laterally while withdrawing it so that the guidewire is pulled through the guidewire removing means 40 until the distal end of the catheter is outside the patient. The guidewire is then held distally of the catheter and a new catheter is inserted, this time in rapid exchange mode. Once that catheter is in place, the guidewire can be rapidly exchanged (if desired) to convert the catheter back into the over-the-wire mode of use as explained above.
In another method of use, the catheter of FIG. 6 can be used. This catheter can be used with the guidewire in the side port or the proximal opening, as explained above, with the same catheter and guidewire exchanges possible. Moreover, it can be used with the guidewire extending through the entire length of the guidewire lumen 20 through the guidewire adapter 64. Exchange of the guidewire from the guidewire adapter 64 to the proximal opening 32 and vice versa is also contemplated.
The identical modes of use explained in connection with the FIG. 1 catheter can be used with the removable or severable "Y" connector catheter of FIGS. 7-28, except the guidewire passes simultaneously through the proximal opening 32, 232 and the guidewire adapter 64, 240 of the "Y" connector 80, 242. Further, in these modes of use, the conversion from over-the-wire use to rapid exchange use will require removal of the removable "Y" connector 80 or removal a portion of the breakaway "Y" connector 242 (or other provision of a longitudinal slot or passageway through the "Y" connector) prior to and in addition to use of the guidewire removing means 40, 250.
Thus, for example, the catheter 210 of FIGS. 16-28 can be first inserted in over the wire mode, with the guidewire 252 extending from the proximal opening 232 through the guidewire connector 240 and distally through the guidewire lumen 220, through the balloon 224, and out of the distal end 216 of the catheter. In this configuration, the catheter is inserted into the patient and positioned in the conventional manner. The guidewire 252 is exchanged simply by maintaining the positioning of the catheter 210 in the patient, withdrawing the guidewire out of the proximal end 214 of the guidewire connector 240, and inserting another guidewire 252. If exchange of the catheter 210 is necessary, the breakaway piece 246 of the "Y" connector 242 is removed, the guidewire is removed laterally out of the "Y" connector 242 beginning at the proximal end of the connector 242, and then the guidewire 252 is held securely in position while the catheter is withdrawn from the patient, simultaneously pulling the guidewire 252 laterally out of the guidewire lumen 220 through the guidewire removing means 250. Where a tear-away strip 266 comprises the guidewire removing means 250, the strip 266 is pulled off while the catheter 210 is pulled out of the patient. When the distal end 216 of the catheter 210 is out of the patient and the guidewire 252 is exposed at the distal end 216, then the guidewire is grasped distally of the catheter 210 and the catheter 210 is removed off of the proximal end of the guidewire 252. Next, a new catheter 210 is threaded onto the guidewire by inserting the guidewire into the distal end of the guidewire lumen 220, proximally through the guidewire lumen 220 to the side port 234, and out of the side port 234. The catheter 210 is then advanced into the patient over the guidewire 252 while holding the guidewire 252 securely in position. If desired, the guidewire 252 can then be removed while holding the catheter 210 in position, and reinserted through the proximal end 214 of the guidewire lumen 220 through the entire length of the catheter 210, to convert back to over the wire mode.
Although the present invention has been described in the context of certain preferred embodiments, it is intended that the scope of the present patent be measured with reference with the appended claims and reasonable equivalence thereof.
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A multi-lumen vascular catheter for use with a guidewire, comprising a longitudinally extending catheter shaft having a proximal end and a distal end and having at least first and second lumens extending distally from the proximal end, each of the lumens having a proximal opening, wherein the first lumen is adapted to receive a guidewire, and a first connector at the proximal end of the catheter providing a first channel communicating with the interior of the first lumen for insertion of a guidewire therethrough, the connector including means for permitting a guidewire extending longitudinally through the first channel into the first lumen to be moved laterally out of the first channel through the first connector beginning at the proximal end of the first connector. The catheter may be an angioplasty catheter. Also disclosed are methods for using the catheter and for exchanging catheters and guidewires during vascular catheterization procedures.
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This invention relates generally as indicated to a jack assembly and more particularly to a jack assembly having built in, low cost position controls which have high repeatable accuracy and which are environmentally secure and corrosion resistant providing long service life for the jack assembly.
BACKGROUND OF THE INVENTION
In ball screw and machine screw jacks, such as sold by Nook Industries of Cleveland, Ohio under the trademark ACTIONJAC, rotary limit switches are commonly employed to control and regulate jack travel. Such rotary switches are mounted directly on the jacks and are worm gear operated and regulate jack travel by sensing the number of input shaft revolutions.
In such application rotary limit switches present a number of problems. A major problem is the cost. Another problem is bulk. Such rotary switches can be mounted in a number of positions but in each project substantially from the jack creating clearance problems in some installations. They of course also require a shaft drive connection. Rotary limit switches also are subject to wear, have a relatively short service life, and tend to drift as they wear, thus not providing highly reliable repeatability.
Mechanical pole arm actuated limit switches have many of the same problems, particularly when mounted on projecting brackets. Moreover, the screws of such jacks are usually sealed in a cover tube such that physical contact with the screw is not really feasible.
In such jacks the cover and screw are usually made of steel which are subject to magnetic flux making the use of low cost magnetic switches unreliable, without modification of the jack assembly. If low cost magnetic reed switches or Hall effect sensors could be employed with easy installation and adjustment and achieve reliable repeatability, a lower cost, more reliable jack assembly with longer service life can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation partially broken away and in section illustrating a machine screw jack in accordance with the present invention;
FIG. 2 is an enlarged fragmentary axial section through the screw stem cover taken substantially on the line 2--2 of FIG. 1;
FIG. 3 is a transverse section taken from the line 3--3 of FIG. 2;
FIG. 4 is an end elevation partially in section of the semi-circular switch mounts;
FIG. 5 is a side elevation of the switch mounts with one mount partially broken away and showing a magnetic reed switch in place;
FIG. 6 is an axial section of the one mount without the switch in place;
FIG. 7 is a side elevation of a ball screw jack assembly utilizing another form of plastic stem cover and switch mounting;
FIG. 8 is an enlarged broken axial section of a stem cover of the type seen in FIG. 7;
FIG. 9 is a broken plan view of the stem cover of FIG. 8 as seen from the top of FIG. 8;
FIG. 10 is a tranverse section seen from the line 10--10 of FIG. 9;
FIG. 11 is a transverse section as seen from the line 11--11 of FIG. 9;
FIG. 12 is a side elevation of a machine screw jack assembly utilizing a wire cover with a stem cover cap and connector mounted thereon;
FIG. 13 is an enlarged plan view of the switch mounting surface on the stem cover as seen from the top of FIG. 12;
FIG. 14 is an enlarged top plan view of the switch assembly seen in FIG. 12;
FIG. 15 is an end elevation of the switch assembly as seen from the right hand end of FIG. 14;
FIG. 16 is a side elevation broken away and in section of a ball screw jack assembly utilizing proximity switches mounted on a square stem cover sensing the presence and absence of the end of the screw;
FIG. 17 is a reduced broken axial section of the stem cover of FIG. 16;
FIG. 18 is a transverse section of the stem cover as seen from the line 18--18 of FIG. 17;
FIG. 19 is an enlarged plan view of the switch mount seen in FIG. 16; and,
FIG. 20 is an end elevation of the mount as seen from the right hand end of FIG. 19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1-6, and initially to FIG. 1, there is illustrated a machine screw jack assembly 30 which includes a nut housing 31 which includes a cover 32 and in which is journalled nut 33 which includes a pinion 34 in mesh with worm gear 35 on worm shaft 36. The nut 33 is in mesh with screw 38 which projects from both ends of the nut housing. Operation of the jack rotates the nut 33 causing the nut or screw 38 to move axially. On one end, usually the upper end, the screw is provided with a stop 39 and may be threadedly connected as indicated at 40 to an element to be lifted or moved indicated at 41. The nut housing includes a mounting flange 43 by means of which the nut housing and thus the jack may be affixed to another element such as a frame, so that operation of the jack will move the element 41 with respect to such frame. The jack, as illustrated in FIG. 1, is shown in its closed or down position and a flexible boot seen at 44 may be employed to protect and seal the projecting screw as the element 41 moves away from and toward the nut housing. The nut housing may include a motor adapter so that worm shaft 36 may be driven directly by a motor. Where more than one jack is employed the worm shaft may be driven through an arrangement of shafts, couplings, gear boxes and a single motor remote from the jack.
In the illustrated machine screw jack, the screw does not rotate, being fixed to the element 41. The jack may, for example, have a worm gear ratio of 6 to 1 and the number of turns of the worm to move the screw one inch may be 24.
The opposite end of the screw projects into a screw stem cover indicated generally at 50 which is mounted on and projects from the cover 32 of the nut housing. Mounted on the stem cover are two limit switch assemblies seen at 52 and 53 as well as a terminal block 54. The limit switch assemblies are mounted generally at the opposite ends of the elongated stem cover, while the terminal block may be mounted midway between such switch assemblies.
Referring now additionally to FIGS. 2 and 3, it will be seen that the end of the metal screw 38 is provided with an axially extending blind tapped hole 56 in which the shank 57 of plastic bolt 59 is threaded. Captured between the head of the bolt and the end of the metal screw are plastic washers 60 and 61 with an annular magnet 62 therebetween. In this manner there is proper sinking of the magnet 62 with respect to the screw 38 permitting little flux drain off through the screw. Subsequently, as the contained end of the metal screw 38 progresses towards one of the limit switches 52 or 53, the proximate limit switch will electromagnetically sense the presence of the magnet 62 and operate to stop or reverse the drive mechanism and progress of the screw.
The stem cover 50 at each of the switch mounts or assemblies 52 and 53 is chordally cut away as indicated at 64 to provide a rectangular cylindrical opening through the stem cover wall from the circumference points 65 and 66 on the I.D. of the stem cover.
Surrounding the stem cover at the opening is a switch mount assembly which comprises opposed semi-circular generally similar switch mounts 67 and 68 and a surrounding circular sleeve 69. Both semi-circular switch mounts have the same I.D. as the O.D. of the stem cover, are slightly less than a half circle, and are provided with an inner circular center recess as seen at 72 and 73, respectively. The switch mount 67 is provided with a pair of tapped holes 74 and 75 which are within such recess 72 but which are parallel to but offset from the radius through the center of the switch mount. Such tapped holes are employed with threaded fasteners 77 and 78, respectively which extend through axially elongated slots in offset flange 79 of reed switch 80. The reed switch 80 is thus mounted so that its radially inward projection is sustantially flush with the I.D. of the stem cover 50.
The switch mount 67 is provided with a blind axial center slot 82 which provides a passage for the wires 83 to exit the switch mount assembly over the O.D. of the stem cover 50.
As indicated more clearly in FIGS. 2, 3 and 4, the opposing switch mount 68 is provided with tapped holes 85 and 86 which are axially aligned and in the center of the switch mount. These holes receive jack screws 87 and 88, the heads of which fit through slightly enlarged holes 89 and 90 in sleeve 69. As the jack screws are tightened, the flat ends thereof bear against the O.D. of the stem cover forcing the switch mount 68 against the inside of the sleeve in effect pulling the sleeve downwardly as seen in FIGS. 2 and 3 firmly clamping the other switch mount 67 in place. With the sleeve-clamp assembly illustrated the reed switch 80 may not only be firmly secured in place, but also may readily be adjusted axially of the opening in the stem cover. This is in addition to any axial adjustment obtained by the elongated slots in the flange 78.
Referring again to FIG. 1, it will be seen that the terminal block 54 mounted halfway between the switch mounts 52 and 53 may be mounted on a flat surface on the exterior of the stem cover, such surface being essentially the same as seen in FIG. 11 and being formed by a flat or chord formed in the outside of the stem cover. After the switch assemblies are properly positioned and secured in place and wired to the terminal block, a plastic tubular sleeve is then positioned over the entire length of the stem cover and then heat shrunk in place as indicated at 93. The heat shrinking of the tube causes it closely to conform to the slightly radially projecting switch mounts and if access is required to the terminal block a small flap may be formed in the heat shrink cover as indicated at 94. The flap may be formed by cutting the cover along the axial line 95 and the two circumferential lines indicated at each end at 96 and 97. By folding the flap back access may be obtained to the terminal block. After the required access is obtained, the flap may be repositioned and sealed in place. The sealed heat shrink sleeve not only contains the grease normally found in the stem cover, but also protects the screw with in the stem cover from environmental contaminants.
Referring now to FIG. 7, there is illustrated a ball screw jack 100 which includes a worm gear housing 101, part of which includes the housing 102 for the ball nut. The screw 103 projects axially from both ends of the housing and moves axially within stem cover 104 connected to the housing 101. Operation of the jack rotates the ball nut causing the relative axial movement of the ball nut or screw 103.
Again, the end of the screw is provided with an annular magnet 106 secured between the plastic washers 107 and 108 captured by the head of fastener 110 threaded in the blind tapped hole in the end of the screw. As illustrated, the stem cover 104 is plastic and the magnet 106 is surrounded by plastic, thus properly sinking the magnet and allowing little flux drain off.
Mounted on the exterior of the stem cover are magnetic reed switch 112, terminal block 113, and magnetic reed switch 114. The manner in which the two reed switches and terminal block are mounted on the stem cover is more clearly seen in FIGS. 8-11. As indicated at 116 and 117, the tubular stem cover is chordally cut away to provide at each location two coplanar flat surfaces 118 and 119 with a rectangular opening therebetween through the wall of the stem cover as seen at 120. The opening is formed because the plane of the surfaces 118 and 119 is slightly radially inwardly of the radius of the I.D. of the stem cover.
A similar planar relief at 122 is provided for the terminal block 113, but the plane of the relief is beyond the radius of the I.D. of the stem cover. In this manner no hole through the wall of the stem cover is formed. The planar reliefs 116, 117 and 122 are all parallel to each other and normal to a plane through the axis of the stem cover with the relief 122 being radially outwardly offset from the plane of the surfaces 118 and 119.
As indicated in FIG. 7, the reed switches 112 and 114 include a lateral mounting flange as seen at 124 and 125 which are provided with axially elongated mounting slots seen at 126 and 127. Such mounting flanges may preferably be simply adhesively secured to the surfaces 118 and 119 of the reliefs 116 and 117, respectively, and the reed switches may be radially adjustably positioned by the use of shims. Alternatively, the reed switches may be secured to the stem cover by fasteners extending through the axially elongated slots and into relatively shallow tapped holes seen at 129 and 130. The use of the fasteners permits limited axial adjustment to the extent of the elongation of the slots. The terminal 113 may also be adhesively secured to the surface 122 or alternatively secured by the fasteners indicated at 131.
One end of the stem cover is provided with external threads 133 as seen in FIG. 8 to mount the stem cover on the housing 101, while the opposite end is provided with a cap 134 seen in FIG. 7. Once the reed switches and the terminal blocks are in place and connected, a shrink wrap tubular sleeve 135 also seen in FIG. 7 may be provided completely surrounding and sealing the stem cover.
Referring now to FIGS. 12-15, there is illustrated a machine screw jack assembly shown generally at 136 which includes nut drive housing 137 and screw 138 connected to load 139 at one end, and at the opposite end projecting into stem cover 140. The stem cover is tubular plastic and is secured to the housing 137 and surrounds the projecting screw which moves axially therewithin. The end of the screw is provided with annular magnet 142 which is positioned between plastic washers 143 and 144 each clamped against the end of the screw by plastic bolt 145.
The end of the stem cover is provided with a stem cap 147 to which is secured electrical connector 148. The stem cover is also provided with a plug or wall 149 and between the plug and stem cap there is provided a radial somewhat enlarged opening 150 in the stem cover so that wiring may pass from the connector through the chamber 151 formed between the cap 147 and plug 149 to exit the hole 150 to enter the interior of wire cover 152 which extends the length of the stem cover. The wire cover may be secured to the stem cover by fasteners 153.
As seen in FIG. 13, the stem cover 140 is chordally cut away at each end as indicated at 154 to form a planar mounting surface 155. Positioned in such mounting surface is hole 156, such hole extending completely through the wall of the stem cover. Also positioned in such mounting surface are shallow tapped blind holes, 157, 158 and 159. The hole 156 has the profile configuration seen in FIG. 13 which is generally rectangular but with rounded corners and an inwardly extending projection 160 which is offset from the longitudinal axis of the hole but aligned with the center of the stem cover. The mounting surface and hole at the opposite end of the stem cover appears as an inverted mirror image of what is seen in FIG. 13.
Referring now to FIGS. 14 and 15, there is illustrated a switch assembly which includes a rectangular switch plate 162, a reed switch 163 and a terminal block 164. The plate is provided with three elongated fastener receiving slots 165, 166 and 167 adapted to receive fasteners 168 threaded in the holes 157, 158 and 159, respectively. The plate 162 also includes a circular wire aperture 169 which will generally align with the projection 160 of the hole 156 to permit wires to pass from the switch 163 on the interior of the plate to the terminal block on the exterior. the reed switch 163 is provided with a lateral flange 170 through which fasteners 171 extend and one or more shims indicated at 172 may be provided for radial adjustment of the switch 163.
The machine screw jack assembly of FIGS. 12-15 may be provided with an encoder shown generally at 174 also provided with a wire connector 175. The encoder is mounted on one end of the worn shaft and is driven thereby. The magnetically operated reed switches together with the encoder provide a sophisticated electrical control system for the jack assembly.
Referring now to FIGS. 16-20, there is illustrated a ball screw jack assembly in accordance with the present invention shown generally at 178. The assembly 178 includes a ball screw 179 which is moved axially by ball nut 180 which is driven by pinion 181 in turn driven by worm 182 secured to worm shaft 183. The ball nut and pinion are journalled in two part housing 184. One end of the screw is connected to a load as indicated by the plate 185 while the opposite end has secured thereto a square nut or block 186 which fairly closely fits within the square interior 187 of stem cover 188. As seen more clearly in FIG. 17, the stem cover is open at one end and provided with an external flange 190. Fasteners 191 extending through such flange secure the stem cover to the nut housing. The opposite end of the stem cover is closed by end wall 192. The stem cover cooperates with the nut 186 to keep the screw from rotating and also protects the screw as it projects from the housing 184.
One of the walls of the stem cover is provided at each end with elongated openings as seen at 194 and 195, each of which are provided on opposite sides with paired tapped holes 196 and 197. Secured to the exterior of such wall of the stem cover are switch mounts 198 and 199, such switch mounts being shown in more detail in FIGS. 19 and 20. The switch mounts are in the form of square plates which include a center tapped hole 201, the underside of which is circularly relieved as indicated at 202. On opposite sides of the center tapped hole there is provided elongated mounting slots 203 and 204 which are adapted to receive headed fasteners secured in the tapped holes 196 and 197. In this manner the switch mounts may adjustably be secured to the exterior of the stem cover to the extent permitted by the elongation of the slots 203 and 204. Secured in the tapped holes 201 of each switch mount are tubular proximity switches 206 and 207. Such switches are externally threaded and may be adjusted axially (normal to the axis of screw 179) and locked in such axial adjustment by lock nuts 208 and 209, respectively. The relieved portion 202 of the switch mounts enables the sensing field of the tip 210 of each proximity switch properly to be adjusted to sense accurately the presence of the nut or block 186 at the end of the screw 179, or the absence of the nut. When one of the proximity switches electromagnetically senses the presence of the nut or block 186, the switch will act to stop or reverse the drive mechanism and progress of the ball screw 179.
In the magnetic switch embodiments of the present invention, such switches may be of the type obtained from Hamlin, Inc. of Lake Mills, Wis. Proximity switches such as seen in FIG. 16 may be obtained from NAMCO Controls of Cleveland, Ohio. The magnets employed may be ceramic or metal and the materials of the parts used to sink the magnets with respect to the screw may be plastic such as nylon. The stem covers may preferably be plastic or nonferrous materials, although in some instances metal may be employed, while the shrink wrap tubing may be polyethylene.
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A jack assembly of the ball screw or machine screw type includes a screw, a nut in driving engagement with the screw whereby rotation of the nut causes the nut or screw to move axially. A nut drive housing in which the nut rotates includes a worm gear transmission which may be driven directly or indirectly by an electric motor. The screw projecting through the nut is enclosed by a screw stem cover mounted on the housing which environmentally protects the screw. The cover and screw move axially relative to each other. In a preferred embodiment, the screw stem cover is made of plastic and is provided with slots extending axially in which are adjustably positioned magnetic reed switches. The switches may be clamped in place by a sleeve type clamp or the exterior of the cover may be flattened in the area of the slot for direct mounting of the switch. The stem cover may also have a flattened area for mounting of the required terminal. The end of the screw is provided with an annular magnet held in place with non-magnetic materials to provide proper sinking of the magnet permitting little flux drain-off through the screw. The entire cover with the reed switches in place and connected to the terminal may be encapsulated by a heat shrink sleeve with access to the terminal provided by a flap which can be opened and resealed. Optionally, Hall effect or proximity sensors may be employed with or without the magnet in some applications for electronic control.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 08/376,661, filed on Jan. 23, 1995 U.S. Pat. No. 6,810,606; which is a continuation of U.S. application Ser. No. 08/127,487, filed on Sep. 28, 1993, now abandoned; which is a continuation of U.S. application Ser. No. 07/729,886, filed on Jul. 11, 1991, now abandoned; which is a continuation of U.S. application Ser. No. 07/400,714, filed on Aug. 30, 1989, now abandoned; which is a continuation-in-part of International Application no. PCT/US89/03076, filed on Jul. 14, 1989, designating the United States; a continuation-in-part of U.S. application Ser. No. 07/239,667, filed on Sep. 2, 1988, now abandoned; and a continuation-in-part of U.S. application Ser. No. 07/219,387, filed on Jul. 15, 1988, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to the structure of shoes. More specifically, this invention relates to the structure of running shoes. Still more particularly, this invention relates to variations in the structure of such shoes using a theoretically-ideal stability plane as a basic concept.
Existing running shoes are unnecessarily unsafe. They profoundly disrupt natural human biomechanics. The resulting unnatural foot and ankle motion leads to what are abnormally high levels of running injuries.
Proof of the unnatural effect of shoes has come quite unexpectedly from the discovery that, at the extreme end of its normal range of motion, the unshod bare foot is naturally stable, almost unsprainable, while the foot equipped with any shoe, athletic or otherwise, is artificially unstable and abnormally prone to ankle sprains. Consequently, ordinary ankle sprains must be viewed as largely an unnatural phenomena, even though fairly common. Compelling evidence demonstrates that the stability of bare feet is entirely different from the stability of shoe-equipped feet.
The underlying cause of the universal instability of shoes is a critical but correctable design flaw. That hidden flaw, so deeply ingrained in existing shoe designs, is so extraordinarily fundamental that it has remained unnoticed until now. The flaw is revealed by a novel new biomechanical test, one that is unprecedented in its simplicity. It is easy enough to be duplicated and verified by anyone; it only takes a few minutes and requires no scientific equipment or expertise. The simplicity of the test belies its surprisingly convincing results. It demonstrates an obvious difference in stability between a bare foot and a running shoe, a difference so unexpectedly huge that it makes an apparently subjective test clearly objective instead. The test proves beyond doubt that all existing shoes are unsafely unstable.
The broader implications of this uniquely unambiguous discovery are potentially far-reaching. The same fundamental flaw in existing shoes that is glaringly exposed by the new test also appears to be the major cause of chronic overuse injuries, which are unusually common in running, as well as other sport injuries. It causes the chronic injuries in the same way it causes ankle sprains; that is, by seriously disrupting natural foot and ankle biomechanics.
The applicant has introduced into the art the concept of a theoretically ideal stability plane as a structural basis for shoe designs. That concept as implemented into shoes such as street shoes and athletic shoes is presented in pending U.S. application Ser. Nos. 07/219,387, filed on Jul. 15, 1988 and Ser. No. 07/239,667, filed on Sep. 2, 1988, as well as in PCT Application No. PCT/US89/03076 filed on Jul. 14, 1989. This application develops the application of the concept of the theoretically ideal stability plane to other shoe structures and presents certain structural ideas presented in the PCT application.
Accordingly, it is a general object of this invention to elaborate upon the application of the principle of the theoretically ideal stability plane to other shoe structures.
It is another general object of this invention to provide a shoe sole which, when under load and tilting to the side, deforms in a manner which closely parallels that of the foot of its wearer, while retaining nearly the same amount of contact of the shoe sole with the ground as in its upright state.
It is still another object of this invention to provide a deformable shoe sole having the upper portion or the sides bent inwardly somewhat so that when worn the sides bend out easily to approximate a custom fit.
It is still another object of this invention to provide a shoe having a naturally contoured sole which is abbreviated along its sides to only essential structural stability and propulsion elements, which are combined and integrated into the same discontinuous shoe sole structural elements underneath the foot, which approximate the principal structural elements of a human foot and their natural articulation between elements.
These and other objects of the invention will become apparent from a detailed description of the invention which follows taken with the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
Directed to achieving the aforementioned objects and to overcoming problems with prior art shoes, a shoe according to the invention comprises a sole having at least a portion thereof following the contour of a theoretically ideal stability plane, and which further includes rounded edges at the finishing edge of the sole after the last point where the constant shoe sole thickness is maintained. Thus, the upper surface of the sole does not provide an unsupported portion that creates a destabilizing torque and the bottom surface does not provide an unnatural pivoting edge.
In another aspect, the shoe includes a naturally contoured sole structure exhibiting natural deformation which closely parallels the natural deformation of a foot under the same load. In a preferred embodiment, the naturally contoured side portion of the sole extends to contours underneath the load-bearing foot. In another embodiment, the sole portion is abbreviated along its sides to essential support and propulsion elements wherein those elements are combined and integrated into the same discontinuous shoe sole structural elements underneath the foot, which approximate the principal structural elements of a human foot and their natural articulation between elements. The density of the abbreviated shoe sole can be greater than the density of the material used in an unabbreviated shoe sole to compensate for increased pressure loading. The essential support elements include the base and lateral tuberosity of the calcaneus, heads of the metatarsal, and the base of the fifth metatarsal.
The shoe sole is naturally contoured, paralleling the shape of the foot in order to parallel its natural deformation, and made from a material which, when under load and tilting to the side, deforms in a manner which closely parallels that of the foot of its wearer, while retaining nearly the same amount of contact of the shoe sole with the ground as in its upright state under load. A deformable shoe sole according to the invention may have its sides bent inwardly somewhat so that when worn the sides bend out easily to approximate a custom fit.
These and other features of the invention will become apparent from the detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a rear view of a heel of a foot for explaining the use of a stationery sprain simulation test.
FIG. 2 is a rear view of a conventional running shoe unstably rotating about an edge of its sole when the shoe sole is tilted to the outside.
FIG. 3 is a diagram of the forces on a foot when rotating in a shoe of the type shown in FIG. 2 .
FIG. 4 is a view similar to FIG. 3 but showing further continued rotation of a foot in a shoe of the type shown in FIG. 2 .
FIG. 5 is a force diagram during rotation of a shoe having motion control devices and heel counters.
FIG. 6 is another force diagram during rotation of a shoe having a constant shoe sole thickness, but producing a destabilizing torque because a portion of the upper sole surface is unsupported during rotation.
FIG. 7 shows an approach for minimizing destabilizing torque by providing only direct structural support and by rounding edges of the sole and its outer and inner surfaces.
FIGS. 8A to 8 I illustrate functionally the principles of natural deformation as applied to the shoe soles of the invention.
FIG. 9 shows variations in the relative density of the shoe sole including the shoe insole to maximize an ability of the sole to deform naturally.
FIG. 10 shows a shoe having naturally contoured sides bent inwardly somewhat from a normal size so then when worn the shoe approximates a custom fit.
FIG. 11 shows a shoe sole having a fully contoured design but having sides which are abbreviated to the essential structural stability and propulsion elements that are combined and integrated into discontinuous structural elements underneath the foot that simulate those of the foot.
FIG. 12 is a diagram serving as a basis for an expanded discussion of a correct approach for measuring shoe sole thickness.
FIGS. 13A-13F show embodiments of the invention in a shoe sole wherein only the outer or bottom sole includes the special contours of the design of the invention and maintains a conventional flat upper surface to ease joining with a conventional flat midsole lower surface.
FIG. 14 shows in frontal plane cross sections an inner shoe sole enhancement to the previously described embodiments of the show sole side stability quadrant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in a real illustration a foot 27 in position for a new biomechanical test that is the basis for the discovery that ankle sprains are in fact unnatural for the bare foot. The test simulates a lateral ankle sprain, where the foot 27 —on the ground 43 —rolls or tilts to the outside, to the extreme end of its normal range of motion, which is usually about 20 degrees at the heel 29 , as shown in a rear view of a bare (right) heel in FIG. 1 . Lateral (inversion) sprains are the most common ankle sprains, accounting for about three-fourths of all.
The especially novel aspect of the testing approach is to perform the ankle spraining simulation while standing stationary. The absence of forward motion is the key to the dramatic success of the test because otherwise it is impossible to recreate for testing purposes the actual foot and ankle motion that occurs during a lateral ankle sprain, and simultaneously to do it in a controlled manner, while at normal running speed or even jogging slowly, or walking. Without the critical control achieved by slowing forward motion all the way down to zero, any test subject would end up with a sprained ankle.
That is because actual running in the real world is dynamic and involves a repetitive force maximum of three times one's full body weight for each footstep, with sudden peaks up to roughly five or six times for quick stops, missteps, and direction changes, as might be experienced when spraining an ankle. In contrast, in the static simulation test, the forces are tightly controlled and moderate, ranging from no force at all up to whatever maximum amount that is comfortable.
The Stationary Sprain Simulation Test (SSST) consists simply of standing stationary with one foot bare and the other shod with any shoe. Each foot alternately is carefully tilted to the outside up to the extreme end of its range of motion, simulating a lateral ankle sprain.
The Stationary Sprain Simulation Test clearly identifies what can be no less than a fundamental flaw in existing shoe design. It demonstrates conclusively that nature's biomechanical system, the bare foot, is far superior in stability to man's artificial shoe design. Unfortunately, it also demonstrates that the shoe's severe instability overpowers the natural stability of the human foot and synthetically creates a combined biomechanical system that is artificially unstable. The shoe is the weak link.
The test shows that the bare foot is inherently stable at the approximate 20 degree end of normal joint range because of the wide, steady foundation the bare heel 29 provides the ankle joint, as seen in FIG. 1 . In fact, the area of physical contact of the bare heel 29 with the ground 43 is not much less when tilted all the way out to 20 degrees as when upright at 0 degrees.
The new Stationary Sprain Simulation Test provides a natural yardstick, totally missing until now, to determine whether any given shoe allows the foot within it to function naturally. If a shoe cannot pass this simple litmus test, it is positive proof that a particular shoe is interfering with natural foot and ankle biomechanics. The only question. is the exact extent of the interference beyond that demonstrated by the new test.
Conversely, the applicant's designs are the only designs with shoe soles thick enough to provide cushioning (thin-soled and heel-less moccasins do pass the test, but do not provide cushioning and only moderate protection) that will provide naturally stable performance, like the bare foot, in the Stationary Sprain Simulation Test.
FIG. 2 shows that, in complete contrast, the foot equipped with a conventional running shoe, designated generally by the reference numeral 20 and having an upper 21 , though initially very stable while resting completely flat on the ground, becomes immediately unstable when the shoe sole 22 is tilted to the outside. The tilting motion lifts from contact with the ground all of the shoe sole 22 except the artificially sharp edge of the bottom outside corner. The shoe sole instability increases the farther the foot is rolled laterally. Eventually, the instability induced by the shoe itself is so great that the normal load-bearing pressure of full body weight would actively force an ankle sprain if not controlled. The abnormal tilting motion of the shoe does not stop at the barefoot's natural 20 degree limit, as you can see from the 45 degree tilt of the shoe heel in FIG. 2 .
That continued outward rotation of the shoe past 20 degrees causes the foot to slip within the shoe, shifting its position within the shoe to the outside edge, further increasing the shoe's structural instability. The slipping of the foot within the shoe is caused by the natural tendency of the foot to slide down the typically flat surface of the tilted shoe sole; the more the tilt, the stronger the tendency. The heel is shown in FIG. 2 because of its primary importance in sprains due to its direct physical connection to the ankle ligaments that are torn in an ankle sprain and also because of the heel's predominant role within the foot in bearing body weight.
It is easy to see in the two figures how totally different the physical shape of the natural bare foot is compared to the shape of the artificial shoe sole. It is strikingly odd that the two objects, which apparently both have the same biomechanical function, have completely different physical shapes. Moreover, the shoe sole clearly does not deform the same way the human foot sole does, primarily as a consequence of its dissimilar shape.
FIG. 3A illustrates that the underlying problem with existing shoe designs is fairly easy to understand by looking closely at the principal forces acting on the physical structure of the shoe sole. When the shoe is tilted outwardly, the weight of the body held in the shoe upper 21 shifts automatically to the outside edge of the shoe sole 22 . But, strictly due to its unnatural shape, the tilted shoe sole 22 provides absolutely no supporting physical structure directly underneath the shifted body weight where it is critically needed to support that weight. An essential part of the supporting foundation is missing. The only actual structural support comes from the sharp corner edge 23 of the shoe sole 22 , which unfortunately is not directly under the force of the body weight after the shoe is tilted. Instead, the corner edge 23 is offset well to the inside.
As a result of that unnatural misalignment, a lever arm 23 a is set up through the shoe sole 22 between two interacting forces (called a force couple): the force of gravity on the body (usually known as body weight 133 ) applied at the point 24 in the upper 21 and the reaction force 134 of the ground, equal to and opposite to body weight when the shoe is upright. The force couple creates a force moment, commonly called torque, that forces the shoe 20 to rotate to the outside around the sharp corner edge 23 of the bottom sole 22 , which serves as a stationary pivoting point 23 or center of rotation.
Unbalanced by the unnatural geometry of the shoe sole when tilted, the opposing two forces produce torque, causing the shoe 20 to tilt even more. As the shoe 20 tilts further, the torque forcing the rotation becomes even more powerful, so the tilting process becomes a self-reenforcing cycle. The more the shoe tilts, the more destabilizing torque is produced to further increase the tilt.
The problem may be easier to understand by looking at the diagram of the force components of body weight shown in FIG. 3 A. When the shoe sole 22 is tilted out 45 degrees, as shown, only half of the downward force of body weight 133 is physically supported by the shoe sole 22 ; the supported force component 135 is 71% of full body weight 133 . The other half of the body weight at the 45 degree tilt is unsupported physically by any shoe sole structure; the unsupported component is also 71% of full body weight 133 . It therefore produces strong destabilizing outward tilting rotation, which is resisted by nothing structural except the lateral ligaments of the ankle.
FIG. 3B show that the full force of body weight 133 is split at 45 degrees of tilt into two equal components: supported 135 and unsupported 136 , each equal to 0.707 of full body weight 133 . The two vertical components 137 and 138 of body weight 133 are both equal to 0.50 of full body weight. The ground reaction force 134 is equal to the vertical component 137 of the supported component 135 .
FIG. 4 show a summary of the force components at shoe sole tilts of 0, 45 and 90 degrees. FIG. 4 , which uses the same reference numerals as in FIG. 3 , shows that, as the outward rotation continues to 90 degrees, and the foot slips within the shoe while ligaments stretch and/or break, the destabilizing unsupported force component 136 continues to grow. When the shoe sole has tilted all the way out to 90 degrees (which unfortunately does happen in the real world), the sole 22 is providing no structural support and there is no supported force component 135 of the full body weight 133 . The ground reaction force at the pivoting point 23 is zero, since it would move to the upper edge 24 of the shoe sole.
At that point of 90 degree tilt, all of the full body weight 133 is directed into the unresisted and unsupported force component 136 , which is destabilizing the shoe sole very powerfully. In other words, the full weight of the body is physically unsupported and therefore powering the outward rotation of the shoe sole that produces an ankle sprain. Insidiously, the farther ankle ligaments are stretched, the greater the force on them.
In stark contrast, untilted at 0 degrees, when the shoe sole is upright, resting flat on the ground, all of the force of body weight 133 is physically supported directly by the shoe sole and therefore exactly equals the supported force component 135 , as also shown in FIG. 4 . In the untilted position, there is no destabilizing unsupported force component 136 .
FIG. 5 illustrates that the extremely rigid heel counter 141 typical of existing athletic shoes, together with the motion control device 142 that are often used to strongly reinforce those heel counters (and sometimes also the sides of the mid- and fore-foot), are ironically counterproductive. Though they are intended to increase stability, in fact they decrease it. FIG. 5 shows that when the shoe 20 is tilted out, the foot is shifted within the upper 21 naturally against the rigid structure of the typical motion control device 142 , instead of only the outside edge of the shoe sole 22 itself. The motion control support 142 increases by almost twice the effective lever arm 132 (compared to 23 a ) between the force couple of body weight and the ground reaction force at the pivot point 23 . It doubles the destabilizing torque and also increases the effective angle of tilt so that the destabilizing force component 136 becomes greater compared to the supported component 135 , also increasing the destabilizing torque. To the extent the foot shifts further to the outside, the problem becomes worse. Only by removing the heel counter 141 and the motion control devices 142 can the extension of the destabilizing lever arm be avoided. Such an approach would primarily rely on the applicant's contoured shoe sole to “cup” the foot (especially the heel), and to a much lesser extent the non-rigid fabric or other flexible material of the upper 21 , to position the foot, including the heel, on the shoe. Essentially, the naturally contoured sides of the applicant's shoe sole replace the counter-productive existing heel counters and motion control devices, including those which extend around virtually all of the edge of the foot.
FIG. 6 shows that the same kind of torsional problem, though to a much more moderate extent, can be produced in the applicant's naturally contoured design of the applicant's earlier-filed applications. There, the concept of a theoretically-ideal stability plane was developed in terms of a sole 28 having a lower surface 31 and an upper surface 30 which are spaced apart by a predetermined distance which remains constant throughout the sagittal frontal planes. The outer surface 27 of the foot is in contact with the upper surface 30 of the sole 28 . Though it might seem desireable to extend the inner surface 30 of the shoe sole 28 up around the sides of the foot 27 to further support it (especially in creating anthropomorphic designs), FIG. 6 indicates that only that portion of the inner shoe sole 28 that is directly supported structurally underneath by the rest of the shoe sole is effective in providing natural support and stability. Any point on the upper surface 30 of the shoe sole 28 that is not supported directly by the constant shoe sole thickness (as measured by a perpendicular to a tangent at that point and shown in the shaded area 143 ) will tend to produce a moderate destabilizing torque. To avoid creating a destabilizing lever arm 132 , only the supported contour sides and non-rigid fabric or other material can be used to position the foot on the shoe sole 28 .
FIG. 7 illustrates an approach to minimize structurally the destabilizing lever arm 32 and therefore the potential torque problem. After the last point where the constant shoe sole thickness (s) is maintained, the finishing edge of the shoe sole 28 should be tapered gradually inward from both the top surface 30 and the bottom surface 31 , in order to provide matching rounded or semi-rounded edges. In that way, the upper surface 30 does not provide an unsupported portion that creates a destabilizing torque and the bottom surface 31 does not provide an unnatural pivoting edge. The gap 144 between shoe sole 28 and foot sole 29 at the edge of the shoe sole can be “caulked” with exceptionally soft sole material as indicated in FIG. 7 that, in the aggregate (i.e. all the way around the edge of the shoe sole), will help position the foot in the shoe sole. However, at any point of pressure when the shoe tilts, it will deform easily so as not to form an unnatural lever causing a destabilizing torque.
FIGS. 8A-8C illustrate clearly the principle of natural deformation as it applies to the applicant's design, even though design diagrams like those preceding (and in his previous applications already referenced) are normally shown in an ideal state, without any functional deformation, obviously to show their exact shape for proper construction. That natural structural shape, with its contour paralleling the foot, enables the shoe sole to deform naturally like the foot. In the applicant's invention, the natural deformation feature creates such an important functional advantage it will be illustrated and discussed here fully. Note in the figures that even when the shoe sole shape is deformed, the constant shoe sole thickness in the frontal plane feature of the invention is maintained.
FIG. 8A shows upright, unloaded and therefore undeformed the fully contoured shoe sole design indicated in FIG. 15 of U.S. patent application Ser. No. 07/239,667 (filed Sep. 2, 1988). FIG. 8A shows a fully contoured shoe sole design that follows the natural contour of all of the foot sole, the bottom as well as the sides. The fully contoured shoe sole assumes that the resulting slightly rounded bottom when unloaded will deform under load as shown in FIG. 8 B and flatten just as the human foot bottom is slightly rounded unloaded but flattens under load. Therefore, the shoe sole material must be of such composition as to allow the natural deformation following that of the foot. The design applies particularly to the heel, but to the rest of the shoe sole as well. By providing the closes match to the natural shape of the foot, the fully contoured design allows the foot to function as naturally as possible. Under load, FIG. 8A would deform by flattening to look essentially like FIG. 8 B.
FIGS. 8A and 8B show in frontal plane cross section the essential concept underlying this invention, the theoretically ideal stability plane which is also theoretically ideal for efficient natural motion of all kinds, including running, jogging or walking. For any given individual, the theoretically ideal stability plane 51 is determined, first, by the desired shoe sole thickness (s) in a frontal plane cross section, and, second, by the natural shape of the individual's foot surface 29 .
For the case shown in FIG. 8B , the theoretically ideal stability plane for any particular individual (or size average of individuals) is determined, first, by the given frontal plane cross section shoe sole thickness (s); second, by the natural shape of the individual's foot; and, third, by the frontal plane cross section width of the individual's load-bearing footprint which is defined as the supper surface of the shoe sole that is in physical contact with and supports the human foot sole.
FIG. 8B shows the same fully contoured design when upright, under normal load (body weight) and therefore deformed naturally in a manner very closely paralleling the natural deformation under the same load of the foot. An almost identical portion of the foot sole that is flattened in deformation is also flattened in deformation in the shoe sole. FIG. 8C shows the same design when tilted outward 20 degrees laterally, the normal barefoot limit; with virtually equal accuracy it shows the opposite foot tilted 20 degrees inward, in fairly severe pronation. As shown, the deformation of the shoe sole 28 again very closely parallels that of the foot, even as it tilts. Just as the area of foot contact is almost as great when tilted 20 degrees, the flattened area of the deformed shoe sole is also nearly the same as when upright. Consequently, the barefoot is fully supported structurally and its natural stability is maintained undiminished, regardless of shoe tilt. In marked contrast, a conventional shoe, shown in FIG. 2 , makes contact with the ground with only its relatively sharp edge when tilted and is therefore inherently unstable.
The capability to deform naturally is a design feature of the applicant's naturally contoured shoe sole designs, whether fully contoured or contoured only at the sides, though the fully contoured design is most optimal and is the most natural, general case, as note in the referenced Sep. 2, 1988, Application, assuming shoe sole material such as to allow natural deformation. It is an important feature because, by following the natural deformation of the human foot, the naturally deforming shoe sole can avoid interfering with the natural biomechanics of the foot and ankle.
FIG. 8C also represents with reasonable accuracy a shoe sole design corresponding to FIG. 8B , a naturally contoured shoe sole with a conventional built-in flattening deformation, as in FIG. 14 of the above referenced Sep. 2, 1988, Application, except that design would have a slight crimp at 145 . Seen in this light, the naturally contoured side design in FIG. 8B is a more conventional, conservative design that is a special case of the more generally fully contoured design in FIG. 8A , which is the closest to the natural form of the foot, but the least conventional.
FIGS. 8D-8F show a stop action sequence of the applicant's fully contoured shoe sole during the normal landing and support phases of running to demonstrate the normal functioning of the natural deformation feature. FIG. 8D shows the foot and shoe landing in a normal 10 degree inversion position; FIG. 8E shows the foot and shoe after they have rolled to an upright position; and FIG. 8F shows them having rolled inward 10 degrees in eversion, a normal pronation maximum. The sequence of figures illustrate clearly the natural deformation of the applicant's shoe sole design follows that of the foot very closely so that both provide a nearly equal flattened base to stabilize the foot. Comparing those figures to the same action sequence of FIGS. 8G-8I for conventional shoes illustrates clearly how unnatural the basic design of existing shoes is, since a smooth inward rolling motion is impossible for the flat, uncontoured shoe sole, and rolling of the foot within the shoe is resisted by the heel counter. In short, the convention shoe interferes with the natural inward motion of the foot during the critical landing and support phases of running.
FIG. 9 shows the preferred relative density of the shoe sole, including the insole as a part, in order to maximize the shoe sole's ability to deform naturally following the natural deformation of the foot sole. Regardless of how many shoe sole layers (including insole) or laminations of differing material densities and flexibility are used in total, the softest and most flexible material 147 should be closest to the foot sole, with a progression through less soft 148 to the firmest and least flexible 149 at the outermost shoe sole layer, the bottom sole. This arrangement helps to avoid the unnatural side lever arm/torque problem mentioned in the previous several figures. That problem is most severe when the shoe sole is relatively hard and non-deforming uniformly throughout the shoe sole, like most conventional street shoes, since hard material transmits the destabilizing torque most-effectively by providing a rigid lever arm.
The relative density shown in FIG. 9 also helps to allow the shoe sole to duplicate the same kind of natural deformation exhibited by the bare foot sole in FIG. 1 , since the shoe sole layers closest to the foot, and therefore with the most severe contours, have to deform the most in order to flatten like the barefoot and consequently need to be soft to do so easily. This shoe sole arrangement also replicates roughly the natural barefoot, which is covered with a very tough “seri boot” outer surface (protecting a softer cushioning interior of fat pads) among primitive barefoot populations.
Finally, the use of natural relative density as indicated in this figure will allow more anthropomorphic embodiments of the applicant's designs (right and left sides of FIG. 9 show variations of different degrees) with sides going higher around the side contour of the foot and thereby blending more naturally with the sides of the foot, since those conforming sides will not be effective as destabilizing lever arms because the shoe sole material there would be soft and unresponsive in transmitting torque, since the lever arm will bend. For example, the portion near the foot of the shaded edge area 143 in FIG. 6 must be relatively soft so as not to provide a destabilizing lever arm.
As a point of clarification, the forgoing principle of preferred relative density refers to proximity to the foot and is not inconsistent with the term uniform density as used in U.S. patent application Ser. No. 07/219,387 filed Jul. 15, 1988 and Ser. No. 07/239,667 filed Sep. 2, 1988. Uniform shoe sole density is preferred strictly in the sense of preserving even and natural support to the foot like the ground provides, so that a neutral starting point can be established, against which so-called improvements can be measured. The preferred uniform density is in marked contrast to the common practice in athletic shoes today, especially those beyond cheap or “bare bones” models, of increasing or decreasing the density of the shoe sole, particularly in the midsole, in various areas underneath the foot to provide extra support or special softness where believed necessary. The same effect is also created by areas either supported or unsupported by the tread pattern of the bottom sole. The most common example of this practice is the use of denser midsole material under the inside portion of the heel, to counteract excessive pronation.
FIG. 10 illustrates that the applicant's naturally contoured shoe sole sides can be made to provide a fit so close as to approximate a custom fit. By molding each mass-produced shoe size with sides that are bent in somewhat from the position 29 they would normally be in to conform to that standard size shoe last, the shoe soles so produced will very gently hold the sides of each individual foot exactly. Since the shoe sole is designed as described in connection with FIG. 9 to deform easily and naturally like that of the bare foot, it will deform easily to provide this designed-in custom fit. The greater the flexibility of the shoe sole sides, the greater the range of individual foot size variations can be custom fit by a standard size. This approach applies to the fully contoured design described here in FIG. 8 A and in FIG. 15, U.S. patent application Ser. No. 07/239,667 (filed Sep. 2, 1988), as well, which would be even more effective than the naturally contoured sides design shown in FIG. 10 .
Besides providing a better fit, the intentional undersizing of the flexible shoe sole sides allows for simplified design of shoe sole lasts, since they can be designed according to the simple geometric methodology described in FIG. 27, U.S. patent application Ser. No. 07/239,667 (filed Sep. 2, 1988). That geometric, approximation of the true actual contour of the human is close enough to provide a virtual custom fit, when compensated for by the flexible undersizing from standard shoe lasts described above.
FIG. 11 illustrates a fully contoured design, but abbreviated along the sides to only essential structural stability and propulsion shoe sole elements as shown in FIG. 21 of U.S. patent application Ser. No. 07/239,667 (filed Sep. 2, 1988) combined with the freely articulating structural elements underneath the foot as shown in FIG. 28 of the same patent application. The unifying concept is that, on both the sides and underneath the main load-bearing portions of the shoe sole, only the important structural (i.e. bone) elements of the foot should be supported by the shoe sole, if the natural flexibility of the foot is to be paralleled accurately in shoe sole flexibility, so that the shoe sole does not interfere with the foot's natural motion. In a sense, the shoe sole should be composed of the same main structural elements as the foot and they should articulate with each other just as do the main joints of the foot.
FIG. 11E shows the horizontal plane bottom view of the right foot corresponding to the fully contoured design previously described, but abbreviated along the sides to only essential structural support and propulsion elements. Shoe sole material density can be increased in the unabbreviated essential elements to compensate for increased pressure loading there. The essential structural support elements are the base and lateral tuberosity of the calcaneus 95 , the heads of the metatarsals 96 , and the base of the fifth metatarsal 97 (and the adjoining cuboid in some individuals). They must be supported both underneath and to the outside edge of the foot for stability. The essential propulsion element is the head of the first distal phalange 98 . FIG. 11 shows that the naturally contoured stability sides need not be used except in the identified essential areas. Weight savings and flexibility improvements can be made by omitting the non-essential stability sides.
The design of the portion of the shoe sole directly underneath the foot shown in FIG. 11 allows for unobstructed natural inversion/eversion motion of the calcaneus by providing maximum shoe sole flexibility particularly between the base of the calcaneus 125 (heel) and the metatarsal heads 126 (forefoot) along an axis 120 . An unnatural torsion occurs about that axis if flexibility is insufficient so that a conventional shoe sole interferes with the inversion/eversion motion by restraining it. The object of the design is to allow the relatively more mobile (in inversion and eversion) calcaneus to articulate freely and independently from the relatively more fixed forefoot instead of the fixed or fused structure or lack of stable structure between the two in conventional designs. In a sense, freely articulating joints are created in the shoe sole that parallel those of the foot. The design is to remove nearly all of the shoe sole material between the heel and the forefoot, except under one of the previously described essential structural support elements, the base of the fifth metatarsal 97 . An optional support for the main longitudinal arch 121 may also be retained for runners with substantial foot pronation, although would not be necessary for many runners.
The forefoot can be subdivided (not shown) into its component essential structural support and propulsion elements, the individual heads of the metatarsal and the heads of the distal phalanges, so that each major articulating joint set of the foot is paralleled by a freely articulating shoe sole support propulsion element, an anthropomorphic design; various aggregations of the subdivision are also possible.
The design in FIG. 11 features an enlarged structural support at the base of the fifth metatarsal in order to include the cuboid, which can also come into contact with the ground under arch compression in some individuals. In addition, the design can provide general side support in the heel area, as in FIG. 11E or alternatively can carefully orient the stability sides in the heel area to the exact positions of the lateral calcaneal tuberosity 108 and the main base of the calcaneus 109 , as in FIG. 11 E′ (showing heel area only of the right foot). FIGS. 11A-D show frontal plane cross sections of the left shoe and FIG. 11E shows a bottom view of the right foot, with flexibility axes 120 , 122 , 111 , 112 and 113 indicated. FIG. 11F shows a sagittal plane cross section showing the structural elements joined by very thin and relatively soft upper midsole layer. FIGS. 11G and 11H show similar cross sections with slightly different designs featuring durable fabric only (slip-lasted shoe), or a structurally sound arch design, respectively. FIG. 11I shows a side medial view of the shoe sole.
FIG. 11J shows a simple interim or low cost construction for the articulating shoe sole support element 95 for the heel (showing the heel area only of the right foot); while it is most critical and effective for the heel support element 95 , it can also be used with the other elements, such as the base of the fifth metatarsal 97 and the long arch 121 . The heel sole element 95 shown can be a single flexible layer or a lamination of layers. When cut from a flat sheet or molded in the general pattern shown, the outer edges can be easily bent to follow the contours of the foot, particularly the sides. The shape shown allows a flat or slightly contoured heel element 95 to be attached to a highly contoured shoe upper or very thin upper sole layer like that shown in FIG. 11 F. Thus, a very simple construction technique can yield a highly sophisticated shoe sole design. The size of the center section 119 can be small to conform to a fully or nearly fully contoured design or larger to conform to a contoured sides design where there is a large flattened sole area under the heel. The flexibility is provided by the removed diagonal sections, the exact proportion of size and shape can vary.
FIG. 12 illustrates an expanded explanation of the correct approach for measuring shoe sole thickness according to the naturally contoured design, as described previously in FIGS. 23 and 24 of U.S. patent application Ser. No. 07/239,667 (filed Sep. 2, 1988). The tangent described in those figures would be parallel to the ground when the shoe sole is tilted out sideways, so that measuring shoe sole thickness along the perpendicular will provide the least distance between the point on the upper shoe sole surface closest to the ground and the closest point to it on the lower surface of the shoe sole (assuming no load deformation).
FIG. 13 shows a non-optimal but interim or low cost approach to shoe sole construction, whereby the midsole and heel lift 127 are produced conventionally, or nearly so (at least leaving the midsole bottom surface flat, though the sides can be contoured), while the bottom or outer sole 128 includes most or all of the special contours of the new design. Not only would that completely or mostly limit the special contours to the bottom sole, which would be molded specially, it would also ease assembly, since two flat surfaces of the bottom of the midsole and the top of the bottom sole could be mated together with less difficulty than two contoured surfaces, as would be the case otherwise. The advantage of this approach is seen in the naturally contoured design example illustrated in FIG. 13A , which shows some contours on the relatively softer midsole sides, which are subject to less wear but benefit from greater traction for stability and ease of deformation, while the relatively harder contoured bottom sole provides good wear for the load-bearing areas.
FIG. 13B shows in a frontal plane cross-section at a heel (ankle joint) a quadrant side design the concept applied to conventional street shoe heels, which are usually separated from the forefoot by a hollow instep area under the main longitudinal arch. As shown, the contours are located on the bottom sole 128 only.
FIG. 13F illustrates a horizontal plane cross-section overview of the heel bottom of the shoe sole of FIG. 13 B. As shown, the shoe sole includes a flat bottom 31 b and contoured sides 25 . The heel portion of the shoe sole may include an optional front contour 31 c. FIG. 13F is scaled to represent a shoe sized for a size 10D foot.
FIG. 13C shows a shoe sole construction technique in frontal plane cross section the concept applied to the quadrant sided or single plane design. FIG. 13C includes a midsole and heel lift 127 , an outer or bottom sole 128 and a shoe upper 21 . As illustrated, the contours are located on the bottom sole only. The shaded area 129 of the bottom sole of FIG. 13D identified that portion which should be honeycombed (axis on the horizontal plane or axis of the honeycomb perpendicular to the horizontal plane) to reduce the density of the relatively hard outer outer sole to that of the midsole material to provide for relatively uniform density. FIG. 13D illustrates a frontal plane cross-section at the heel (ankle joint) and is scaled to represent a shoe size for a size 10D foot. FIG. 13D also depicts an edge 100 widened to facilitate bonding of the bottom sole to the midsole.
FIG. 13E shows in bottom view (horizontal plane cross-section) the outline of a bottom sole 128 made from flat material which can be conformed topologically to a contoured midsole of either the one or two plane designs by limiting the side areas to be mated to the essential support areas discussed in FIG. 21 of U.S. patent application Ser. No. 07/239,667, filed Sep. 2, 1988; by that method, the contoured midsole and flat bottom sole surfaces can be made to join satisfactorily by coinciding closely, which would be topologically impossible if all of the side areas were retained on the bottom sole. As illustrated, shoe sole 128 includes a frontal plane cross-section of uniform thickness.
FIGS. 14A-14C , frontal plane cross sections, show an enhancement to the previously described embodiments of the shoe sole stability quadrant invention. As stated earlier, one major purpose of that design is to allow the shoe sole to pivot easily from side to side with the foot 90 thereby following the foot's natural inversion and eversion motion; in conventional designs shown in FIG. 14A , such foot motion is forced to occur within the shoe upper 21 , which resists the motion. The enhancement is to position exactly and stabilize the foot, especially the heel, relative to the preferred embodiment of the shoe sole; doing so facilitates the shoe sole's responsiveness in following the foot's natural motion. Correct positioning is essential to the invention, especially-when the very narrow or “hard tissue” definition of heel width is used. Incorrect or shifting relative position will reduce the inherent efficiency and stability of the side quadrant design, by reducing the effective thickness of the quadrant side 26 to less than that of the shoe sole 28 b. As shown in FIGS. 14B and 14C , naturally contoured inner stability sides 131 hold the pivoting edge 41 of the load-bearing foot sole in the correct position for direct contact with the flat upper surface of the conventional shoe sole 22 , so that the shoe sole thickness (s) is maintained at a constant thickness (s) in the stability quadrant sides 26 when the shoe is everted or inverted, following the theoretically ideal stability plane 51 .
The form of the enhancement is inner shoe sole stability sides 131 that follow the natural contour of the sides 91 of the heel of the foot 90 , thereby cupping the heel of the foot. The inner stability side 131 can be located directly on the top surface of the shoe sole and heel contour, or directly under the shoe insole (or integral to it), or somewhere in between. The inner stability sides are similar in structure to heel cups integrated in insoles currently in common use, but differ because of its material density, which can be relatively firm like the typical mid-sole, not soft like the insole. The difference is that because of their higher relative density, preferably like that of the uppermost midsole, the inner stability sides function as part of the shoe sole, which provides structural support to the foot, not just gentle cushioning and abrasion protection of a shoe insole. In the broadest sense, though, insoles should be considered structurally and functionally as part of the shoe sole, as should any shoe material between foot and ground, like the bottom of the shoe upper in a slip-lasted shoe or the board in a board-lasted shoe.
The inner stability side enhancement is particularly useful in converting existing conventional shoe sole design embodiments 22 , as constructed within prior art, to an effective embodiment of the side stability quadrant 26 invention. This feature is important in constructing prototypes and initial production of the invention, as well as an ongoing method of low cost production, since such production would be very close to existing art.
The inner stability sides enhancement is most essential in cupping the sides and back of the heel of the foot and therefore is essential on the upper edge of the heel of the shoe sole 27 , but may also be extended around all or any portion of the remaining shoe sole upper edge. The size of the inner stability sides should, however, taper down in proportion to any reduction in shoe sole thickness in the sagittal plane.
The same inner shoe sole stability sides enhancement as it applies to the previously described embodiments of the naturally contoured sides design. The enhancement positions and stabilizes the foot relative to the shoe sole, and maintains the constant shoe sole thickness (s) of the naturally contoured sides 28 a design, The inner shoe sole stability sides 131 conform to the natural contour of the foot sides 29 , which determine the theoretically ideal stability plane 51 for the shoe sole thickness (s). The other features of the enhancement as it applies to the naturally contoured shoe sole sides embodiment 28 are the same as described previously under FIGS. 14A-14C for the side stability quadrant embodiment. It is clear that the two different approaches, that with quadrant sides and that with naturally contoured sides, can yield some similar resulting shoe sole embodiments through the use of inner stability sides 131 . In essence, both approaches provide a low cost or interim method of adapting existing conventional “flat sheet” shoe manufacturing to the naturally contoured design described in previous figures.
Thus, it will clearly be understood by those skilled in the art that the foregoing description has been made in terms of the preferred embodiment and various changes and modifications may be made without departing from the scope of the present invention which is to be defined by the appended claims.
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A shoe sole having at least one midsole or outer surface portion that is concavely rounded relative to a space inside the shoe adapted to receive an intended wearer's foot. The sole includes a midsole and an outer sole. The midsole extends up the side of the sole to a vertical height above the vertical height of a lowest point of the inner midsole surface. The midsole includes a portion of greatest thickness in a side portion that is greater than a thickness of a second midsole portion located in a middle sole portion of the shoe sole. The combination of the midsole height and thickness with the concavely rounded surface portion together provide improved stability of the shoe sole.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to an apparatus for control of operation of an intake or exhaust valve means in an internal combustion engine primarily for use in a vehicle.
The applicants in this application have disclosed in Japanese Patent Application No. 141715/Showa 56 (1981) (not prior art herein) a cylinder of an internal combustion engine with at least two intake or exhaust valves, in which either one of the two valves is provided with a pause means for stopping the opening and closing of the valve and keeping the same in its closed position so that the engine output characteristics may be improved. The pause means is operated when the engine is in its low speed range. In the apparatus the engine speed and the throttle valve open degree are detected as analog signals and the pause means is controlled in operation in accordance with a predetermined data matrix. This analog type arrangement, however, is inconvenient in that it is necessary to provide a CPU (Central Processing Unit) as a control means and consequently the apparatus is expensive.
SUMMARY OF THE INVENTION
The present invention is directed to a valve operation control apparatus for use in an internal combustion engine. The device comprises a cylinder with at least two intake or two exhaust valves, one of the two valves including a pause means for holding the valve in a closed position. The control apparatus comprises a control circuit operatively coupled to the pause means. The control circuit has at least two open degree sensors responsive to two different degrees of opening of a throttle valve of the engine and at least two engine speed sensors responsive to two different speeds of the engine, wherein the control circuit controls the operation of the pause means in response to predetermined combinations of the operation of the open degree sensors and the engine speed sensors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of one embodiment of the present invention.
FIG. 2 is a sectional side view of a pause means of the present invention.
FIG. 3 is a diagram control circuit thereof, and
FIG. 4 is a diagram showing engine output characteristics thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an internal combustion engine of a vehicle has a cylinder 1 with two intake valves 2 on one side thereof and two exhaust valves 3 on the other side thereof. Intake cam 4 is provided above the intake valves on the one side for driving each intake valve 2 and an exhaust cam 5 is provided above the exhaust valves 3 on the other side for driving each exhaust valve 3.
One of the two intake valves 2, that is, the valve 2 positioned on the upper side as viewed in FIG. 1 has a pause means 6 for stopping the opening and closing operations of the valve and keeping the valve in its closed position. Additionally, one of the two exhaust valves 3, that is, the valve 3 on the upper side in FIG. 1, has a pause means 7 for stopping the opening and closing operations of the valve and keeping the valve in its closed position. Thus, if the two pause means 6 and 7 are operated, the intake and exhaust of cylinder 1 are effected through only the intake valve 2 on the lower side and the exhaust valve 3 on the lower side as viewed in FIG. 1.
As shown clearly in FIG. 2, the pause means 6 comprises an electromagnetic valve 6a arranged to be closed on energization thereof. When the valve 6a is opened, a control cylinder 10 for supporting, through a spring 9, a pivot point 8a of a rocker arm 8 on the upper side of the valve 2 is opened at its outlet opening 11, and thereby pressurized oil introduced into the cylinder 10 through an inlet opening 12 is discharged through the outlet opening 11. Thus the internal pressure in the cylinder 10 is decreased and the resilient force of the spring 9 on the upper side thereof is decreased, whereby the arm 8 moves downwards at its pivot point 8a so as to be brought into its inoperative condition. In other words, when the valve 6a is opened, operation of the valve 2 on the upper side is stopped from opening and closing and is held in its closed position. This operation is similarly applicable to the pause means 7 which also comprises an electromagnetic valve 7a arranged to be closed on energization thereof.
According to the present invention, there is provided a control means for controlling the operations of the pause means 6 and 7. One example thereof is as shown in FIG. 3. Namely, the control means comprises a control circuit 13 with at least two open degree sensors 14 responsive to two different degrees of openings of a throttle valve of the engine and at least two engine speed sensors 15 responsive to two different speeds of revolution of the engine.
The at least two open degree sensors 14 comprise a sensor 14a which is a switch that closes when the throttle valve is in a full open condition which is a large open degree, a sensor 14b which is a switch that closes when the throttle valve is in a half (1/2) open condition which is a middle open degree and a sensor 14c which is a switch which closes when the throttle valve is a quarter (1/4) open which is a small open degree. The at least two speed sensors 15 comprise a sensor 15a which is a switch that closes when the engine is at a comparatively high speed N e1 , for instance, above 8000 rpm and a sensor 15b which is a switch that closes when the engine is at a comparatively low speed N e2 , that is, above 5000 rpm, for instance. The large open degree sensor 14a and the small open degree sensor 14c are connected in parallel with each other and in series with the high speed sensor 15a, and in parallel therewith the middle open degree sensor 14b is connected to the low speed sensor 15b. The sensors are connected in a circuit with a relay 17 having a relay contact 17a connected between the electromagnetic valves 6a and 7a and an electric power source 16.
In operation, the output characteristics of the engine in the inoperative condition of the pause means 6 and 7 are changed in accordance with a change in throttle valve open degree, as for example shown by a curve A 1 , a curve B 1 and a curve C 1 in FIG. 4, respectively, at full open degree, 1/2 open degree and 1/4 open degree. When the pause means 6 and 7 are in their operating conditions, the characterstics are shown by a curve A 2 , a curve B 2 and a curve C 2 , respectively, in FIG. 4.
At the full open degree and at the 1/4 open degree, by a combination of each of the large open degree sensor 14a and the small open degree sensor 14c with the high speed sensor 15a, the pause means 6 and 7 are brought into their operative conditions in a low speed range which is below the speed N e1 . In accordance therewith the output characteristics are changed from the curves A 1 and C 1 to the curves A 2 and C 2 , respectively and consequently are improved on the lower speed side. At the 1/2 open degree, by a combination of the middle open degree sensor 14b with the low speed sensor 15b, the pause means 6 and 7 are similarly brought into their operative conditions in a low speed range which is below the speed N e2 , and in accordance therewith the output characteristics are changed from the curve B 1 to the curve B 2 , and consequently improved on the low side. Thus, at each throttle open degree, the higher characteristic is selected from the operative conditions of the pause means 6 and 7 and the inoperative conditions of the pause means 6 and 7, in relation to a change in engine speed can be obtained.
In the case where the open degree sensor 14 and the engine speed sensor 15 with the throttle valve being at the 1/2 open degree, for instance, are combined together as described above to obtain a higher engine output over the whole speed range, the output characteristics are increased as shown by the curve B 1 until the engine speed is decreased below the speed N e2 , and consequently this makes one's deceleration feeling unsatisfactory. For improving this unsatisfactory deceleration feeling, in the illustrated example, at least two negative pressure sensors 18 responsive to two different intake negative pressures of the engine are incorporated in the control circuit 13 so that the combinations between the open degree sensor 14 and the speed sensor 15 may be varied thereby. In the example, the above-mentioned at least two negative pressure sensors 18 comprise a sensor 18a which is a switch that closes at a comparatively high negative pressure and a sensor 18b which is a switch that closes at a comparatively low negative pressure. The sensor 18b is connected between the middle open degree sensor 14b and the low speed sensor 15b, and the sensor 18a is connected in a circuit connected between the middle open degree sensor 14b and the high speed sensor 15a.
With this arrangement, at the time of accelerating with the throttle valve being at the 1/2 open degree, when the middle open degree sensor 14b and the low speed sensor 15b are coupled together by closing the sensor 18b due to the increase in intake negative pressure, and the speed reaches above the speed N e2 , the characteristics are changed from the curve B 2 to the curve B 1 and consequently the feeling of acceleration is improved. On the other hand, at the time of decelerating with the same throttle valve opening condition, when the middle open degree sensor 14b and the high speed sensor 15a are coupled together by closing of the sensor 18a due to a decrease in intake negative pressure, and the speed falls below the speed N e1 , the output characteristics are changed from the curve B 1 to the curve B 2 , and consequently the feeling of deceleration is improved.
In the above-described arrangement, when applied to an engine for a vehicle, if the engine is revved up when the vehicle is stopped, the engine switches between its idling operation and its high speed operation, and the operations of the pause means 6 and 7 are repeated each time the engine speed is in a low speed range. This is not only wasteful but also deteriorates the durability of the means 6 and 7. For preventing this, a vehicle speed sensor 19 is provided which is responsive to a comparatively low driving speed of a vehicle, so that the pause means 6 and 7 may be held in their operating conditions by the operation of the sensor 19 without being controlled by the control circuit 13. Additionally, when the pause means 6 and 7 are an oil pressure operated type as described above, and the engine is at a comparatively low temperature, the oil for operating means 6 and 7 becomes comparatively high in viscosity, and consequently if the means 6 and 7 are repeatedly switched between operative and inoperative modes, a poor responsive property occurs and the shock on the means 6 and 7 is increased. Also the durability thereof is liable to be deteriorated. For preventing this, in the illustrated embodiment, a temperature sensor 20 responsive to a comparatively low engine temperature is provided, so that when the sensor 20 is operated, the means 6 and 7 may be held in their operating conditions, without being controlled by the control circuit 13.
The vehicle speed sensor 19 is a switch which is opened when the vehicle speed is below 15 km/h, for instance, and the temperature sensor 20 is a switch which is opened when the oil temperature corresponding to the engine temperature is below 40° C., for instance. The sensors 19 and 20 are connected in series to one with another, in a power circuit between the control circuit 13 and the relay 17. Thus, when the vehicle is in its stopped condition or the engine temperature is low, the means 6 and 7 are held in their operating conditions owing to cutting off of the electric current flowing to the relay 17 by the opening of the sensors 19, 20, and thereby a change between operative and inoperative conditions as described above by the control circuit 13 cannot be made.
Thus, according to this invention, the control circuit has at least two open degree sensors responsive to two different open degrees of a throttle valve and at least two speed sensors responsive to two different engine speeds. The control circuit controls the operation of a pause means by predetermined combinations of the open degree sensors and the speed sensors.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are, therefore, to be embraced therein.
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The present invention is directed to a valve operation control apparatus for use in an internal combustion engine. The device comprises a cylinder with at least two intake or two exhaust valves, one of the two valves including a pause member for holding the valve in a closed position. The control apparatus comprises a control circuit operatively coupled to the pause member. The control circuit has at least two open degree sensors responsive to two different degrees of opening of a throttle valve of the engine and at least two engine speed sensors responsive to two different speeds of the engine, wherein the control circuit controls the operation of the pause member in response to predetermined combinations of the operation of the open degree sensors and the engine speed sensors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject of the present invention is a valve and, in particular, a valve that can be controlled to deliver a pulsed flow of gas at its outlet.
The expression “pulsed flow” is to be understood as meaning that this flow alternates between a high level and a low level during predetermined periods of time resulting from the application of a control signal, generally in the form of square waves
2. Description of the Related Art
Valves which can be controlled to make them supply a pulsed flow at their outlet may find numerous applications, particularly in installations for the pulsed supply to burners of the oxyfuel type. An installation such as this is described in particular in document EP 524 880.
As mentioned in that document, it has in fact been demonstrated that if a burner were to be supplied with a pulsed flow, at least as regards either its fuel or its oxygen supply, it would be possible to obtain a very significant reduction in the nitrogen oxide content of the residual flue gases from the burner. A valve may be fitted to the fuel, particularly natural gas, supply or to the pipe supplying the oxygen supply, typically oxygen, or to both pipes, depending on the installation. As is also described in the aforementioned document, the pulsation frequency is preferably below 1 Hz. Furthermore, in order to obtain a significant effect of reducing the oxides of nitrogen produced, it is necessary for the flow rate or pressure of pulsed gas to have a shape as close as possible to the square waves corresponding to the signals used to control the valve or valves used.
Such valves can also be used for supplying burners with air by way of a source of oxygen.
Depicted in the appended FIGS. 1 a and 1 b is one example of a control signal S for controlling the electrically operated valve as a function of time, and the curve of gas pressure P delivered at the outlet of the valve receiving this control signal. FIG. 1 a depicts the control signal S which has a first high level during periods T 1 , known as the open level, and a low level during periods T 2 , known as the closed level. The periods T 1 and T 2 are usually equal. FIG. 1 b depicts the pressure of the gas at the outlet of the valve in a temporal relationship with the control signal S. The pressure level corresponding to the closed control signal has been labelled C and the pressure difference between the open and closed signals has been labelled Q. It can be seen from this figure that during the periods corresponding to the application of the open signal, the pressure is not strictly in the shape of a square wave but has an inclined rising edge F 1 , a falling edge F 2 which is also inclined and, while the open signal is applied, the pressure is not constant. As has been mentioned, it is desirable for the shape of the pressure waves to be as rectangular as possible.
Another problem in supplying a pulsed flow lies in the fact that these valves are used and controlled a great many times during the period that the burner is operating. It is therefore necessary that the valve should not only be as near as possible to a perfect square wave, but also for it to have very good repeatability in terms of the opening pressure and closure pressure of the fluid delivered over time.
In an attempt at solving this problem, a valve described in particular in American Patent U.S. Pat. No. 5,222,713 has already been proposed. The flow control element of this valve consists of a part whose periphery is deformable, thus making it possible, depending on the stress applied to it, to allow the fluid to pass or to interrupt its passage. The actuator allowing the pulsed deformation of this component is, for example, a piezoresistive element controlled electrically according to the desired pulsation frequency. However, it has become apparent that the deformation of the element constituting the shutter element of the valve alters with use and is not very repeatable from one valve to another, particularly as far as the flow rates corresponding respectively to the open and to the closed states are concerned.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a controllable valve, particularly for delivering a pulsed flow, which has an outlet curve in terms of flow or in terms of pressure which is approximately in the form of rectangular square waves and which, moreover, has satisfactory repeatability, particularly as far as the flow rate or pressure supplied in the open state and in the closed state are concerned.
In order to achieve this objective according to the invention, the controllable valve particularly for delivering a pulsed flow of fluid, comprises:
a valve body;
a valve seat dividing the inside of the valve body into a fluid inlet chamber and an outlet chamber;
a valve shutter element capable of moving in one direction of travel to collaborate with the valve seat;
an actuator comprising a stationary control part for receiving control signals and a moving part, the said stationary part applying to the moving part a force which corresponds to the control signal;
first rigid means of connection extending in the direction of travel so as to connect the said moving part of the actuator to the said valve shutter element;
a mechanical stop;
a member that can be compressed under the effect of a force applied to it, comprising a first end secured to the said mechanical stop; and
second rigid means for dynamically connecting one of the faces of the said valve shutter element to the second end of the said compressible member.
It will be understood that, on the one hand, since the open and closed flow rates respectively are defined by a rigid seat and by a rigid valve shutter element, these flow rates are intrinsically perfectly stable over time. It will also be understood that, when the control signal is no longer applied to the stationary part of the actuator, the shutter element moves in one direction or the other depending on the embodiment in question, not only under the effect of the cancellation of the corresponding force but also under the effect of the release of the compressible member which was previously compressed. It will be understood that by using a compressible member which has properties which are very stable over time, it will be possible to obtain very uniform valve operation. Furthermore, it is understood that the rising or falling edges will be improved by comparison with the known solutions, because of the action of the compressible member
According to a first embodiment, the second rigid means of connection connect to the second end of the compressible member that face of the valve shutter element which faces towards the valve seat.
According to a second embodiment, the second rigid means of connection connect to the second end of the compressible member that face of the valve shutter element which does not face towards the valve seat, the said second rigid means including the said first rigid means of connection.
It will be understood that, according to the first embodiment, in the absence of a control signal, the valve shutter element returns spontaneously to its open position under the effect of the compressible member. By contrast, in the second embodiment, the valve shutter element returns to its closed position under the effect of the release of the compressible member. As will be indicated later on, the term “closed position” must not be taken as necessarily meaning that the shutter element is pressed against its seat in such a way that the flow rate is effectively zero, but as meaning a position of the shutter element such that the flow rate supplied is low by comparison with the flow rate supplied in the open position.
As a preference, the compressible member consists of a part made of elastomeric material chosen for the consistency of its compressibility characteristics, this part having two parallel faces which are interposed directly or indirectly between the mechanical stop and the shutter element.
The invention also relates to a method of combustion in which a flow of oxidizing agent and a flow of fuel are injected into a furnace, in which the oxidizing agent and the fuel react with one another to produce a flame capable of heating a charge. According to the invention, this method is characterized in that the flow of oxidizing agent and/or the flow of fuel is or are injected in a pulsed manner using a pulsing valve as described in the text of this specification.
As a preference, at least one pulsing valve is used to inject fuel and at least one pulsing valve is used to inject oxidizing agent, the pulsations being identical (or different) in terms of duration but in phase opposition. According to another alternative form of the invention, the pulsations have the same duration (or different durations) but are in phase.
According to another alternative form of the invention, in which there are at least two separate injections of oxidizing agent, using identical or different oxidizing agents chosen from oxygen, substantially pure oxygen, (and particularly oxygen delivered by an apparatus for separating the gases in the air, operating by adsorption, also known as VSA or “vacuum swing adsorption”, particularly containing at least 88% of oxygen, about 2 to 5% of argon, and any remainder being 0 to 10% of nitrogen) oxygen-enriched air, air or oxygen-impoverished air, at least one of the two injections being carried out using a pulsing valve. In general, the invention also relates to the use of a pulsing valve as defined in this specification for pulsing an oxidizing gas and/or fuel.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
Other features and advantages of the invention will become better apparent from reading the description which follows of a number of embodiments of the invention which are given by way of non-limiting example. The description makes reference to the appended drawings in which:
FIGS. 1 a and 1 b, already described, show the control signal S and the pressure of the fluid delivered by the valve, respectively;
FIGS. 2 a and 2 b show, in diagrammatic form, one first embodiment of the valve in the closed position and in the open position, respectively;
FIGS. 3 a and 3 b show a skeleton diagram of a second embodiment of the valve which is depicted in the closed position and in the open position, respectively;
FIGS. 4 a and 4 b show a preferred embodiment of the valve in greater detail in the open position and in the closed position, respectively, and corresponding to the principle of the valves shown in FIGS. 3 a and 3 b; and
FIGS. 5 a and 5 b show curves expressing the pressure of the fluid at the outlet of the valve depicted in FIGS. 4 a and 4 b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the valve will be described referring first of all to FIGS. 2 a and 2 b . This valve consists of a valve body 10 comprising a seat 12 which divides the inside of the valve body into an inlet chamber 14 and an outlet chamber 16 for the fluid. The chambers 14 and 16 are equipped respectively with an inlet pipe 18 and with an outlet pipe 20 which open into the lateral wall 10 a of the valve body. The valve also comprises a valve shutter element 22 capable of moving along the axis X-X′ of the valve body. This shutter element is of course intended to collaborate with the seat 12 to define the flow rate through the valve according to the position of the shutter element. The shutter element 22 is connected by its face 22 a away from the seat 12 to an actuator 24 . The actuator 24 consists of a stationary control part 26 consisting, for example, of an induction coil powered with a control voltage and of a moving part 28 which, for example, is an electromagnetic core plunger. The face 22 a of the shutter element is connected to the core plunger 28 by a rigid rod 30 which passes through the end wall 32 of the valve body. As a preference, this penetration is equipped with a sealing boot 34 . The core plunger 28 is extended by a second rigid rod 36 , the end 36 a of which collaborates with the first end 38 a of a compressible member 38 . The second end 38 b of the compressible member 38 is pressed against a mechanical stop 40 .
It will be understood that the position of the valve shutter element 22 with respect to the seat 12 and therefore the through flow rate depend on the combination of the axial force produced by the coil 26 , applied to the core plunger 28 and referenced F, and of the compression force F′ of the compressible member.
It will also be understood that the force F applied to the core plunger 28 of course depends on the control voltage V applied to the coil 26 . For the position of the shutter element corresponding to the minimum flow rate which, as has already been explained, is not necessarily zero, a voltage V m is applied such that the combination of the forces F and F′ produces the desired position of the shutter element. As a preference, the control voltage V m is zero. By contrast, as FIG. 2 b shows, when the control voltage V M corresponding to the open position is applied, the resultant of the forces F and F′ is such that the shutter element 22 is moved away from its seat to produce the maximum flow rate.
It will also be understood that, in this embodiment, the closure of the valve, or more specifically the arrival of the shutter element in its minimum-flow-rate position, results not only from the change in control voltage corresponding to the control signal S, but also from the action of the compressible member 38 . Very quick valve closure is thus achieved. By contrast, the opening of the valve is simply the result of the action of the force F applied to the core plunger to compress the compressible member 38 .
In the embodiment depicted in FIGS. 3 a and 3 b , we see again the valve body 10 with its upper chamber 14 and lower chamber 16 , its valve seat 12 and its moving shutter element 22 . The face 22 a of the shutter element away from the seat 12 is still connected by a rigid rod 30 to the moving core plunger 28 of the actuator 24 . The other face 22 b of the shutter element is connected to the first end 38 a of the compressible member 38 by a rigid rod 36 ′, the other end 38 b of the compressible member 38 being pressed against the mechanical stop 40 ′.
It will be understood that, in this second embodiment, when the control voltage is equal to V M , the shutter element 22 is brought closer to its seat 12 and the compressible member 38 is compressed. By contrast, when the control voltage V m is applied, the force applied to the core plunger 28 is smaller and the shutter element 22 moves away from the seat 12 , allowing the compressible member 38 to expand. It will be understood that, in this embodiment, closure is obtained simply by applying the electromagnetic force of the actuator, which also compresses the compressible member 38 . By contrast, valve opening is associated both with the change in control voltage and with the return of the compressible member 38 to its state of rest.
The so-called open and closed positions still result from the antagonistic effect of the force applied to the core plunger of the actuator and of the force developed by the compressible member. By appropriately adjusting the force applied to the core plunger, that is to say by appropriately adjusting the control voltage applied to the coil 26 , different open and closed positions which will be perfectly repeatable can thus be defined. As will be explained later on, it is also possible to envisage for the mechanical stop 40 or 40 ′ to be adjustable.
In FIGS. 2 and 3, the compressible member 38 consists of a coil spring, the axis of compression of which coincides with the axis of travel of the shutter element. It is also possible, as will be explained in greater detail later on, to use a part made of compressible material which has a very stable and very repeatable curve of compression as a function of applied force. It will also be understood that the choice between the two embodiments described previously will be made on the basis of whether it is more appropriate to have a high valve closure speed or a high valve opening speed.
It should also be added that the actuator may be a double-acting actuator, that is to say that the two control voltages cause the core plunger 28 to move in opposite directions with respect to the position of rest corresponding to a zero control voltage.
One preferred embodiment of the second type of valve depicted in FIGS. 3 a and 3 b will now be described in greater detail with reference to FIGS. 4 a and 4 b . That figure again shows the inlet chamber 14 , the outlet chamber 16 and the respective inlet pipe 18 and outlet pipe 20 , occupying lateral positions with respect to the longitudinal axis X-X′ of the valve body. The valve seat consists of a plate 50 pierced with an orifice 52 , the lateral wall 54 of which has the shape of a cone frustum of axis X-X′. As a preference, the half-angle a of this cone frustum, the vertex of which points towards the outlet chamber 16 , is at least equal to 45 degrees. Likewise, FIG. 4 a depicts a preferred embodiment of the shutter element of this valve, which carries the reference 56 . The face 56 a of the shutter element, facing towards the seat, is approximately flat, whereas its other face 56 b also has the overall shape of a cone frustum, the vertex of which cone would be in the inlet chamber 14 . The half-angle b of the cone frustum forming the face 56 b of the shutter element is of the order of 60 degrees.
The particular shape given to the seat 52 and to the shutter element 56 makes it possible, on the one hand, to stabilize the flow around the shutter element and, on the other hand, to have a faster change in passage cross section for the fluid between the two chambers when the shutter element 56 is moved away from this seat. These arrangements encourage straighter and more upright pulsed pressure waves rising and falling edges.
As FIGS. 4 a and 4 b show, the valve body 10 is preferably made in two parts, an upper part 60 which corresponds to the inlet chamber 14 , and a lower part 62 corresponding to the outlet chamber 16 . The seat 12 is machined in a plate 64 , the periphery 64 a of which is trapped between the upper part 60 and lower part 62 of the valve body, these two parts being assembled by any appropriate means. It is thus possible for the two parts forming the valve body to be taken apart to extract the plate 64 and replace it with another one in which a seat of different dimensions has been machined. In addition, it is envisaged for the shutter element 22 to be detached from the rod 30 such that it can be disassembled. It is then possible for different seat/shutter element assemblies to be fitted in the valve to correspond to different flow rates.
In this embodiment, the position of the mechanical stop 40 ′ supporting the compressible member 38 is adjustable with respect to the end 42 of the valve body. As a preference, the valve comprises a second axial mechanical stop 44 , also adjustable, which can collaborate with a peg 46 which is an extension of the core plunger 28 . This second mechanical stop defines the valve wide-open position. By altering the value of the opening voltage V m , it is possible to define other open positions of the valve, which are of course not as wide open as this wide-open position.
Elastomeric springs of the EFFBE type produced by CEF based on chloroprene or polyurethane may be used to make the compressible member. These “springs” have a compression rate of 30 to 40%. They consist of a single ring or of two superposed rings. As they display residual deformation, it is desirable to envisage a fixture that allows a preload suited to this residual deformation.
FIGS. 5 a and 5 b show the pulsed flows obtained with the electrically operated valve described in conjunction with FIGS. 4 a and 4 b . In these figures, the time is shown on the abscissa axis and the ordinate axis shows a parameter P representing the pressure at the outlet of the valve as measured with a pressure sensor. In the example under consideration, the frequency is 0.5 hertz. FIG. 5 a shows a pressure signal with almost vertical rising and falling edges. In the case of FIG. 5 b , the square waves have rising and falling edges which are less vertical while remaining acceptable, but have very good consistency of the “high” and “low” levels. The difference between these curves is the result of the different amount of preload applied to the elastomeric part. In the known solutions, the control signal is of the “square wave” type, as depicted in FIG. 1 a.
According to an alternative implementation of the invention, it is possible to alter the shape of the electric control signal so as to further improve the rising and falling edges of the pressure wave at the valve outlet. In particular, it may be envisaged for the voltage, for a brief period of time during valve opening, to reach a value higher than the “open” state control value, as this further “accelerates” valve opening. Likewise, during valve closure, it may be envisaged for the control voltage, for a brief period of time, to drop to a value below the “closed” state control voltage value, as this accelerates valve closure.
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The invention relates to a controllable valve, particularly for delivering a pulsed flow of fluid.
It comprises a valve body ( 10 ); a valve seat ( 12 ) dividing the inside of the body into an inlet chamber ( 14 ) and an outlet chamber ( 16 ); a valve shutter element ( 22 ) capable of moving; an actuator ( 24 ) comprising a stationary control part ( 26 ) for receiving control signals and a moving part ( 28 ); first rigid means of connection ( 30 ) for connecting the said moving part of the actuator ( 28 ) to the said shutter element ( 22 ); a mechanical stop ( 40′ ); a member ( 38 ) that can be compressed under the effect of a force applied to it, comprising a first end secured to the said mechanical stop; and second rigid means ( 36′ ) for dynamically connecting one of the faces of the said shutter element ( 22 b ) to the second end of the said compressible member ( 38 ).
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This is a continuation of application Ser. No. 510,844, filed July 5, 1983, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a final texture annealing cycle to promote improved secondary recrystallization. Particularly, the invention relates to a substantially isothermal anneal at a selected recrystallization temperature.
In the manufacture of grain-oriented silicon steel, it is known that if improved secondary recrystallization texture, e.g., Goss texture (110)[001], is achieved, the magnetic properties, particularly permeability and core loss, will be correspondingly improved. The Goss texture (110)[001], in accordance with Miller's indices, refers to the body-centered cubes making up the grains or crystals being oriented in the cube-on-edge position. The texture or grain orientations of this type refers to the cube edges being parallel to the rolling direction and in the plane of rolling, and the cube face diagonals being perpendicular to the rolling direction and in the rolling plane. As is well known, steel having this orientation is characterized by a relatively high permeability in the rolling direction and a relatively low permeability in a direction at right angles thereto.
The development of a cube-on-edge orientation is dependent upon a mechanism known as secondary recrystallization. During recrystallization, secondary cube-on-edge oriented grains are preferentially grown at the expense of primary grains having a different and undesirable orientation. The steel composition, particularly the impurity contents, the processing operations including hot rolling and the degree of deformation in each cold-rolling operation, intermediate and final continuous annealing time and temperature cycles, and the final texture annealing procedure must all be carefully controlled to attain the optimum texture development. A steel that has not obtained optimum texture development may have a substantially uniform but inadequate grain size and structure and resulting poor magnetic properties or may exhibit a "banding" of inferior grain structure. Generally, banding means areas or bands of inferior grain structure extending across the width of the coil surrounded by areas of well-textured steel. Generally, the initial phases of secondary recrystallization occur at about 1550° F. (843° C.), however, secondary grain growth proceeds much faster and more efficiently at temperatures of about 1600° F. (871° C.) or more. The operation through which the secondary grains are preferentially grown and consume the primary grains is known as final texture annealing.
In the manufacture of grain-oriented silicon steel, the typical steps include subjecting the melt of 2.5-4% silicon steel through a casting operation, such as a continuous casting process, hot rolling the steel, cold rolling the steel to final gauge with an intermediate annealing when two or more cold rollings are used, decarburizing the steel, applying a refractory oxide base coating to the steel, and final texture annealing the steel, such as in a hydrogen atmosphere, to produce the desired secondary recrystallization, and purification treatment to remove impurities, such as nitrogen and sulfur. The final texture annealing is typically performed at a temperature in excess of 2000° F. (1093° C.) and held for an extended time period of at least 4 hours and generally longer to remove impurities.
A typical thermal cycle of the final texture annealing practice may include a reasonably continuous heating rate of approximately 50° F./hour (27.8° C./hour) from the charge temperature of the coated strip to a temperature high enough to effect purification. The charge temperature in mill practice, typically, is on the order of room temperature of 80° F. (26.7° C.) or more and the purification temperature may range from 2000° F. (1093° C.) up to a maximum of about 2300° F. (1260° C.) and preferably up to 2250° F. (1232° C.). The steel is generally subjected to a soaking at the purification temperature to remove the impurities for a long time, typically on the order of about 20 hours at or higher than 2100° F. (1150° C.).
Numerous attempts by others have been made to improve the final texture. U.S. Pat. No. 2,534,141--Morrill et al discloses a two-stage final texture anneal to improve the orientation. First, the decarburized sheet is held for 4-24 hours at 850°-900° C. (1560°-1650° F.), and preferably at 875° C. (1605° F.), in a reducing or nonoxidizing atmosphere to encourage and permit nucleation of well-oriented crystals and their growth. Second, the steel is then held at a temperature at 900° to 1200° C. (1650°-2192° F.), and preferably 1175° C. (2147° F.) in a reducing atmosphere to permit completion of the growth of the well-oriented crystals and to relieve mechanical strain.
U.S. Pat. No. 4,157,925--Malagari et al discloses a process for producing a cube-on-edge orientation in a boron-inhibited silicon steel. The process includes heating the steel from a temperature of 1700° to 1900° F. (926° to 1038° C.) at an average rate of less than 30° F./hour (16.7° C./hour) so as to provide a minimum time period for the selective grain-growth process to occur and to final texture anneal the steel by heating to a temperature in excess of 2000° F. (1093° C.) and to a maximum temperature of 2300° F. (1260° C.) for purification of the steel.
U.S. Pat. No. 4,318,738--Kuroki et al discloses in Example 3 a method for producing grain-oriented silicon steel containing aluminum wherein the decarburized and coated sheet is heated up to 900° C. (1650° F.) in a 75% H 2 and 25% N 2 atmosphere with a heating rate of 20° C./hour (36° F./hour), then heating between 900° to 1050° C. (1650°-1922° F.) in the same atmosphere at a heating rate of 5° C./hour (9° F./hour), between 1050° and 1200° C. (1922°-2192° F.) in 100% H 2 atmosphere at a heating rate of 20° C./hour (36° F./hour) where the steel is maintained at 1200° C. (2192° F.) for 20 hours in the 100% H 2 atmosphere.
None of these patents disclose the present invention. What is needed is an improved final texture annealing process wherein improved cube-on-edge orientation of the secondary grains may be achieved during secondary recrystallization to result in improved permeability and core loss values. The improved final texture annealing process should include control of the heating cycle and result in improved productivity as measured by an overall improvement in quality.
It is known that variations occur in magnetic properties within a given coil of silicon steel. The variations can be measured by taking samples from the coil ends and measuring the core loss values of those samples. A convenient measure of quality improvement is the percentage of coils having a poor end core loss at 60 Hz equal to or less then 0.714 WPP at 17 KG (1.57 WPKg at 1.7 Tesla). It is desirable to improve productivity so that an increasing percentage, and preferably the majority, of the coils produced satisfy minimum core loss values, such as that above.
It is also an objective to develop a process which substantially eliminates the "banding" problem.
SUMMARY OF THE INVENTION
In accordance with the present invention, a process is provided for producing electromagnetic silicon steel having cube-on-edge orientation wherein the process includes the conventional steps of preparing a steel melt containing 2.5-4% silicon, casting the steel, hot rolling the steel, cold rolling the steel to final gauge, decarburizing the steel, applying a refractory oxide base coating to the steel, and final texture annealing the steel by heating to and maintaining at a temperature in excess of 2000° F. The improvement comprises heating the steel during the final texture annealing to a selected recrystallization temperature within the range of 1600° to 1700° F., substantially isothermally heating the steel at that temperature for about 6 to 20 hours to substantially complete secondary recrystallization, and heating the steel from that substantially isothermal hold temperature to a temperature in excess of 2000° F. to effect purification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b are plots of core loss and permeability, respectively, versus hold temperature for 11-mil steel; and
FIGS. 2a and 2b are plots of core loss and permeability, respectively, versus hold temperature for 9-mil steel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The final texture annealing process of the present invention includes a controlled heating cycle wherein the steel is substantially isothermally annealed at selected temperatures for particular periods of time to effect substantially complete secondary recrystallization. As used herein, substantially isothermal heating or annealing during recrystallization means heating at a very low heating rate. The heating rate need not be zero, but preferably should be less then about 10° F./hour (5.5° C./hour), and more preferably less than 5° F./hour (2.8° C./hour). As a practical consideration, it is difficult to isothermally hold at a particular temperature in a production furnace, but very small variations in heating rate about a selected recrystallization temperature is within the scope of the invention. Most preferably such an isothermal hold shall mean a heating rate of less than 5° F./hour.
Specific processing of the steel up to final texture annealing may be conventional and is not critical to the present invention. The specific processing may include a number of conventional steps which include preparing a melt of the steel, casting the steel, hot rolling the steel, cold rolling the steel to final gauge with intermediate annealing steps, decarburizing the steel, applying a refractory oxide base coating, and then final texture annealing the steel in excess of 2000° F.
Although the texture annealing method of the invention described in detail hereinafter has utility with grain-oriented silicon steel generally, the following typical composition is one example of a silicon steel composition adapted for use with the method of this invention:
______________________________________C Mn S Cu Si Fe______________________________________0.030 0.065 0.025 0.22 3.15 Balance______________________________________
To illustrate the several aspects of the final texture annealing process of the present invention, various samples of a silicon steel having a composition similar to the above-described typical composition were process and the results of the tests are shown in the following Table I.
TABLE I______________________________________ Average Hold Hold WPP μSample No. of Temp. Time at at 10 HGroup Samples (°F.) (Hrs.) 17 KG (Gauss)______________________________________A 18 None -- .754 1812B 25 None -- .746 1820C 25 None -- .726 1819D 25 1600 6 .706 1833E 25 1650 6 .711 1830F 25 1700 6 .728 1824G 25 1750 6 .736 1816H 17 None -- .730 1821I 17 1460 6 .724 1828J 17 1540 6 .724 1823K 17 1650 6 .706 1834L 17 1600 6 .719 1828M 17 1600 12 .717 1827N 15 None -- .727 1820O 15 1550 12 .731 1816P 15 1600 6 .737 1820Q 15 1650 6 .718 1832R 15 1700 12 .736 1815S 11 1600 50 .707 1831T 15 1550 50 .744 1812U 15 1600 6 .731 1821V 15 1600 20 .695 1838W 15 1650 6 .703 1833X 15 1650 20 .708 1832Y 15 1700 6 .740 1812Z 15 1700 20 .738 1814AA 15 1550 12 .731 1816BB 15 1600 12 .717 1833CC 15 1650 12 .709 1837DD 15 1700 12 .736 1815______________________________________
All the Sample Groups of Table I were obtained from various heats of nominally 11-mil gauge silicon steel having the above-identified typical composition. The samples were all coated with MgO slurry and heated from a charge temperature at a relatively constant heating rate of about 50° F./hour (27.7° C./hour) or greater. Groups D-G and I-M and O-DD were all heated from charge temperature up to the specified hold temperature. Sample Groups A, B, C, H and N were not isothermally annealed and so were not held at any temperature, but were heated from the charge temperature up to a purification soak temperature. All the Sample Groups were texture annealed in a hydrogen atmosphere at a soak temperature of 2150° F. (1177° C.). Groups A-Z were held at 2150° F. for 20 hours, and Groups AA-DD for 10 hours.
The magnetic properties listed in Table I represent an average value for core loss and permeability for the number of samples for that group. The distribution of 60 Hz core losses at 17 KG (1.7 Tesla) and permeability at 10 Oersteds for those samples are shown in FIGS. 1a and 1b.
The data show that generally the samples which were held for time at a temperature within the recrystallization range of 1600° to 1700° F. have improved properties over those samples not held at temperature (Samples A, B, C, H and N). The data demonstrate that annealed samples demonstrate incomplete recrystallization if the hold temperature is 1550° F. All samples were completely recrystallized at about 1650° F. hold temperature. The data also suggest that within the 1600°-1700° F. range, there may be a range of temperatures within which substantial recrystallization occurs so as to result in improved magnetic properties. The range of about 1600°-1650° F. is preferred.
The hold time for the isothermal anneal is also critical. Insufficient time results in incomplete recrystallization. Too much time will generally result in some deterioration of magnetic properties, as shown by Groups S and T at 50 hours hold time. Results of tests have shown that the hold times of 6 to 20 hours provide good properties with a practical preferred time being about 12 hours.
TABLE II______________________________________ Average Hold Hold WPP μSample No. of Temp. Time at at 10 HGroup Samples (°F.) (Hrs.) 17 KG (Gauss)______________________________________A 25 1550 12 .731 1808B 25 1600 12 .728 1808C 25 1650 12 .686 1853D 25 1700 12 .706 1829E 6 None -- .738 1800F 6 1650 12 .682 1825G 6 1550 12 .733 1789H 6 1550 50 1.010 1640I 6 1650 50 .681 1818J 6 1600 50 .796 1761K 6 1700 12 .693 1817L 6 1600 12 .716 1809M 9 1600 12 .717 1804N 9 1650 40 .675 1827O 9 1650 40 .662 1834P 25 1550 12 .726 1815Q 25 1650 12 .691 1851R 25 1650 12 .683 1838S 25 1700 12 .706 1829______________________________________
All the Sample Groups of Table II were obtained from various heats of nominally 9-mil gauge silicon steel having the same nominal composition as for the 11-mil samples of Table I. The samples were all coated with MgO slurry and heated from a charge temperature at a relatively constant heating rate of about 50° F./hour (27.7° C./hour) or greater. All of the Sample Groups, except Group E, were heated from charge temperature up to the specified hold temperature. Sample Group E was not isothermally annealed and so was not held at temperature, but was heated from the charge temperature up to a purification soak temperature. All the Sample Groups were texture annealed in a hydrogen atmosphere at a soak temperature of 2150° F. (1177° C.) and held for 10 hours.
The magnetic properties listed in Table II represent an average value for core loss and permeability for the number of samples for that group. The distribution of 60 Hz core losses at 17 KG (1.7 Tesla) and permeability at 10 Oersteds for those samples are shown in FIGS. 2a and 2b.
The data show that for 9-mil gauge, as with the 11-mil gauge, the annealed samples were incompletely recrystallized at 1550° F., but completely recrystallized at about 1650° F. hold temperature. The data also suggest that within the 1600°-1700° F. range, there may be a range of temperatures within which substantial recrystallization occurs with a corresponding improvement in magnetic properties. The range of about 1650°-1700° F. is preferred and is slightly higher than the range for the thicker, 11-mil steel.
The data also confirm that the hold times for the isothermal anneal are critical. As with the 11-mil data, the 9-mil samples demonstrate some deterioration of magnetic properties at 50 hours hold time, as shown by Groups H, I and J. Groups H and J show such poor properties that they are not plotted in FIGS. 2a and 2b. It appears that the thin gauge 9-mil material is even more sensitive to hold times than the 11-mil material. Results of tests have shown that hold times up to 20 hours provide good results, preferably 6 to 20 hours, and a practical preferred time of about 12 hours.
The overall results show that a dramatic improvement in overall magnetic properties of core loss and permeability result from both 9-mil and 11-mil steel when processed by an isothermal anneal for 6-20 hours within the range 1600°-1700° F. The preferred ranges for each differ within that range, but the best combination of properties and complete secondary recrystallization occurs at about 1650° F. for both gauges.
The method of the present invention relates to an improved final texture annealing process wherein the steel is heated to a recrystallization temperature within the range of 1600° to 1700° F. The heating rate may be on the order of a conventional 50° F. per hour and the selected isothermal hold temperature be about 1650° F. The steel is then isothermally heated by holding the steel at that temperature for about 6 to 20 hours, preferably about 12 hours, to substantially complete secondary recrystallization. Thereafter the steel is heated from that temperature to a purification temperature in excess of 2000° F., preferably about 2200° F., at a heating rate such as 50° F. per hour and held at that temperature to effect purification. Generally, the heating rate up to the hold temperature and up to the purification temperature are relatively constant heating rates. The heating rate, however, does not appear to be critical to significantly affect the properties.
An advantage of the method of the present invention is that secondary recrystallization is essentially completed during the isothermal portion of the heat treatment, rather than being completed in accordance with conventional practice during heating to the higher purification temperature. As has been demonstrated, the effect of the present invention is to improve both magnetic permeability and core loss values. The method of the present invention is able to improve the magnetic properties in a manner not heretofore recognized in the art.
Although preferred and alternative embodiments have been described, it will be apparent to one skilled in the art that changes can be made therein without departing from the scope of the invention.
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A method is provided for final texture annealing silicon steel to produce a cube-on-edge grain orientation having lower core losses and higher magnetic permeability. The method includes using a controlled heating cycle including a substantially isothermal hold at a selected recrystallization temperature of about 1650° F. to improve secondary recrystallization and the Goss texture (110) [001].
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Phase application of PCT International Application No. PCT/EP2016/053886, filed Feb. 24, 2016, which claims priority to German Patent Application No. 10 2015 203 616.2, filed Feb. 27, 2015, the contents of such applications being incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to a method for detecting a multipath effect in a GNSS receiver and a system for a motor vehicle for carrying out such a method.
BACKGROUND OF THE INVENTION
[0003] The term multipath is also commonly known, amongst other things, as multiway propagation. The term multipath will be used hereinafter as a synonym for multiway propagation. It describes the circumstance in which a signal, e.g. from a satellite, reaches the receiver not only on the direct path, but also indirectly after it has previously been reflected against an object in the environment. This circumstance is not only applicable to satellite signals, but also to any signals transmitted by electromagnetic waves, wherein the effects in satellite navigation result in particularly noticeable deviations in position determination. The deviations occur both with a constructive and with a destructive interference between the reflected and the original signal. It is therefore important to identify such signals to increase the precision during position determination.
[0004] Position-based functions are becoming increasingly important in the field of application of motor vehicles. Owing to the increasing demand for computing power in relation to the low growth in computing power due to high cost pressures, a method is required which enables multipath signals to be detected in a simple manner.
SUMMARY OF THE INVENTION
[0005] An aspect of the invention, therefore, is to demonstrate a method or a system whereby it is possible, in a simple manner, to detect whether a signal has reached a receiver on the direct or indirect path.
[0006] According to the method according to an aspect of the invention, it is proposed that, by means of a global navigation satellite system (GNSS) receiver, different signals are received from a GNSS satellite, wherein the GNSS receiver includes a parameter which is determined from directly received signals and has a substantially constant target value, and wherein the method comprises the steps:
receiving at least two mutually independent signals which are preferably based on a measured value, determining a current parameter value from at least the first and the second signal, evaluating the parameter value in relation to the target value, and detecting a multipath effect when the parameter value has a deviation which deviates from the already known target value.
[0011] An aspect of the invention is based on the basic idea of using the changes in the parameter value to detect multipath effects on received signals. An essential feature here is the assumption that the parameter in a normal case, i.e. without influence from multipath effects, is substantially constant but changes markedly as a result of multipath effects. The detection of multipath effects can therefore be realized from the difference between the target value of the parameter and a current determined parameter value.
[0012] This parameter value is determinable from at least two different signals. Without multipath effects on the signals, the parameter value is, and remains, substantially constant and therefore corresponds to the target value of the parameter or the target parameter value. If this parameter value is determined on the basis of currently received signals which have been changed by multipath effects, the current parameter value deviates from the constant target parameter value. If the current parameter value from two received signals deviates substantially from the target parameter value, it can be concluded from this that one of the two, or both, received signals has or have previously experienced a reflection against an object. Through continuous observation or determination of the current parameter value from two currently received signals and the comparison of the current parameter value with the target parameter value, an influence from multipath effects can be established for each pair of received signals. The parameter value can be formed, for example, from the ratio between an offset of the first signal and an offset of the second signal. The offset is preferably an offset in the travel-time measurement.
[0013] The target parameter value must firstly be determined and available. It can be left open here as to how the target value of the parameter is determined and how often this is updated. As soon as the target parameter value is determined, this can be assumed to be constant for a certain time period.
[0014] An essential condition is that the received signals or such a signal enable a conclusion about the same measured value, although they represent mutually independent signals. Such a measured value can be e.g. the travel time of the signals in relation to the same instant at which the signals were transmitted from a satellite. The signals therefore enable the receiver to determine the same measured value on two different paths. It is, for example, possible to carry out, for each signal, a travel-time measurement which is independent of the other signal so that it can be established whether both signals deliver approximately the same result.
[0015] The signals preferably have different carrier signals or carrier frequencies. An example of different carrier signals in the field of application of navigation satellites are e.g. C/A code signals and P/Y code signals. An example of signals with different carrier frequencies are signals at L1, L2 or L5.
[0016] The method is applicable to a plurality of global satellite navigation systems current today, such as, for example, GPS, Galileo, Glonass and BeiDou.
[0017] The method according to an aspect of the invention is preferably further developed in that the parameter value includes an atmospherically induced error in the signals. The parameter value takes into account the delay in receiving the signals caused by the troposphere and ionosphere. The deviation in the travel time of the signals owing to atmospheric influences should therefore particularly preferably be used as a parameter. The calculation of atmospherically induced influences on the travel time is generally available in GNSS receivers in motor-driven road vehicles, which means that additional computing costs are not necessary here. The correlation of the current parameter value with the target value described here is realizable with low computing costs. It is moreover particularly advantageous for the use of the method in a motor-driven road vehicle, since the assumption of the constant target value is applicable to within a limited movement circle with sufficiently high accuracy.
[0018] The method according to an aspect of the invention is preferably further developed in that the target value of the parameter is newly determined after expiry of a predefined period, upon the occurrence of a predefined event or upon environmental changes. It is thus ensured that the desired value remains as current as possible.
[0019] The method according to an aspect of the invention is preferably further developed in that the parameter value exceeds a predefined upper and lower threshold value.
[0020] A broadening of the method such that the upper and lower threshold value is specified in relation to the target value of the parameter or to an absolute value is particularly advantageous here.
[0021] A particularly advantageous further development of the method according to an aspect of the invention moreover involves one of the threshold values being exceeded substantially without warning, i.e. the value of the parameter changes suddenly or instantaneously and exceeds one of the threshold values. A clear, but possibly isolated, influence of the multipath effect is thus detectable. The time period to be observed can be restricted, for example, to the number of one or several data or samples. It could, for example, also be in the range of fractions of a second.
[0022] A further advantageous embodiment of the method according to an aspect of the invention takes into account a deviation in which the parameter value exceeds a first tolerance range within a predefined time period. The time period to be applied here is substantially greater than the time period of the above-mentioned embodiment. The time domain could be, for example, in the range of a plurality of seconds. A duration of 5 seconds has proven advantageous in initial tests.
[0023] The preceding further development of the method according to an aspect of the invention is advantageously combined to take into account whether the change over time of the parameter or the difference or deviation of the parameter has a trend. Creeping effects (drift) caused by multipath are thus detectable, which, owing to the low amplitude of the deviation, could otherwise remain within a tolerable deviation.
[0024] The method according to an aspect of the invention is advantageously further developed here in that the first tolerance range is set in relation to or depending on a measured value from the first and/or second signal. The magnitude of the deviation over the time period can thus be flexibly adapted to a respective signal value in order to adapt the sensitivity of the multipath detection.
[0025] An advantageous embodiment of the method according to an aspect of the invention furthermore includes a deviation in which the parameter value exceeds a second tolerance range.
[0026] The method according to an aspect of the invention can particularly advantageously be further developed here in such a way that the second tolerance range is set in relation to the signal strength of the first and/or the second signal. An influence of multipath on the noise behavior of the signals can thus be taken into better account.
[0027] The method according to an aspect of the invention is advantageously further developed in that the signals differ in terms of their carrier frequency.
[0028] The method according to an aspect of the invention is advantageously further developed in that the signals differ in terms of their modulation frequency.
[0029] The method according to an aspect of the invention is advantageously further developed in that a C/A signal and a P/Y signal are compared with one another.
[0030] It is furthermore advantageous to further develop the method according to an aspect of the invention such that an L1 signal and an L2 or L5 signal or other combinations of the carrier frequencies of a GNSS are compared with one another.
[0031] The method according to an aspect of the invention is advantageously further developed in that, after detecting a multipath effect, the received GNSS signals are marked as erroneous.
[0032] A second aspect of the invention relates to a system appropriate for a motor vehicle for receiving satellite signals to determine the actual position of the vehicle and to implement a method according to one of the above-mentioned embodiments, wherein the receiver is designed to receive and to process signals of different frequencies.
[0033] The system is preferably a sensor fusion system for combining a plurality of sensor data with different output variables.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The invention is described in more detail below with reference to an exemplary embodiment and drawings, which show:
[0035] FIG. 1 a block diagram of a system according to the invention for implementing the method according to the invention; and
[0036] FIG. 2 an exemplary illustration of a travel-time measurement of a signal.
[0037] FIG. 3 a , 3 b an exemplary illustration of the parameter determination with reference to the travel-time measurement of two signals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIG. 1 shows an exemplary embodiment of a system 1 according to an aspect of the invention, including a receiver or multi-frequency receiver A, which is designed to receive two different mutually independent signals S 1 , S 2 at different frequencies f 1 , f 2 . A multi-frequency receiver A of this type is well known from the prior art.
[0039] The choice of signals to be observed can be made depending on the receiver and the availability of the signals. However, it is advantageous to use two signals which differ in terms of their carrier frequency, modulation frequency and/or signal type, for example C/A and P/Y signal. It is also possible to use more than two signals for multipath evaluation.
[0040] FIG. 2 shows the correlation of 3 phase-shifted replicas to a received signal S, namely E (Early), P (Prompt) and L (Late). The time shift is applied to the x-coordinate, wherein the point of origin represents the start of the time mark of the receiver. For brevity of terminology, the common English scientific terms for the replica signals are used below.
[0041] The phase shift from Prompt to the other replicas Early and Late amounts to one nav-chip length in each case, which corresponds to 10 ms for a C/A code and 1 ms for a P/Y code. The illustration in FIG. 2 shows the necessary time shift of the replicas Early and Late so that they correspond with the received signal S. This results in the travel-time measurement with a duration of t 2 for the correlation maximum corr_max.
[0042] If, instead of only one signal, two signals S 1 , S 2 are now received and the distance from the satellite or the signal travel-time measurement therefor is determined for both signals in relation to the same instant, for example C/A and P/Y code, the results should be approximately identical since both signals S 1 , S 2 should have the same distance from the satellite at the same instant.
[0043] Reflections have a slightly different effect on the different signals. Added to this are influences resulting from different measuring methods owing to different sampling rates and resolutions.
[0044] A signal which is distorted by multipath would therefore result in the instant t 2 at which the replica signal Prompt reaches the correlation maximum corr-max with the received signal being shifted by a certain value to t 2 ′, for example 5% of the nav-chip length. The result of such a shift would be that the multipath influence on a signal would amount to 500 μs=149500 m according to the C/A code and yet only 50 μs=14950 m based on the P/Y code. Since the distance between C/A and P/Y should be approximately identical but, in this exemplary case, there is a mutual deviation of 135 km, the multipath can be detected via the method.
[0045] FIGS. 3 a and 3 b show the correlation peak and therefore the signal travel time for the signals S 1 and S 2 .
[0046] FIG. 3 a shows the offset of both signals under ideal conditions and therefore forms the target value of the parameter. Since, owing to different signal properties (e.g.: different frequencies), the signal travel time of both signals is slightly different—signal 2 is more delayed on the transmission path (e.g. as a result of the ionosphere)—the result is a mutual offset of both signals.
[0047] FIG. 3 b shows how the current parameter value changes when multipath is present, which has a different effect on the two signals owing to different signal properties. Signal S 1 and S 2 are both delayed by the multipath, but signal S 2 is more delayed than S 1 .
[0048] It is therefore possible to detect a multipath effect from the changed offset between the two signals S 1 and S 2 . The target value of the parameter would then be the difference or the offset in the travel-time measurement between the two signals S 1 , S 2 , preferably minus the respective distortion of the travel times due to atmospheric factors. The current parameter value would then need to be determined on the basis of the currently received signals, one of which can be falsified by multipath.
[0049] The normal target value of the parameter could have, for example, an offset of 5 m between the signals. If the current parameter value, i.e. offset for a signal pair, jumps to 15 m, it should be assumed that a multipath effect is present. The difference between the two signals can also be determined in other units, for example in nav-chip lengths.
[0050] A further example for a parameter is described below. The influence of atmospheric disturbance effects can be determined from the received signals by means of multi-frequency receivers. This variable can likewise be used as a parameter. It takes into account, amongst other things, the influence of the ionosphere and troposphere on the breaking and absorption of the signals. The parameter depends for the most part on a plurality of factors in the ionosphere and troposphere, such as e.g. time of day, humidity, temperature, cloud cover etc. and can be assumed to be constant over a certain time period. Based on this assumption, the target value of the parameter can also be used as a constant offset. If the target value is subtracted from the current parameter value or the current atmospheric offset, a residual difference remains which is not atmospherically induced and can be attributed to multipath effects. The differential value determined in this way is therefore also suitable for detecting different types of deviation due to multipath.
[0051] A parameter within the context of the invention is therefore preferably an offset between the received signals, which generally has a constant value and can have different deviations from the target value as a result of multipath.
[0052] For the comparison between the target value and the current parameter value, the system 1 has a computing unit C which determines the difference K from the two variables. The system furthermore has a plurality of comparison units 20 , 30 , 40 which are suitable for detecting unique, creeping multipath effects or an influence on noise behavior of the signals which is changed by multipath based on the difference ΔK.
[0053] The first comparison unit 20 compares the difference ΔK in relation to an upper and lower threshold value s_max, s_min. The threshold values can be specified relatively in relation to the target value of the parameter or in relation to an absolute value. If the difference K exceeds one of these threshold values s_max, s_min, it can be established that one of the signals S 1 , S 2 has not reached the receiver on the direct path and is therefore erroneous and should be discarded. It is thus possible to detect individual runaways in the parameter value owing to multipath effects.
[0054] The second comparison unit 30 checks whether a slow or creeping change in the difference ΔK is present. To this end, a time period t_D is defined, in which the difference ΔK must remain within a tolerance range D. A so-called drift of the signals cased by multipath is thus detectable. The current parameter value, or the offset in the travel-time measurement, could change by several millimeters per second within several seconds. The tolerance range specified for a time period or a time window ensures that such drifts are detected.
[0055] The comparison unit 40 takes into account whether the multipath has a negative effect on the noise behavior. To this end, a further tolerance range D_r is introduced, which is set depending on the signal strength.
[0056] The invention has the advantage that the computing costs for detecting multipath effects are relatively low, since it is only necessary to determine the current parameter value from the two signals and to compare it with a substantially constant target parameter value.
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A method for detecting a multipath effect in a GNSS receiver which is designed to receive different signals from a GNSS satellite and includes a parameter which is determined from directly received signals and has a substantially constant target value, including the steps receiving at least two mutually independent signals; determining a current parameter value from at least the first and the second signal; evaluating the parameter value in relation to the target value, and detecting a multipath effect when the parameter value has a deviation (ΔK) which deviates from the already known target value.
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BACKGROUND OF THE INVENTION
This invention relates to the proving or calibration of fluid meters and particularly to the proving of oil well volumetric meters.
Once an oil well is in production it will pump a solution of oil and water along with natural gas entrained therein to the surface. This fluid is pumped along a pipeline to a testing station or satellite where the oil-gas-water mixture is fed into a test separator. At the separator the gas, being lighter, is separated from the oil and water mixture and is taken out through the top of the separator vessel. The water, being heavier than the oil, is taken from the bottom of the separator vessel. The oil, which floats on the water in the separator vessel, is skimmed from the vessel through an outlet located about 1/3 of the vessel's height above the water outlet. Each constituent is metered as it flows from the separator vessel whereby the total production of the well may be determined. In these days of high energy costs many governments require that an accurate record of production of wells within their jurisdiction be maintained. Such governments also usually require that the meters used to measure oil, gas and water be repaired and calibrated for accuracy on a regular basis.
The calibration (or proving) of a meter involves obtaining an accurate reading by way of a separate meter of the volume of fluid passing the meter in question for a specific period of time. It is possible to install separate proving apparatus on a permanent basis in the pipeline near the meter, which apparatus can be used on a regular basis to check the accuracy of the meter. Alternatively, portable proving equipment can be used, which equipment is taken from well to well, thereby reducing the capitalization required. Such portable equipment conventionally involves a portable tank having a sight glass thereon. The tank is connected to the pipeline downstream of the meter. A specific volume of fluid is fed into the tank and the volume caught in the tank is compared with the volume recorded by the meter during the period of flowing fluid into the tank. The ratio between the two volumes recorded provides a factor by which the meter reading can be multiplied to achieve the correct volume of fluid produced by the well.
The above describes the basic steps taken to prove a fluid meter. If the steps are followed closely then a reasonably accurate factor can be obtained. If the steps are not followed closely then inaccuracies will result. Furthermore, when dealing with oil meters, inaccuracies can result if there are surges in the flow; if the oil is not sufficiently degassed (giving inaccurate volumes); or if there are no corrections for temperatures (i.e. if the recorded volume is not corrected to the temperature at which the meter was factory calibrated).
SUMMARY OF THE INVENTION
The present invention is concerned primarily with the proving of oil meters although some of the principles enunciated hereinafter could be used, for example, with the water meter as well. Essentially the present invention relates to improvements in the basic procedure outlined hereinabove to achieve a much higher degree of accuracy in obtaining the meter correction factor. By following the improved procedure the number of test runs to achieve an accurate factor is reduced and, more significantly, the accuracy of the factor does not depend on the expertise of the proving operator.
In order to utilize the procedures of the present invention is is also necessary to revise slightly the apparatus of the test satellite. That apparatus, for the oil meter, includes a conduit leading to the meter and a valved by-pass conduit whereby flow may be directed exclusively through the meter or the by-pass conduit. A dump valve downstream of the meter and the by-pass is used to maintain the designed pressure drop across the meter. The dump valve has a pilot supply pressure fed thereto from the separator vessel. Downstream of the dump valve, in the main pipeline are two spaced apart valved calibration connections to which the prover vessel is connected. A shut-off valve is provided in the main pipeline between these connections. In order to practice the present invention effectively it is recommended that a tap be provided in the meter connections for bleeding off the meter and for ascertaining the pressure drop across the meter to ensure that it is up to design specification. Also it is recommended that a second by-pass line be valved into the first by-pass line and into the main pipeline downstream of the last calibration connection so that the meter and the other aforementioned valves may be repaired without shutting down the entire system.
There are several steps which may be added to the basic proving procedure by the present invention which result in improved accuracy in determining the meter factor. Firstly it is recommended that the pressure drop across the meter be determined and, if it is not at the designed level, the port in the dump valve should be changed to bring the pressure drop back to specification. Then, once the prover has been connected to the pipeline by way of the calibration connections, and a suitable initial volume of fluid has been fed to the prover vessel and has degassed so as to provide an initial (or zero) base level in the vessel, the separator vessel should be allowed to dump fluid into the main pipeline to establish a "packed" line from the dump valve to the first calibration connection valve. That first valve is then opened to permit the separator to dump a predetermined volume of fluid, say about 100 liters, into the prover vessel at the same rate of flow or pressure drop as previously determined. Just before that volume is reached, say within about 4% thereof, the operator should be ready to close the first valve and when that is done the line from the dump valve to the first valve will be repacked with fluid. Then, once the prover has been isolated and the meter reading recorded, so as to ascertain the volume of fluid recorded by the meter, the prover vessel is completely degassed and it is then possible to take a reading on the sight glass of the prover vessel and determine the total volume of fluid that entered the prover vessel. That volume is compared with the volume recorded by the meter to determine a true factor for the meter in question.
If the well produces more than 5 cubic meters per day it is recommended that the operator make at least two runs to determine an "as found" meter factor. Then, since it is likely that repairs will be required the meter should be repaired so as to put it into a like-new condition, after which an average of three final calibration runs can be made to compute the new factor for the repaired meter.
Broadly speaking, therefore, the present invention may be broadly defined as providing the method of proving the calibration of a fluid flow meter which registers the volume of fluid passing therethrough, the meter being in a conduit downstream of a separator vessel, comprising the steps of: (a) connecting a prover vessel to the conduit downstream of the dump valve, there being a shut-off valve in the connection between the prover vessel and the conduit, the prover vessel having accurate volume reading means thereon; (b) opening the shut-off valve to introduce a first volume of fluid via the conduit into the prover vessel, closing the shut-off valve to isolate the prover vessel from the conduit, completely degassing the first volume of fluid within the prover vessel and establishing a first volume reading for the fluid introduced into the prover vessel; (c) permitting the conduit to pack with fluid between the dump valve and the closed shut-off valve; (d) establishing a baseline reading on the meter, opening the shut-off valve to introduce a second volume of fluid into the prover vessel, closing the shut-off valve to isolate the prover vessel from the conduit, permitting the conduit to pack with fluid between the dump valve and the closed shut-off valve, establishing a final reading on the meter, completely degassing the total volume of fluid in the prover vessel, and establishing a second volume reading for the total volume of fluid; and (e) dividing the volume represented by the difference between the second and first volume readings at the prover vessel by the volume represented by the difference between the final and baseline registered at the meter in order to determine a meter factor by which a volume registered by the meter may be multiplied to derive the true volume of fluid passed through the meter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in schematic form a test separator facility modified as per the present invention.
FIG. 2 shows a portable prover apparatus as used in the present invention.
FIG. 3 shows in schematic form the manner in which the portable prover apparatus is connected to the test separator for proving an oil meter.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the test satellite to which the oil-water-gas mixture is pumped from the well. The satellite includes a main vessel 10 having an inlet 12 through which the aforementioned mixture is introduced from the well to the vessel 10. The gas, which is lighter than the other two constituents rises to the top of the vessel and exits through a conduit 14, passes through a volume gas meter (not shown) and a back pressure valve, whereby the volume of gas produced may be ascertained. The water, being the heaviest constituent exits the vessel 10 via an outlet 18 at the base of the vessel. Outlet conduit 20 leads from outlet 18 to a volume meter 22 by way of shut-off valve 24 whereby the meter records the volume of water passing thereby. A shut-off valve 26 is provided at the exit side of the meter. The meter can be isolated for repair or replacement by shutting the two valves 24, 26. If valves 24, 26 are closed the water will flow through a by-pass conduit 28 connected at one end to conduit 20 and at the other end to exit conduit 30. A normally closed shut-off valve 32 is provided in the by-pass conduit, valve 32 being opened only when it is desired to by-pass the meter 22.
Exit conduit 30 carries a snap acting liquid level valve 34 which is fed by a pilot supply of pressure via conduit 36. Downsteam of valve 34 are two calibration connections 38 and 40 controlled by shut-off valves 42 and 44 respectively. A shut-off valve 46 is positioned in the conduit 30 between the connections 38 and 40. When the meter 22 is to be calibrated or proved the portable proving equipment would be connected to the calibration connections 38 and 40. Otherwise these connections are unused.
The oil is taken from the vessel 10 by an outlet 48 about 1/3 of the height of the vessel above the water outlet 18. Without the modifications suggested by the present invention the oil conduit system would appear identical to the water metering system just described. At any rate the oil system includes an outlet conduit 50, an oil meter 52, shut-off valves 54, 56, bypass conduit 58, by-pass shut-off valve 60, snap acting liquid level valve 62 in outlet conduit 64, pilot supply conduit 66, calibration connections 68, 70, calibration shut-off valves 72, 74, and shut-off valve 76. As modified in accordance with the present invention an optional by-pass extension 78 leading from by-pass 58 via shut-off valve 80 and terminating in exit conduit 64 downstream of calibration connection 70 may be provided. Such an extension could be provided in the water metering system as well if the procedure of the present invention is to be used to prove the water meter. The purpose of the extension 78 will become apparent hereinafter. Also added are pressure taps 149, 150 used to determine the pressure drop across meter 52. They can be used as well to depressurize the meter when it is to be repaired.
FIG. 2 shows a portable prover 82 as it might be mounted on a vehicle, such as a truck or a trailer. The prover 82 includes a pressure vessel 84 contained within a surrounding housing or jacket 86, the jacket being sealed to the tank so that an anti-freeze fluid, such as ethylene glycol may be contained therein for winter operation. The jacket is provided with an inlet 88 and an outlet or drain 90 for the glycol. An electric immersion heater 92 is provided to heat the glycol in extremely frigid conditions.
The tank 84 has a pressure release safety valve 94 at the top and a fluid inlet/outlet 96 at the bottom. Inlet/outlet 96 is connected to a conduit 98 containing a shut-off valve 100 which in turn is connected to a conduit 102 which is connected to calibration connection 68 when in use. A further conduit 106 is connected at one end via valve 110 to the conduit 102 and in use the other end would be connected to the calibration connection 70. A check valve 112 is contained in the conduit 106 to prevent unwanted reverse flow.
A gas equalizer line 114 is connected at one end to the conduit 106 and at the other end to the top of the tank 84. Line 114 contains a check valve 116 and a block or shut off valve 118. A metered gas inlet line 120 feeds into the line 114 and is also connected to a vent line 122. Lines 120 and 122 are valved so that the desired flow paths may be established and controlled. A pressure gauge 124 is provided so as to monitor the gas pressure in the lines 114 and 120 and in tank 84.
Also provided are two collars 126, 128 the former for receiving an appropriate measuring device to monitor the temperature of glycol in the jacket 86 and the latter, positioned on the tank 84, for receiving an appropriate measuring device to monitor the temperature of the fluid within the prover tank 84.
An opening 130 in the jacket 86 provides access to a sight glass chamber 132 which is, of course sealed in so far as the glycol chamber is concerned. Contained within chamber 132 are one or two vertically spaced apart and aligned sight glasses 134, 136 both of which are fluidly connected to the tank and are calibrated so as to accurately display the volume of fluid within the tank. The sight glass chamber should also be provided with an explosion-proof propane heater 138 so as to keep that chamber at an appropriate temperature during operation in cold weather.
A typical prover vessel or tank 84 will have a minimum volume of 160 liters, a diameter in the calibrated zone of between 16 and 24 inches (O.D.) and means for ensuring that it is level in operation. Desirably the scales on the sight glasses will be in increments of 1/2% and one should be able to distinguish to 1/4% in measurement area. Calibration points should be at -5%, 0, +5%, 20%, 40%, 60%, 80%, 90%, 95%, 100%, 105% and 110%.
FIG. 3 illustrates schematically the manner in which the separator vessel is hooked or connected to the prover vessel or tank 84 so that calibration of the oil meter 52 may be effected. First of all the conduit 102 of the prover is secured to the calibration connection 68 in the conduit 64 and in a similar manner the conduit 106 of the prover is connected to the calibration connection 70. The gas inlet line 114 is connected to the gas outlet line 120 from the separator vessel. These are the only connections required to effect proving of the oil meter 52. The steps to be taken in carrying out the procedure of the invention will be presented hereinbelow with reference to FIGS. 1, 2 and 3.
Having connected the prover into the separator system as illustrated in FIG. 3, and assuming total production is less than 5 m 3 per day, the operator should first of all put the meter into an "as-new" condition should it be inoperable as found. To do this the operator would isolate the meter by opening the valve 60 and closing the valves 54 and 56 to send the oil through the bypass conduit 58, thereby removing the meter from the circuit. The meter would then be bled of oil through pressure tap 150 and repaired as necessary. After repair the meter should be pressure tested and the rate of flow and pressure drop across the meter checked to ensure that they meet the manufacturers specifications. If they do not, further repair, including replacement of meter parts or the port in dump valve 62, should be effected to bring the meter into agreement with its specification. By utilizing by-pass 78 valve 62 could be repaired without shutting down the separator vessel 10. Once the meter is in like-new condition proving can begin.
If the meter is operable and if the well is producing more than 5 m 3 per day it is desirable to establish an approximate "as found" meter factor by way of the following proving steps before effecting any repairs to the meter. This will provide an indication of the drop in efficiency of the meter between repairs.
In order to proceed with proving of the meter 52 the operator first of all opens valves 72 and 100 to permit an initial volume of fluid to enter the prover vessel 84. During this step valve 74 is open and valve 76 is closed, valve 110 is closed, valve 118 is closed, valve 121 is closed and valve 123 is open (venting to atmosphere). The operator then closes valve 100 and then 72 to isolate the prover, keeping valve 123 open so that the initial volume of oil in the vessel 84 can completely degas. During this step valve 76 is opened to keep the separator vessel 10 from flooding. The operator then closes the vent valve 123 and opens the gas supply valve 121 which permits gas flow from the separator vessel 10 to the prover vessel 84 and hence the pressure in the prover vessel is brought up to operating pressure (the pressure of gas in the separator vessel 10). Once the prover vessel is at operating pressure valve 100 is opened and then a zero point or baseline reading is taken on the sight glass 134 on the prover vessel.
The gas line 114 is then opened to the downstream side of the proving manifold by closing gas supply valve 121 and opening equalizing valve 118. Valve 76 is then closed and with valve 72 closed the separator is allowed to pack lines 64 and 68 from the dump valve 62 to the valve 72. When this is complete a zero or base reading is taken on the register of the meter 52 and the valve 72 is opened whereby the test separator 10 can dump as it would normally until almost 100 liters (1/10 m 3 ) of oil have been dumped into the prover vessel 84 (valve 100 open, valve 110 closed).
At a point when about 96% of the 100 liters has been reached on the register of meter 52 the operator should be ready to close valve 72 so that it can be closed right at the 100 liter reading. The valve is then closed, at the 100 liter meter reading, so as to repack the lines 64 and 68 from the dump valve 62 to the valve 72. Whenever valve 72 is being opened or closed the dump valve 62 must be open.
When the run has stopped, the prover vessel is isolated by closing valves 100 and 118 and by opening valve 76. The operator then allows the oil in the prover vessel 84 to degas as by opening valve 123. When the vessel is completely degassed valve 121 is opened (valve 123 closed) to increase the pressure in the vessel 84 by about 15 to 20 psi so as to settle any foam on the surface of the oil in the vessel 84. A test sight glass reading from glass 136 is taken and valve 121 is again opened to bring the prover vessel 84 up to the operating pressure. Another test sight glass reading is taken and if there is no change in the reading that reading represents the final reading for that run. If the test reading changes there is thus an indication that insufficient time has been taken for degassing and the degassing steps outlined above must be repeated until there is no change in the gauge reading between 15 psi and the operating pressure. Several runs are suggested for each well in order to obtain more accurate readings so that a better determination of the meter factor can be obtained. Care must be taken to ensure that all gauge readings are taken at the same static pressure to reduce any error caused by remaining entrained gas in the oil. When satisfied that degassing is complete valve 100 is opened and the final sight glass reading is recorded.
When all base line readings in the prover vessel are taken the valve 100 is open. With the prover vessel being pressurized up to a known pressure, usually that of the separator vessel 10, the fluid and entrained gas in the line 102 is forced towards the valve 72 at the same pressure for each base line reading. By opening valve 100 only when the vessel 84 is up to its operating pressure the entrained gas cannot escape from line 102 into the prover vessel.
If the valve 100 is used for control rather than valve 72, packing of lines 64, 68 and 102 will take place from the dump valve 62 to the valve 100 when the latter valve is closed. The base reading is taken with valve 100 closed and then the valve 100 is opened, with valve 72 open and valve 110 closed, so as to dump the desired volume into the prover vessel. During dumping, the operator refers to the sight glasses 134, 136 to ascertain the correct time to close valve 100 (dump valve 62 open), so as to capture approximately 100 liters of fluid in the vessel 84. Valve 100 is then closed and care is taken to ensure packing of lines 64, 68 and 102 up to the valve 100. The final meter reading is recorded after packing is complete. Isolation of the prover vessel is obtained by closing valve 118 and opening either valve 110 or valve 76 so that the oil by-passes the prover vessel 84. After degassing is complete the final gauge readings can be taken (valve 100 still closed) and the meter factor calculated.
As there is a possibility that different pressures could exist in the inlet conduit 102 and the outlet conduit 106 when the valve 72 is used as the main control valve it is then desirable to equalize those pressures. Equalization is not required when valve 100 is used as the main control valve. Equalization may be achieved in one of two ways: (a) by opening the valve 110 for a short period of time (5-10 seconds) after the base reading on the prover vessel has been obtained; or (b) as previously stated, by opening the valve 100 (with valve 72 closed) to pack the line 102 back from the prover vessel to the valve 72 just before the readings are taken at the prover vessel.
When the run is complete valves 100 and 110 are opened. The pressure in the prover vessel will empty the vessel by forcing the fluid therein back through the conduit 106 to the main conduit 64.
Once a set of readings for each run has been recorded, namely the meter readings (initial and final) and the gauge (sight glass) readings (initial and final) and the temperature for each run recorded the operator can calculate a factor by which the meter reading can be multiplied to obtain the true volume of oil (in degassed stock tank oil readings) that has passed through the meter. A correction factor based on the actual temperature of oil in the meter and in the prover vessel as compared to the standard temperature of 15° C. is applied to the volumes recorded at the meter and at the prover vessel. The meter factor is then determined by dividing the temperature corrected volume at the prover vessel by the temperature corrected volume at the meter, which factor is recorded and applied to all readings taken from the meter in question until that meter is again proved (the following year, say).
Since the factor for a meter is based on a temperature corrected to 15° C. it is recommended that the volume recorded at a meter should also be subject to a daily temperature correction factor before the meter factor is applied. If it is possible to maintain constant temperature of fluid at meter 52 year-round, the temperature correction factor is eliminated and daily oil temperature correction is not required.
By following the steps as outlined above it is possible to accurately determine a meter factor for any oil meter so that a correct determination of the volume passing therethrough can be made. In following the method of the present invention it is essential that the system be packed between the open dump valve 62 and closed valve 72 or 100, depending on which is used as the main control valve, before taking the zero or base line reading on the meter register so that a normal dumping can take place after the valve 72 or 100 has been opened; that the operator closes the valve 72 or 100 at the desired reading and permit the system to repack; and that the oil in the prover vessel be completely degassed before any sight glass gauge reading is recorded.
It is also necessary to maintain a constant pressure drop or rate of flow across the meter 52 both during and after proving (this requires correct porting of dump valve 62). If the pressure drop across the meter is changed after proving has been completed, the calculated meter factor may not be applicable.
It is conceivable that people skilled in the art could vary aspects of the present invention without substantially departing from the spirit thereof. For example essentially the same procedure could be used to calibrate gas, condensate, water or meters. When the present invention is used to calibrate condensate meters problems can result when the light condensate escapes through the vent valve 123 and a true measurement thereof is not possible. The condensate then is treated as a gas and it is necessary to insert a pressure regulator 152 in the line 106 so that a known pressure is maintained in the prover vessel 84. The pressure setting of the regulator is the separator pressure minus the known pressure drop that the meter is allowed. All gauge readings are taken at that pressure setting. Also it is not necessary to degas out through the vent 123 as with oil meters and by following the other steps previoulsy discussed a flow line barrel factor is achieved. By knowing the specific gravity of the condensate and the meter factor it is then possible to calculate the condensate as a gas rather than as a liquid. Finally, the present invention can also be applied to gravimetric proving wherein the weight of fluid rather than the volume is measured. The same steps of operating the prover vessel, but based on weight, would be used. Thus the protection to be afforded the present invention should be ascertained from the claims appended hereto.
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The invention relates to improved methods of proving the calibration of meters, such as oil and water meters used in measuring fluid output of a producing oil well prior to the fluid reaching a stock tank. The method generally involves connecting a prover vessel, having an accurate volume reading sight glass, downstream of the meter to be tested, introducing a first volume of fluid into the prover vessel, degassing the fluid and pressurizing the vessel so as to establish a baseline reading. A preselected volume of fluid as registered by the meter is then introduced into the vessel, degassing and pressurizing are repeated and a second volume reading is obtained. The volume represented by the difference between the second and first volumes read at the prover vessel is divided by the volume registered by the meter to obtain a factor by which a meter reading may be multiplied to derive the true volume of fluid passing thereby. The volumes recorded may be temperature corrected to 15° C. before the dividing step. The proved vessel may be portable so that it can be taken from well to well by a prover crew.
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FIELD OF THE INVENTION
[0001] The present invention relates in general to receptacles for receiving liquids, and in particular relates to drip trays having liquid-tight covers or lids.
BACKGROUND OF THE INVENTION
[0002] Drip trays are commonly used in many industrial applications, such as in the field of oil and gas exploration and production, and also for non-industrial uses. For example, a drip tray may be placed under a motor, transmission, pump, or other piece of equipment during servicing or removal to catch liquids such as hydraulic fluid or lubricating oil. In some cases a drip tray may be placed under a piece of equipment while it is in operation, as a precaution to catch any liquids that might leak from the equipment due to mechanical breakdown or deterioration of gaskets and other sealing means. Drip trays may be fabricated in a variety of configurations, but they typically feature a bottom section with side walls defining an open pan, and may or may not have a cover. For industrial applications in particular, where a drip tray is being used in association with a large piece of equipment, it will generally be desirable to use a fairly large drip tray.
[0003] In typical uses, the liquid that a drip tray is employed to receive is a potential environmental hazard, or for some other reason it is necessary or desirable to ensure that the liquid does not leak or splash or spill from the tray, particularly when the tray is being transported to a disposal site or is being poured from the tray at the disposal site. At the same time, it is generally desirable for the drip tray to be relatively shallow in order to facilitate use underneath a variety of types of equipment from which liquids may leak or overflow. However, a shallow drip tray, with comparatively short or low perimeter walls and an open top, is difficult to transport to a disposal site without splashing or spilling, because the liquid in the drip tray will be highly prone to sloshing back and forth and splashing over the walls. Accordingly, it is desirable for the drip tray to have means for preventing or minimizing splashing and spillage of liquid from the tray during transport. Balancing against the desirability for a drip tray to have a large open area and means to prevent spillage is the practical necessity or desirability for the drip tray apparatus to be of such size and weight that it can be positioned and transported without undue difficulty by manual or mechanical means whether empty or substantially full of liquid.
[0004] The importance of these considerations can be illustrated by a particular example of drip tray use in the field of oil and gas exploration and production. Mobile well testing equipment commonly travels to well sites to conduct on-site testing of fluids being produced from the wells. These fluids may include liquid and gaseous hydrocarbons (i.e., crude oil and natural gas produced from a subsurface formation), drilling fluid (commonly called “drilling mud”), “frac oil” (a liquid introduced into the well to induce or promote fracture of subsurface formations to enhance flow of hydrocarbons into the well), and formation water. These fluids commonly will contain sand or rock particles. The well testing procedure typically involves running a testing line of nominal 2-inch or 3-inch (50 to 75 mm) pipe across the ground surface (typically raised on blocks) from the wellhead to the mobile unit, which is commonly required by regulation to be 40 feet (12 meters) or more away from the wellhead. The testing line is connected to a wellhead pipe nipple so that well fluids will flow into the testing line from the production tubing of the well, or in some instances from the annulus between the production tubing and the wellbore or casing. The well fluids are then pumped into a tank on the mobile unit, so that samples can be extracted from the tank for testing.
[0005] In order to do this testing with a mobile unit, the testing line is made up of several smaller sections (typically 10 to 15 feet or 3.0 to 4.5 meters long) that are easy to transport on a truck, plus a variety of associated pipe fittings. When the testing procedure is complete, the testing line is typically flooded with liquid of some sort, and this liquid will drain out when the testing line is disassembled for transport to a different well site. This liquid generally cannot be allowed to contaminate the ground surface, so an open-top drip tray is positioned under each joint between pipe sections and/or pipe fittings in the testing line. Each drip tray is sized to receive an amount of liquid greater than the volume of the pipe components that will drain into it; rectangular trays measuring about 2 feet by 5 feet (0.6 meters by 1.5 meters) are commonly used for this purpose. The pipe components rest on the tray edges so that when each pipe joint is eventually broken open, the liquid in the pipe will flow into the trays.
[0006] The problem then becomes moving these liquid-laden, open-top trays to a disposal facility without spilling any of the liquid. In common oilfield practice, the trays are manually transported by a couple of workers to a disposal tank, which is often elevated above ground. The workers then need to pour the liquid out of the trays into the tanks, which often entails raising the trays up to open top of the tank. In some cases, a hoisting means is used to raise the trays up to the top of the tank, but whether the trays are raised manually or with mechanical assistance, it is difficult to carry out this procedure without risk of spillage or splashing from the trays.
[0007] Drip trays are used in a similar way in other oilfield applications, such as for draining piping used for circulating water through a well (such as for sand removal or other common purposes) during well servicing operations by a service rig. Drip trays are used where hoses from vacuum trucks (or “vac trucks”) are connected to a piece of equipment, such as for emptying a tank. In general, drip trays are typically used in oil and gas operations where there are piping connections or hose connections for any purpose, and where there is a risk that harmful or otherwise undesirable liquids could drip or spill onto the ground when the pipe or hose is disconnected.
[0008] The prior art discloses a number of drip trays directed to one or more of the objectives and desirable features discussed above.
[0009] U.S. Pat. No. 6,446,907 (Wilson et al.) describes a fluid-tight drip pan specifically intended to catch drips from the engine or transmission compartment of a helicopter. While this drip pan may be effective for this intended use, it is not readily adaptable for non-analogous uses, since it is specifically adapted to be securely mounted to the engine or transmission compartment.
[0010] U.S. Pat. No. 5,775,869 (Bishop) discloses a transportable spill pan with hinged covers. This apparatus is specially adapted for use under rail cars, and thus has the disadvantage of not being suitable for general use in a range of different applications. It has further disadvantages in that it is must be moved using equipment such as a forklift, and the covers do not provide a liquid-tight seal to prevent leakage during transport.
[0011] U.S. Pat. No. 6,102,086 (Holtby) describes a drip tray that unlike the Wilson and Bishop trays can be readily used in many different situations, such as to catch oil drips when the oil filter on a motor is being changed, or to catch drilling fluids dripping from drill pipe withdrawn (or “tripped”) from a wellbore. The Holtby drip tray is actually an assembly of individual shallow, open-top trays interconnected so as to enlarge the total coverage area. Jaw-like locking members may be used to interconnect the trays. To empty the drip tray assembly, the locking members are removed and the individual trays are emptied separately. The Holtby tray apparatus thus can be effective to facilitate catching drips over a large area while keeping the components of the apparatus (i.e., the individual trays) small enough that manual workers can lift them without great difficulty whether empty or full. However, the Holtby apparatus does not address the problem of splashing and spillage during transport to a disposal site, because the individual trays of the apparatus are always open-topped.
[0012] One possible way to address the splashing and spillage problem would be for the drip tray to have a perimeter partial cover extending inward from the tops of the walls of the tray, leaving a central opening through which liquids could drip into the tray. The perimeter partial cover would act as a barrier to liquid tending to splash the walls while the tray is being transported. However, transport of the tray would still require a considerable degree of care to prevent liquid splashing and spillage out of the central opening. A further disadvantage of this concept is that the perimeter partial cover would reduce the open area available to catch drips to area, compared to the total tray area.
[0013] For the foregoing reasons, there remains a need for a drip tray that has an optimally large open area for receiving liquids, while at the same time providing means for preventing liquids retained in the tray from leaking or splashing out of the tray while the tray is being transported to a liquid disposal facility. The present invention is directed to these needs and objects.
BRIEF SUMMARY OF THE INVENTION
[0014] The foregoing needs and objects are addressed in the present invention by providing a drip tray and cover that provide a continuous liquid-tight seal around the perimeter of the tray when the cover is in place on the tray. The tray has a bottom plate with upstanding walls forming a chamber for receiving liquids. The tray will preferably be rectilinear, but could take other shapes as well, including polygonal (e.g., hexagonal or octagonal) and curvilinear (e.g., circular or elliptical). A continuous shoulder is formed in the top of the walls, and the cover is fashioned with a continuous, downwardly-extending lip that aligns with the shoulder in the walls. A resilient sealing material, such as a rubber or foam gasket (or other suitable material known in the art), is positioned on the shoulder. When the cover is positioned on the tray, the lip presses into the resilient sealing material to create a liquid-tight seal between the tray and cover. Therefore, when the tray needs to be emptied, the cover can be closed onto the tray, and the tray/cover assembly can be transported to a disposal site by any convenient means without concern that the liquid contained in the tray will splash or leak from the tray.
[0015] Accordingly, in one aspect the present invention is a drip tray apparatus comprising:
(a) a tray having a bottom plate and a plurality of walls extending upward from the bottom plate so as to define a chamber having an open top; and (b) a cover having a top plate with an upper surface and a lower surface, said cover being adapted to engage the upper edges of the walls so as to create a substantially liquid-tight seal between the cover and the walls when the cover is in a closed position on the tray.
In the preferred embodiment, the upper edges of the tray walls are configured to define a continuous primary shoulder, continuous resilient sealing means is positioned on the primary shoulder, and the cover is configured to define a continuous, downwardly-extending primary lip, said primary lip being matingly engageable with the primary sealing means, such that when the cover is placed over the tray with the primary lip aligned with the primary sealing means, application of downward force on the cover will urge the primary lip into mating and substantially liquid-tight engagement with the primary sealing means.
[0018] The primary shoulder may be adjacent to and contiguous with either the inner or outer surfaces of the tray walls. Alternatively, the tops of the walls may be formed with a continuous central groove, with the bottom of the groove forming the primary shoulder.
[0019] The cover may be completely separable from the tray, thus allowing for several trays to be deployed adjacent to each other so as to increase the area over which dripping liquids may be captured. Alternatively, the cover may be connected to the tray in a fashion (such as with hinges or similar means) allowing the cover to be moved between an open position and a closed position.
[0020] In the preferred embodiment, the drip tray apparatus includes latching means for releasably securing the cover onto the tray when the cover is in the closed position. Preferably, the latching means will be configured such that actuation of the latching means will induce compressing force between the cover and the tray, with the result that the downwardly-extending lip of the cover is urged, or further urged, into sealing contact with the resilient sealing material. The latching means may be provided by way of one or more latching devices having mating male and female components. Preferably a number of latching devices will be deployed at selected spacing around the perimeter of the tray to ensure that the cover will remain sealingly secured to the tray should one of the devices fail or be inadvertently disengaged.
[0021] In an alternative embodiment, further assurance of liquid-tightness may be provided by way of a secondary resilient sealing means adjacent to the primary resilient sealing means.
[0022] The drip tray preferably will have two or more lifting handles to facilitate manual transport of the tray.
[0023] The drip tray may be emptied by removing the cover (or, in the case of a hinged cover, opening the cover) and pouring the liquid-directly out of the tray chamber over the walls. In alternative embodiments, however, the tray is provided with an outlet through which the liquid can be drained from the tray chamber without needing to remove or open the cover. In such alternative embodiments, the cover may be provided with vent means facilitate drainage through the outlet, by preventing the development of negative air pressure inside the tray/cover assembly due to the flow of liquid through the outlet.
[0024] The drip tray and cover may be made using any suitable materials of construction, which could include sheet steel or aluminum. In the preferred embodiment, however, both the tray and cover are made from a rigid, durable plastic material providing the tray and cover with good structural strength without being unmanageably heavy. The materials used for the tray and cover, whether plastic or other material, will preferably have good impact resistance to minimize the risk of fracture or deformation damage in the event of the tray and/or cover being inadvertently dropped or otherwise damaged. As well, the materials will preferably have good resistance to extreme cold temperatures, to ensure that the tray/cover assembly can be reliably used in winter in cold climates such as northern Canada, without special concern regarding brittle fracture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Embodiments of the invention will now be described with reference to the accompanying figures, in which numerical references denote like parts, and in which:
[0026] FIG. 1 is a plan view of a drip tray in accordance with a first embodiment of the present invention.
[0027] FIG. 2 is a plan view of a drip tray cover in accordance with a first embodiment of the invention.
[0028] FIG. 3 is a side view of the drip tray and drip tray cover shown in FIGS. 1 and 2 respectively, with the cover in position for being lowered into position on the drip tray.
[0029] FIG. 4 is a partial cross-section through the drip tray and cover on line A-A in FIG. 3 , showing the sealed joint between the tray and cover in accordance with a first embodiment of the invention.
[0030] FIG. 5 is a partial cross-section through the drip tray and cover on line A-A in FIG. 3 , showing the sealed joint between the tray and cover in accordance with a second embodiment of the invention.
[0031] FIG. 6 is a partial cross-section through the drip tray and cover on line A-A in FIG. 3 , showing the sealed joint between the tray and cover in accordance with a third embodiment of the invention.
[0032] FIG. 7 is a partial cross-section through the joint formed between the drip tray and cover of a fourth embodiment of the invention.
[0033] FIG. 8 is a plan view illustrating the drip tray of the invention being used to capture liquids from a system of jointed horizontal pipes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Referring to FIGS. 1, 2 , and 3 , the present invention includes a drip tray 10 , plus a drip tray cover 20 adapted to be matingly engageable with the drip tray 10 . The drip tray 10 has a bottom plate 12 and walls 14 extending upward from the bottom plate 12 to form an open-topped, liquid-tight tray chamber 15 into which liquids can be received. In the embodiments illustrated in the Figures, drip tray 10 has opposing side walls 14 S and opposing end walls 14 E defining a drip tray that is rectangular in plan, and further descriptions herein will be with reference to a drip tray 10 and corresponding cover 20 of such rectangular configuration. However, this shape is not essential to the invention; the drip tray 10 may take any of various shapes, including polygonal or curvilinear, or a combination of polygonal and curvilinear, without departing from the scope of the present invention.
[0035] The uppermost portion of the side walls 14 S and end walls 14 E is notched to define a continuous primary shoulder surface 16 . In the embodiment shown in FIGS. 1, 2 , and 3 , the primary shoulder 16 is adjacent to and contiguous with the exterior faces of the side walls 14 S and end walls 14 E, as illustrated in greater detail in FIG. 4 . In this embodiment, the notching of the side walls 14 S and end walls 14 E creates a continuous curb 18 adjacent to the interior faces of the side walls 14 S and end walls 14 E. In the alternative embodiment shown in FIG. 5 , however, the notch is adjacent to the interior faces of the side walls 14 S and end walls 14 E, such that the primary shoulder 16 is adjacent to and contiguous with said interior faces, and the continuous curb 18 is adjacent to the exterior faces of the side walls 14 S and end walls 14 E. In the further alternative embodiment shown in FIG. 6 , a notch or groove 17 is formed within the width of the side walls 14 S and end walls 14 E, such that the primary shoulder 16 is located at the bottom of the groove 17 .
[0036] The drip tray cover 20 has a top plate 22 having an upper surface 22 U and a lower surface 22 L. Extending downward from the lower surface 22 L is a continuous primary lip 24 configured to align with the primary shoulder 16 of drip tray 10 . A continuous primary resilient seal 50 A is disposed between the primary lip 24 and the primary shoulder 16 such that when the cover 20 is lowered onto the drip tray 10 , the primary seal 50 A will be sandwiched between the primary lip 24 and the primary shoulder 16 , thus effecting a seal between the drip tray 10 and the cover 20 , so as to deter or prevent leakage of liquid from the tray chamber 15 .
[0037] The primary seal 50 A may be made of rubber, neoprene, plastic foam, or other material suitable for creating a liquid seal. The primary seal 50 A may be bonded to either the primary shoulder 16 or the primary lip 24 ; alternatively, the primary seal 50 A may be disposed between the primary shoulder 16 and the primary lip 24 (such as by being laid upon the primary shoulder 16 ) without use of a bonding agent.
[0038] Although a satisfactory seal between the drip tray 10 and the drip tray cover 20 can be achieved using the joint detail shown in FIG. 6 , the joint details shown in FIGS. 4 and 5 provide a particular advantage in that debris accumulating on primary shoulder 16 and/or the primary seal 50 A would be somewhat more easily removed than debris collecting in the groove 17 of the embodiment in FIG. 6 .
[0039] The effectiveness of the liquid seal between the drip tray 10 and the cover 20 may be enhanced by providing means for maintaining the primary lip 24 and the primary shoulder 16 in close contact with the primary seal 50 A, preferably under sufficient pressure to compress the primary seal 50 A to at least a minimal degree. This may be accomplished to a beneficial extent by sizing the primary lip 24 so that it will have a friction fit with the curb 18 of the drip tray 10 .
[0040] In the preferred embodiment, the drip tray 10 and cover 20 are provided with latching means to provide further assurance that the cover 20 will not become accidentally or inadvertently separated from the drip tray 10 . Even more preferably, the latching means will be adapted so as to induce a force tending to clamp the drip tray 10 and the cover 20 together (or further together), and thus in turn increasing the force or pressure with which the primary seal 50 A is compressed between the primary lip 24 and the primary shoulder 16 , and further enhancing the effectiveness of the seal as a result.
[0041] It will be readily apparent to persons skilled in the art that various known types of latching means may be used to perform the desired functions described above. In the Figures, the latching means are conceptually shown as a plurality of two-component latching devices 30 spaced around the joint between the drip tray cover 20 and the drip tray 10 . More specifically, each latching device 30 is schematically shown as having a male component 30 A that is releasably and lockingly engageable with a female component 30 B, with the male components 30 A and female components 30 B being mounted to the drip tray cover 20 and the drip tray 10 respectively, or vice versa. Preferably the male components 30 A and female components 30 B are mounted such that some amount of pressure must be applied to the cover 20 , when it is being mounted onto the drip tray 10 , in order to bring the male components 30 A and female components 30 B into mating engagement. This pressure is absorbed by compressive deformation of the primary seal 50 A disposed between the primary lip 24 and the primary shoulder 16 , which in turn enhances the effectiveness of the liquid seal along the joint.
[0042] In preferred embodiments of the present invention, the effectiveness of the liquid seal between the drip tray 10 and the drip tray cover 20 is further enhanced by providing a secondary resilient seal, similar to the primary resilient seal 50 A described above. In the embodiments shown in FIGS. 4 and 5 , the upper surface 18 A of curb 18 serves as a secondary shoulder on which a secondary resilient seal 50 B may be positioned. When the drip tray cover 20 positioned on the drip tray 10 , the secondary seal 50 B will be compressed between the secondary shoulder 18 A and the lower surface 22 L of the top plate 22 of the drip tray cover 20 , thus providing a second line of defence against leakage of liquid from the tray chamber 15 .
[0043] In alternative embodiments, the present invention may be provided with only the secondary resilient seal 50 B, as that term is used herein. In other words, the invention may be practised with a resilient seal on positioned on top of the curb 18 and no resilient seal on the shoulder 16 formed by the notch in the side walls 14 S and end walls 14 E, without departing from the concept and principles of the invention. What is essential is that there be at least one continuous resilient seal disposed between the drip tray cover 20 and the drip tray 10 , and the terminology that may be used to designate that resilient seal and the surfaces of the drip tray 10 and drip tray cover 20 with which it comes into contact are a matter of preference.
[0044] In accordance with this understanding, it will be appreciated that there may be alternative embodiments of the invention in which the side walls 14 S and end walls 14 E are not notched, and therefore do not define a curb in the sense discussed previously herein. In such embodiments, an example of which is illustrated in FIG. 7 , the top surfaces of the side walls 14 S and end walls 14 E serve as the “primary shoulder” on which the primary resilient seal 50 A is disposed. In this embodiment, the drip tray cover 20 does not have a downwardly-extending lip that engages the primary seal 50 A; instead, the primary seal 50 A is compressed between the top surfaces of the side walls 14 S and end walls 14 E, and the lower surface 22 L of the top plate 22 of the drip tray cover 20 .
[0045] In the preferred embodiment, the drip tray 10 is provided with a two or more handles 32 to facilitate manual transport of the drip tray 10 both when empty and when containing liquids. In the Figures, two handles 32 are shown on each side of the drip tray 10 , but the number and location of the handles 32 will be a matter of preference.
[0046] In preferred embodiments, the top plate 22 of the drip tray cover 20 is provided with a drainage port 34 through which liquid may be poured out of the drip tray 10 while the cover 20 is still in place on the drip tray 10 . The drainage port 34 will typically be near one edge of the cover 20 although this is not essential. In alternative embodiments, the drainage port 34 may be adapted to receive a spout or vacuum hose connection or other means to facilitate emptying of liquids from the drip tray 10 . In other alternative embodiments, the drainage port 34 could be provided in one of the side walls 14 S or end walls 14 E of the drip tray 10 , with suitable means for closing off the drainage port 34 until it is desired to drain liquids from the drip tray 10 . To facilitate drainage of liquid through the drainage port 34 , the drip tray cover 20 will preferably have one or more vacuum relief vents, as conceptually indicated by reference numeral 36 in FIG. 2 .
[0047] The drip tray cover 20 may be completely separate from the drip tray 10 . In alternative embodiments (not shown), the drip tray cover 20 may be hingingly attached to the drip tray 10 along one of the side walls 14 S, or along one of the end walls 14 E if desired.
[0048] The operation and use of the present invention may be easily understood. The drip tray 10 is positioned under a potential source of dripping or leaking liquid, with the drip tray cover 20 removed (or in the open position if hinged to the drip tray 10 ). This is illustrated by way of example in FIG. 8 , which shows the drip tray 10 positioned under a pipe joint in a testing line for use in well testing procedures as previously described. When liquid accumulates in the tray chamber 15 (such as when the pipe joint in FIG. 7 is broken out and liquid in the testing line empties into the drip tray 10 ), the cover 20 is positioned on the drip tray 10 (or, in hinged variants, closed onto the drip tray 10 ) as previously described herein. The liquid is thus retained in an enclosed and substantially liquid-tight drip tray assembly which can be conveniently transported, manually or perhaps with the assistance of mechanical hoisting equipment, to a disposal site with little or no risk of spillage in transit. The drip tray cover 20 may be removed at the disposal site to facilitate quick emptying of the drip tray 10 . In embodiments provided with a drainage port 34 , the drip tray 10 may optionally be emptied through the drainage port 34 so as to further reduce the risk of inadvertent spillage from the drip tray 10 during the tray emptying operation.
[0049] It will be readily appreciated by those skilled in the art that various modifications of the present invention may be devised without departing from the essential concept of the invention, and all such modifications are intended to be included in the scope of the claims appended hereto.
[0050] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following that word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one such element.
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A transportable drip tray and cover assembly provides liquid-tight retention of collected liquids. The tray has a bottom plate with upstanding walls forming a chamber for receiving liquids. A continuous shoulder is formed in the top of the walls, and the cover is fashioned with a continuous, downwardly-extending lip that aligns with the shoulder, and a resilient sealing material is positioned on the shoulder. When the cover is mounted on the tray, the lip will press into the sealing material to create a liquid-tight seal. When the tray needs to be emptied, the cover can be closed onto the tray, and the assembly can be transported to a disposal site by any convenient means without liquid splashing or leaking from the tray. The assembly may include latches to secure the cover to the tray and to further compress the resilient sealing material. The tray or cover may include an outlet to facilitate drainage from the chamber without removing the cover.
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This application is a Divisional application of U.S. patent application Ser. No. 13/079,270, filed Apr. 4, 2011, which is a Continuation application of U.S. patent application Ser. No. 11/737,397, filed Apr. 19, 2007, which claims priority of German Patent Application No. 10 2006 018 124.7, filed Apr. 19, 2006, which are incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to a rotary pump having an adjustable, preferably variable, delivery volume, and a method for manufacturing it. The rotary pump can in particular be used as a lube oil pump for supplying lube oil to an internal combustion engine, in particular an internal combustion engine of a motor vehicle engine.
2. Description of the Related Art
Lube oil pumps in motor vehicles are driven in accordance with the rotational speed of the engine which is to be supplied with the lube oil, usually directly or via a mechanical gearing of the engine. The rotational speed of the pump correspondingly increases with the rotational speed of the engine. Since rotary pumps have a constant specific delivery volume, i.e. they deliver substantially the same amount of fluid per revolution at any rotational speed, the delivery volume increases in proportion to the rotational speed of the pump. The engine's requirement also increases roughly in proportion to the rotational speed of the engine, up to a certain limiting rotational speed, beyond which however it deviates or at least levels out, such that when the limiting rotational speed is exceeded, the rotary pump delivers beyond the requirement. Adjustable rotary pumps have been developed in order to not have to direct the excess delivered amount into a reservoir, which incurs losses. Examples of adjustable rotary pumps include the internal-axle and external-axle toothed wheel pumps known from DE 102 22 131 B4. Adjustable vane pumps are also known. These pumps each comprise an actuating member which can be moved back and forth. In the examples cited, the delivery rotor is either a toothed wheel or a vane. In the known internal-axle toothed wheel pumps and vane pumps, the movement of the adjusting member adjusts the eccentricity between two mutually mating toothed wheels or the eccentricity between the vane and the actuating member in accordance with the requirement of the consumer. In external-axle toothed wheel pumps, the axial engagement length of two toothed wheels is adjusted. For adjusting, the respective actuating member is charged with an actuating force, for example charged directly with the high-pressure fluid.
The actuating force is counteracted by a spring member. In pumps of the type cited, which are increasingly manufactured from light metal alloys, in particular aluminum alloys, the surfaces of the pump casing and of the actuating member which are in frictional contact are surprisingly subject to particular wear and determine the service life of the pump.
SUMMARY OF THE INVENTION
An exemplary embodiment of the invention is based on a displacement-type rotary pump which comprises a casing including a delivery chamber, a delivery rotor which can be rotated in the delivery chamber about a rotational axis, and at least one actuating member which can be moved back and forth in the casing. The actuating member can surround the delivery rotor or preferably can be arranged on, i.e. facing, a front face of the delivery rotor. An actuating member which surrounds the delivery rotor can in particular be provided in internal-axle pumps, for example toothed ring pumps and vane pumps, and can be formed as a rotationally mounted eccentric ring such as is known from DE 102 22 131 B4 or EP 0 846 861 B1, or as a lifting ring. Preferably, however, an actuating member such as is known from external toothed wheel pumps, for example from DE 102 22 131 B4, is arranged on or facing a front face of the delivery rotor and axially seals the delivery chamber on the relevant front face. Such an actuating member forms an actuating piston which can be axially moved back and forth along the rotational axis of the feed wheel. An actuating member which surrounds the delivery rotor is rotationally or pivotably mounted, or alternatively can also be mounted such that it can be moved linearly. The delivery chamber comprises a low-pressure side and a high-pressure side. At least one inlet is arranged on the low-pressure side, and at least one outlet for a fluid to be delivered is arranged on the high-pressure side. The low-pressure side of the delivery chamber and the entire upstream portion of the system in which the pump is installed form the low-pressure side of the pump. The high-pressure side of the delivery chamber and the entire subsequent downstream portion of the system form the high-pressure side of the pump. The low-pressure side extends as far as a reservoir for the fluid, and the high-pressure side extends at least as far as the most downstream point of consumption requiring a high fluid pressure.
The actuating member can be charged with an actuating force in the direction of its mobility, said force being dependent on the pressure of the fluid on the high-pressure side of the pump or on another variable of the system which is decisive for the requirement. The pressure can be taken directly at the outlet of the delivery chamber or at a downstream pump outlet or can be taken from a point further downstream in the system, for example from the final point of consumption. Instead of or in addition to the pressure, the temperature of the fluid or of a component in the system in which the pump is installed, for example a temperature of the engine, can for example feature in forming the actuating force. Other physical variables for determining the actuating force are adduced as applicable. The actuating force can be generated by means of an additional actuating member, for example an electric motor. More preferably, however, the actuating member can be directly charged with the pressure of the fluid, i.e. during operation of the pump, it is charged with the pressurized fluid. In preferred embodiments, in particular in embodiments in which it is charged with the pressurized fluid, the actuating member is charged with an elasticity force which counteracts the actuating force. The elasticity force is generated by an elasticity member, preferably a mechanical spring.
The actuating member is in sliding contact with the casing, since the casing forms a track and the actuating member forms an actuating member sliding surface, and the actuating member is guided in the sliding contact by the track by means of its sliding surface. The actuating member can also additionally be guided in other ways, for example in a pivoting joint, however it is more preferably guided by the track only.
In accordance with the exemplary embodiment of the invention, the actuating member sliding surface and/or the track is/are formed from a sliding material. The sliding material can in particular be a plastic, a ceramic material, a nitride, a nickel-phosphorus compound, a sliding varnish, namely a lubricating varnish or solid film lubricant, a DLC coating, a Ferroprint coating or a nano-coating. The sliding material can form a surface coating. If the sliding material is a plastic, the relevant component—i.e. a casing portion forming the track, or the actuating member—can consist exclusively or at least substantially of the sliding material. In preferred embodiments, both the actuating member sliding surface and the track consist of a sliding material, either each of the same sliding material or each of a different sliding material. However, wear is also reduced even if only the actuating member sliding surface or only the track consists of the sliding material, wherein using the sliding material for the actuating member sliding surface is preferred.
The invention is based on the insight that furrowing, or conversely also adhesion, can be decisive for wear. Adhesion can in particular be the frictional mechanism which determines wear when the friction partners which are in sliding contact are so smooth that the frictional mechanism takes a back seat to furrowing or abrasion. It has for instance been established for adjustable external toothed wheel pumps that the actuating members arranged facing the front faces of the delivery rotor which can be axially moved, i.e. the two actuating pistons, are subject to considerable oscillating frictional wear. The adjusting movements required for setting the delivery volume are too slow to be causing the oscillating frictional wear. However, the adjusting movements are superimposed with oscillations having short strokes as compared to the varying movements and a substantially higher frequency. This therefore causes adhesion between the sliding surfaces of the actuating members and the track of the pump casing, resulting locally in material welding, which breaks away due to the adjusting movements. In accordance with the invention, the sliding partners—i.e. the sliding surface of the one or more actuating members and the one or more tracks of the casing—are configured such that the adhesion tendency in the friction system is significantly reduced as compared to the surfaces made of aluminum alloys which are usual for the sliding partners. The sliding material is advantageously chosen to exhibit an adhesion energy or free surface energy which is at most half the adhesion energy of pure aluminum. This condition is fulfilled in particular by plastic materials and ceramic materials, preferably metal oxide ceramics, but also by the other sliding materials cited above. The adhesion energy or free binding energy increases with the density of free electrons. Accordingly, the requirement for a low adhesion energy is fulfilled by materials having a low density of free electrons.
Heat-resistant thermoplasts are one group of materials which are particularly suitable as the sliding material. The one or—as applicable—more polymers of the plastic sliding material are advantageously modified to lubrication, i.e. the plastic contains a sliding additive which improves its sliding properties. Such a sliding material is also highly suitable in cases in which only one of the sliding partners of the friction system consists of a sliding material. A preferred sliding additive is graphite. Alternatively, a polymer from the group of fluoropolymers may above all be considered as a sliding additive. A preferred example from this group is polytetrafluoroethylene (PTFE). Particularly preferably, both graphite and at least one fluoropolymer, preferably PTFE, are added to the polymer, copolymer, polymer mixture or polymer blend, as sliding additives. The proportion of the sliding additive should be at least 10% by weight in total; preferably, the proportion of the sliding additive is 20±5% by weight in total. If different materials form the sliding additive, the individual proportions should be at least substantially the same. Plastic sliding materials containing 10±2% by weight of graphite and 10±2% by weight of fluoropolymer are for instance preferred. Adding fibrous material is also regarded as being advantageous, wherein carbon fibers are preferred as the fibrous material. Glass fibers should not be added, since they can form fine needle points on the surface of the sliding layer formed from the sliding material and therefore impair its sliding properties. The plastic sliding material preferably contains 10±5% by weight, more preferably 10±3% by weight of fibrous material.
Plastics which are preferred as the sliding material contain 70±10% by weight of polymer material. Although polymer mixtures or polymer blends may in principle be considered as the base material, the plastic sliding material preferably contains only one type of polymer. Polymers, with their long hydrocarbon chains, have a very low density of free electrons and also correspondingly few free spaces for free electrons of the sliding partner. Amorphous polymers, with their convoluted chains of molecules, are particularly advantageous in this regard. The degree of crystallinity of the polymer material should be as low as possible. Conversely, the polymer material should not have any practically significant entropy elasticity. The minimum working temperature should be around −40° C., preferably below this. The permanent working temperature should be at least +150° C. Within this range of working temperatures, a low creeping tendency, sufficient mechanical stability and dimensional stability are required. For its use in vehicle manufacturing, the plastic sliding material should also be resistant to fuel. Resistance to the fluid delivered should be a general requirement. It is also advantageous if the sliding material also has the ability to embed or absorb hard particles which can be created by furrowing, i.e. attrition. Preferred polymer materials are:
polysulphone (PSU) or in particular polyether sulphone (PES), and copolymerides of PES and polysulphone (PSU); polyphenylene sulfide (PPS); polyether ketones, namely PAEK, PEK or in particular PEEK; polyphthalamide (PPA); and polyamide (PA).
In preferred first embodiments, the actuating member is formed from the plastic sliding material, preferably by injection molding. In such embodiments, it preferably consists of the plastic. In principle, however, inserts can be embedded in the plastic; in this sense, the actuating member at least substantially consists of the plastic sliding material. Instead of the actuating member, a casing portion which forms the track can also formed from the plastic sliding material, preferably by injection molding and from the plastic alone or at least substantially from the plastic, in the above sense. In a comparatively preferred variant, the casing is formed from a metal, preferably light metal, and the track is formed by an insert, preferably a bushing, consisting of the plastic sliding material. In principle, the actuating member and a casing portion which forms the track, in particular an insert, can also each be formed from the plastic sliding material. Within the context of the first embodiments, it is particularly preferred if only the actuating member consists at least substantially of the plastic sliding material, while the track is formed only as a surface coating by a plastic sliding material or, as applicable, another sliding material, or is formed as a non-coated metal surface.
In preferred second embodiments, at least one of the sliding surfaces which are in sliding contact is formed by a thin sliding layer. The actuating member and/or the casing portion forming the track consists or consists of another material below the superficial sliding layer, i.e. a substrate material. The substrate material can in particular be a metal, preferably a light metal. Prospective light metals are above all aluminum, aluminum alloys and magnesium alloys. In the second embodiments, both sliding surfaces are preferably formed as superficial sliding layers, each from a sliding material which has a significantly lower adhesion energy than aluminum or magnesium. If only one of the sliding surfaces of the two sliding partners consists of the sliding material, it is preferably the sliding surface of the actuating member. A combination of a first and second embodiment is also advantageous, wherein the actuating member or the casing portion forming the track, preferably an insert, at least substantially consists of plastic and the other part comprises a surface layer made of the sliding material, for example also made of plastic or made of a ceramic material.
The superficial sliding layer can be formed by applying the sliding material or by modifying the substrate material. Plastic sliding material is applied; preferably, the plastic is injection-molded around the blank formed from the substrate material. The plastic sliding material should exhibit a longitudinal thermal expansion which comes as close as possible to the longitudinal expansion of the substrate material. Modifying light-metal substrate materials, by contrast, creates a metal-oxide ceramic sliding layer or a nitride layer. If the substrate material is aluminum or an aluminum alloy, the sliding layer is preferably obtained by anodisation. Anodisation can in particular form a so-called Hardcoat® sliding layer or more preferably a so-called Hardcoat® smooth sliding layer. Hardcoat® smooth electrolytes consist of a mixture of oxalic acid and additives. Sulfuric acid (H 2 SO 4 ) is generally used to manufacture Hardcoat® layers. Anodic oxidation methods for forming a metal-ceramic sliding layer comparable to Al 2 O 3 sliding layers are also known for magnesium and magnesium alloys as the substrate material, for example the so-called DOW method. PTFE is preferably dispersed in the ceramic sliding layer; the ceramic is impregnated with PTFE, so to speak.
As already mentioned, the casing or also only a casing portion forming the track can in particular be formed from aluminum or an aluminum alloy. The casing or the relevant casing portion is preferably cast. The aluminum alloy is therefore preferably a cast aluminum alloy. If the actuating member does not at least substantially consist of plastic sliding material, it is preferably formed from aluminum or an aluminum alloy, preferably a cast alloy, preferably by casting and then extruding or by sintering and calibrating. It holds for both the casing portion and the actuating member that the respective aluminum alloy preferably contains 10±2% by weight of silicon. The respective alloy also preferably contains copper, though at a proportion of at most 4% by weight, preferably at most 3% by weight. It can furthermore contain a smaller proportion of iron. The casing portion, and preferably other portions of the casing, is or are preferably formed by sand casting or die casting, wherein die casting is primarily appropriate for larger-volume runs and sand casting is primarily appropriate for smaller-volume runs. Chill casting can also be used instead of sand casting. A particularly preferred alloy for the casing portion and also for the casing as a whole is AlSi8Cu3 if it is formed by sand casting or chill casting, and AlSi9Cu3 plus a small proportion of iron if it is formed by die casting.
Nitrides which are preferred as the sliding material are titanium carbon nitride (TiCN) and in particular nitrided steel. Steels having a high chromium content, preferably with a proportion of molybdenum and also preferably with a proportion of vanadium, for example 30CrMoV9, are in particular used as nitrided steels. TiCN is used as a surface coating on a light-metal substrate material. If nitrided steel forms the sliding material, the corresponding steel is preferably the substrate material. For instance, the actuating member can in particular be formed from the steel and the actuating member sliding surface can consist of the nitrided steel. A particularly preferred tribological pairing is Hardcoat® ceramic or Hardcoat® smooth ceramic for one sliding partner and nitrided steel for the other sliding partner. The ceramic sliding material of this pairing can contain PTFE, however low wear is also achieved when using the ceramic only. A tribological pairing of Hardcoat® ceramic or Hardcoat® smooth ceramic with sintered tin bronze is also an alternative, although only a conditionally preferred alternative with regard to its thermal expansion.
A DLC (diamond-like carbon) coating, and then in particular a tungsten carbide coating, also has a wear-reducing effect. A DLC sliding coating can in particular be produced by plasma-coating.
Sliding varnishes are also suitable sliding materials, wherein it also holds for sliding varnishes that, while wear is reduced even if only one of the sliding partners is coated, a sliding varnish coating on both sliding partners of the friction system is however preferred. A combination of a sliding varnish for one sliding partner and a plastic material for the other sliding partner is also an advantageous solution. The sliding varnish consists of an organic or inorganic binder, one or more solid lubricants and additives. MoS 2 , graphite or PTFE, individually or in combination, may in particular be considered as the solid lubricant. Before being coated with the sliding varnish, the surface to be coated is pre-treated, expediently by forming a phosphate layer on the surface to be coated. One particular sliding varnish is Ferroprint, which contains fine steel tips as the solid lubricant.
If a nano-coating forms the sliding material, nano-phosphorus compounds can in particular form the sliding layer.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments of the invention are explained below on the basis of figures. Features disclosed by the example embodiments, each individually and in any combination of features which are not mutually exclusive, advantageously develop the subjects of the embodiments described above. There is shown:
FIG. 1 is a cross-sectional view of a delivery chamber of an external toothed wheel pump comprising two delivery rotors in toothed engagement; and
FIG. 2 is a longitudinal cross-sectional view of the external toothed wheel pump.
DETAILED DESCRIPTION
FIG. 1 shows a cross-section of an external toothed wheel pump. In a pump casing comprising a casing portion 3 and a cover 6 ( FIG. 2 ), a delivery chamber is formed in which two externally toothed delivery rotors 1 and 2 in the form of externally toothed wheels are mounted such that they can rotate about parallel rotational axes R 1 and R 2 . The delivery rotor 1 is rotary driven, for example by the crankshaft of an internal combustion engine of a motor vehicle. The delivery rotors 1 and 2 are in toothed engagement with each other, such that when the delivery rotor 1 is rotary driven, the delivery rotor 2 mating with it is also rotationally driven. An inlet 4 feeds into the delivery chamber on a low-pressure side, and an outlet 5 on a high-pressure side, for a fluid to be delivered, preferably lube oil for an internal combustion engine. The casing portion 3 forms a radial sealing surface 9 which faces each of the delivery rotors 1 and 2 in the radial direction and encloses the respective delivery rotor 1 or 2 circumferentially, forming a narrow radial sealing gap. For the delivery rotor 1 , the casing 3 , 6 also forms an axial sealing surface on each front face of the delivery rotor 1 , axially facing it, of which the sealing surface 7 can be seen in FIG. 1 . Another axial sealing surface is formed axially facing each of the two front faces of the delivery rotor 2 , of which the sealing surface 17 can be seen in the cross-section in FIG. 1 .
By rotary driving the delivery rotors 1 and 2 , fluid is suctioned into the delivery chamber through the inlet 4 and, in the tooth gaps of the delivery rotors 1 and 2 , delivered through the respective enclosure to the high-pressure side of the delivery chamber, where it is delivered through the outlet 5 to the consumer—in the assumed example, the internal combustion engine. During the delivery action, the high-pressure side is separated from the low-pressure side by the sealing gaps formed between the delivery rotors 1 and 2 and the sealing surfaces cited, and by the toothed engagement of the delivery rotors 1 and 2 . The delivery rate of the pump increases in proportion to the rotational speed of the delivery rotors 1 and 2 . Since, above a certain limiting rotational speed, the internal combustion engine—assumed as the consumer by way of example—absorbs less lube oil than the pump would deliver in accordance with its characteristic curve which increases in proportion to the rotational speed, the delivery rate of the pump is regulated above the limiting rotational speed. For regulation, the delivery rotor 2 can be moved axially, i.e. along its rotational axis R 2 , back and forth relative to the delivery rotor 1 , such that the engagement length of the delivery rotors 1 and 2 , and correspondingly the delivery rate, can be changed.
In FIG. 2 , the delivery rotor 2 assumes an axial position exhibiting an axial overlap, i.e. an engagement length, which has already been reduced as compared to the maximum engagement length. The delivery rotor 2 is part of an adjusting unit consisting of a bearing journal 14 , an actuating member 15 , an actuating member 16 and the delivery rotor 2 which is mounted on the bearing journal 14 between the actuating members 15 and 16 such that it can rotate. The bearing journal 14 connects the actuating members 15 and 16 to each other, secure against rotation. The actuating member 16 forms the axial sealing surface 17 facing the delivery rotor 2 . The actuating member 15 forms the other axial sealing surface 18 . The entire adjusting unit is mounted, secured against rotation, in a shifting space of the pump casing 3 , 6 , such that it can shift axially back and forth.
The casing is formed by the casing portion 3 and the casing cover 6 which is fixedly connected to it. The casing cover 6 is formed with a base, the front face of which facing the delivery rotor 1 forms the sealing surface 7 . On the opposite front face, the casing portion 3 forms the fourth axial sealing surface 8 which axially faces the delivery rotor 1 . The side of the sealing surface 8 facing the adjusting unit is provided with a circular segment-shaped cutaway for the actuating member 15 . The side of the actuating member 16 facing the delivery rotor 1 is provided with a circular segment-shaped cutaway for the base 6 forming the sealing surface 7 . Apart from the respective cutaway, the sealing surface 7 corresponds to the sealing surface 8 , and the sealing surface 17 corresponds to the sealing surface 18 .
The adjusting members 15 and 16 of the example embodiment are adjusting pistons. The shifting space in which the adjusting unit can be moved axially back and forth comprises a partial space 10 which is limited by the rear side of the actuating member 15 and a partial space 11 which is limited by the rear side of the actuating member 16 . The partial space 11 is connected to the high-pressure side of the pump and is constantly charged with pressurized fluid diverted there, thus acting on the rear side of the actuating member 16 . A mechanical pressure spring is arranged in the space 10 as an elasticity member 12 , the elasticity force of which acts on the rear side of the actuating member 15 . The elasticity member 12 counteracts the pressure force acting on the actuating member 16 in the partial space 11 . The regulation of such external toothed wheel pumps is known and does not therefore need to be explained. The regulation can in particular be configured in accordance with DE 102 22 131 B4.
If the axial sealing surfaces 7 , 8 and 17 , 18 were circumferentially smooth and the axial sealing gaps correspondingly circumferentially narrow, fluid on the high-pressure side in the engagement region of the delivery rotors 1 and 2 would be squeezed, i.e. compressed even beyond the pressure of the high-pressure side, and delivered to the low-pressure side. A drive output is consumed for squeezing the fluid, and a delivery flow pulsation is also associated with the particular compression of the fluid and its transport through the toothed engagement.
In order to eliminate the disadvantages cited, the sealing surfaces 7 , 8 , 17 and 18 are each provided with a relieving pocket on the high-pressure side. Of the four pockets, the pockets 7 a and 17 a can be seen in FIG. 1 . Relieving pockets are only formed on the high-pressure side. The casing portion 3 guides the actuating members 15 and 16 in a sliding contact. For the sliding contact, the casing portion 3 forms a track 3 a and the casing portion 3 together with the cover 6 forms a track 3 b , 6 b . The actuating members 15 and 16 each form an actuating member sliding surface 15 a and 16 a at their outer circumferential surface. More specifically, the track 3 a and the actuating member sliding surface 15 a on the one hand, and the track 3 b , 6 b and the actuating member sliding surface 16 a on the other hand, are in sliding contact. In the prior art, it is usual to produce the casing 3 , 6 and the actuating members 15 and 16 from light metal alloys. In the friction systems formed from the tracks 3 a and 3 b , 6 b on the one hand and the actuating member sliding surfaces 15 a and 16 b on the other hand, a particular sliding material forms at least one of each of the sliding partners of the relevant friction system, wherein in the friction system 3 a / 15 a , either the track 3 a or the actuating member sliding surface 15 a can be formed by the sliding material. The same sliding material can also form both the track 3 a and the actuating member sliding surface 15 a . Lastly, the two sliding surfaces 3 a and 15 a can each be formed by a different sliding material. The same applies in relation to the other friction system 3 b , 6 b / 16 a . If only one of the sliding partners of the respective friction system consists of the sliding material, the same sliding material is expediently used in each case. If both friction partners consist of a sliding material, the actuating member sliding surfaces 15 a and 16 b are each formed by the same sliding material or the tracks 3 a , 3 b and 6 b are each formed by the same sliding material.
Although in principle one of the sliding partners in the respective friction system can consist of a metal alloy, preferably a light metal alloy, it is in accordance with preferred example embodiments if each of the sliding partners is formed by a particular sliding material having a low adhesion energy. The sliding material of the sliding partners of the respective friction system can be the same or can be different. The actuating members 15 and 16 can be formed entirely from the sliding material, or can be formed from a substrate material, preferably a light metal alloy, and each superficially comprise a sliding layer made of the sliding material. The casing—in the example embodiment, the casing portion 3 and the cover 6 —can also be formed from plastic, however in preferred example embodiments, at least the casing portion 3 and preferably the cover 6 are cast from a metal alloy, preferably a light metal alloy. Aluminum alloys may in particular be considered as the light metal. Preferred examples are given below:
Example 1
casing portion 3 and cover 6 : each made of an AlSi9Cu3(Fe) die cast
actuating members 15 and 16 : PES compound: 10% by weight of carbon fibers, 10% by weight of graphite, 10% by weight of PTFE, remainder PES (e.g. ULTRASON®)
In Example 1, the casing portion 3 and the cover 6 are each formed from the same aluminum alloy, namely AlSi9Cu3, by die casting. The alloy can contain a small proportion of iron. The tracks 3 a , 3 b and 6 b are obtained in an exact fit by being mechanically machined. The actuating members 15 and 16 are each formed entirely from the specified plastic sliding material. The sliding surfaces 15 a and 16 a are produced in an exact fit by being mechanically machined.
Example 2
casing portion 3 and cover 6 : each made of an AlSi9Cu3(Fe) die cast
actuating members 15 and 16 : PES compound: 10% by weight of carbon fibers, 10% by weight of graphite, 10% by weight of PTFE, remainder PES (e.g. ULTRASON®)
tracks 3 a , 3 b and 6 b : coated with plastic or sliding varnish modified to lubrication
Except for the tracks 3 a , 3 b and 6 b , Example 2 corresponds to Example 1. Unlike Example 1, however, each of the tracks 3 a , 3 b and 6 b is formed by a sliding layer of plastic sliding material or sliding varnish. The plastic sliding material can in particular be the material of the actuating members 15 and 16 .
Example 3
casing portion 3 and cover 6 : each made of an AlSi9Cu3(Fe) die cast
actuating members 15 and 16 : extruded parts made of a cast aluminum semi-finished product as the substrate material, for example AlSi8Cu3
sliding surfaces 15 a and 16 a : PES compound: 10% by weight of carbon fibers, 10% by weight of graphite, 10% by weight of PTFE, remainder PES (e.g. ULTRASON®)
The casing portion 3 and the cover 6 correspond to Example 1. The actuating members 15 and 16 each consist of the same aluminum alloy, preferably AlSi8Cu3. They are formed from a cast semi-finished product of the aluminum alloy, by extrusion. At least the circumferential surfaces are then each provided with a sliding layer of the plastic sliding material. Instead of forming the blanks of the actuating members 15 and 16 by extrusion, the blanks can be formed by sintering and calibrating. The extruded or calibrated blanks are heated and the plastic sliding material is injection-molded around them in a die, preferably completely enclosing them.
Example 4
casing portion 3 and cover 6 : each made of an AlSi9Cu3(Fe) die cast
tracks 3 a , 3 b and 6 b : Hardcoat® smooth (Hardcoat® smooth sliding layer, preferably impregnated with PTFE)
actuating members 15 and 16 : extruded parts made of a cast aluminum semi-finished product as the substrate material, for example AlSi8Cu3
sliding surfaces 15 a and 16 a : Hardcoat® smooth (Hardcoat® smooth sliding layer, preferably impregnated with PTFE)
The casing portion 3 and the cover 6 correspond to Example 1. The actuating members 15 and 16 each consist of the same aluminum alloy, preferably AlSi8Cu3. They are either formed from a cast semi-finished product by extrusion or alternatively by sintering and calibrating. The actuating member blanks are then anodized at least on their circumferential surface forming the respective sliding surface 15 a and 16 a . A mixture of oxalic acid and additives is used as the electrolyte, such that a sliding layer of Al 2 O 3 Hardcoat® smooth is formed on each of the outer circumferential surfaces. The sliding layer is preferably impregnated with PTFE. The tracks 3 a , 3 b and 6 b are formed in the same way, also each as a Hardcoat® smooth sliding layer, preferably as a PTFE-impregnated sliding layer.
In a modification, one of the two sliding partners or also both sliding partners can each be formed as a Hardcoat® sliding layer, also preferably as a PTFE-impregnated sliding layer.
Example 5
casing portion 3 and cover 6 : each made of an AlSi9Cu3(Fe) die cast
tracks 3 a , 3 b and 6 b : Hardcoat® sliding layer
actuating members 15 and 16 : steel, for example 30CrMoV9, as the substrate material
sliding surfaces 15 a and 16 a : nitrided steel
The casing portion 3 and the cover 6 correspond to Example 1 and, once formed, are anodized such that the tracks 3 a , 3 b and 6 b are obtained as an Al 2 O 3 Hardcoat® (Hardcoat® sliding layer). The Hardcoat® sliding layer can be impregnated with PTFE. The actuating members 15 and 16 are formed from steel and nitrided on their surface, at least on their outer circumferential surfaces.
Example 6
casing portion 3 and cover 6 : AlSi8Cu3 sand cast or chill cast
actuating members 15 and 16 : extruded parts made of a cast aluminum semi-finished product as the substrate material, for example AlSi8Cu3
sliding surfaces 15 a and 16 a : Hardcoat® smooth (Hardcoat® smooth sliding layer)
The casing portion 3 and the cover 6 are each formed from AlSi8Cu3 by sand casting or chill casting. The tracks 3 a , 3 b and 6 b are produced in an exact fit by being mechanically machined. The actuating members 15 and 16 are each formed from a cast aluminum semi-finished product by extrusion, and anodized. A mixture of oxalic acid and additives is used as the electrolyte, such that a sliding layer of Al 2 O 3 Hardcoat® smooth (Hardcoat® smooth sliding layer) is formed on each of the outer circumferential surfaces. The Hardcoat® smooth sliding layer preferably contains PTFE.
In a modification, a Hardcoat® ceramic or Hardcoat® smooth ceramic also forms the tracks 3 a , 3 b and 6 b , wherein here, too, the ceramic can advantageously be impregnated with PTFE.
The method of manufacture and choice of materials in the last example embodiment is particularly suitable for smaller-volume runs, while forming the casing portions 3 and 6 by die casting is the better choice for large-volume runs. Metal-ceramic sliding layers are particularly suitable for use in friction systems comprising a light-metal sand cast structure or chill cast structure or light-metal cast alloys in general which are solidified at or near thermodynamic equilibrium. In conjunction with die cast parts as sliding partners, the α-mixed crystals—for example AlSi—of the die cast structure, which are smaller due to the shorter cooling time, cause problems which for metal-oxide ceramic sliding layers act as fine abrasive grains. If one of the sliding partners comprises a die cast structure or a metastable phase in general on its sliding surface, then heat-resistant thermoplasts modified to lubrication are the better choice, or each of the two sliding partners should comprise a Hardcoat® sliding layer or Hardcoat® smooth sliding layer. Even for sand cast structures or chill cast structures, however, both sliding partners preferably consist of a sliding material having a low adhesion energy.
In the foregoing description, preferred embodiments of the invention have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principals of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled to.
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A rotary pump having a variable delivery volume, including: a casing; a delivery chamber formed in the casing; at least one delivery rotor which is rotatable in the delivery chamber; an actuating member which is arranged facing a front face of the delivery rotor or surrounds the delivery rotor, and is moveable in the casing for adjusting the delivery volume; the actuating member chargeable with an actuating force which is dependent on a fluid requirement; a track which is formed in the casing and guides the actuating member on an actuating member sliding surface in a sliding contact; and a sliding material which forms at least one of the track and the actuating member sliding surface.
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BACKGROUND OF THE INVENTION
This invention relates to a fuel control system for internal combuston engines and more particularly to an improved cold starting and warm up fuel control for such engines.
As is well known, it is desirable, if not necessary, to provide additional fuel to an internal combustion engine to assist in its cold starting. In addition to providing additional fuel for cold starting, additional fuel should also be provided when the engine is cold during its warm up operation. The amount of fuel required for warm up is, however, less than that necessary for starting. Various devices have been proposed for achieving cold starting and cold running enrichment. One type of device normally employed for this purpose is a choke valve which is disposed in the intake system of the engine carburetor and which may be operated to provide cold starting and cold running enrichment. The use of choke valves, however, have a number of disadvantages. The choke valve per se does not always provide the desired degree of enrichment for all starting and running conditions. The provision of a choke valve in the induction system also causes a restriction to the flow, at times when choke operation is not necessary. Therefore, the use of the choke valve, even though it is fully opened, may restrict the maximum power output of the engine. Furthermore, if multiple carburetors are employed, it is necessary to provide some interlinking between the choke valves of the various carburetors so that they will all be operated in unison.
Another form of cold starting and cold running enrichment device is the provision of a separate starter system that provides additional fuel during cold starting and/or cold running. Such starter systems also are not fully satisfactory because they are incapable of providing both the necessary degree of enrichment for starting and a proper running mixture during cold warm up. In addition, where multiple carburetors are employed, it is also desirable to interlink the starting systems associated with each carburetor which, as aforenoted, can cause undue complication.
It is, therefore, a principal object of this invention to provide an improved device for cold starting and cold running.
It is a further object of the invention to provide an improved enrichment device for cold operation that will provide stable engine speed during the warm up cycle.
It is a further object of this invention to provide an improved and simplified cold starting and cold running enrichment device for multiple cylinder engines.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a cold enrichment device for an internal combustion engine that includes a fuel pump, means responsive to starting of the engine for delivering fuel under pressure from the fuel pump to the engine for a predetermined period of time for starting enrichment. In addition, temperature responsive means are incorporated for delivering fuel under pressure from the fuel pump to the engine when the temperature of the engine is below a predetermined amount for cold running enrichment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic, cross-sectional view taken through the single cylinder of a multiple cylinder internal combustion engine constructed in accordance with an embodiment of the invention.
FIG. 2 is an enlarged cross-sectional view showing the cold starting and cold running enrichment device of the engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a two-cycle internal combustion engine constructed in accordance with an embodiment of the invention is identified generally by the reference numeral 11. The engine 11 is particular adapted for use in outboard motors and has a plurality of cylinders, although only one cylinder is shown in FIG. 1 in cross-section. The engine 11 is of the crankcase compression type and includes a cylinder block 12 having a cylinder bore 13 in which a piston 14 is supported for reciprocation. The piston 14 is connected by means of a connecting rod 15 to a crankshaft 16 that is journaled in a crankcase 17 of the engine in a known manner. A cylinder head 20 is affixed to the cylinder block 12.
The crankcase 17 defines a sealed chamber 18 for each cylinder to which an intake charge is delivered from an intake manifold 19 having respective induction passages 21. The induction passages 21 communicate with the crankcase chambers 18 through reed type check valves 22 so as to permit a charge to enter the chamber 18 when its volume is increasing and so as to prevent reverse flow.
The compressed charge is transferred from the crankcase chambers 18 to the area above the pistons 14 by means of scavenge passages 23. The charge transferred to the area above the pistons 14 is fired by means of spark plugs 24 that are supported in the cylinder head 20. The burnt charge is discharged from the cylinder bores 13 in a known manner through exhaust ports (not shown).
A fuel/air mixture is delivered to the manifold induction passages 21 by means of suitable charge forming devices. In the illustrated embodiment, the charge forming devices may comprise a carburetors of a conventional type, indicated generally by the reference numeral 25. In a preferred embodiment of the invention, there is a carburetor 25 provided for each cylinder 13. The carburetor 25 includes a fuel bowl 26 in which fuel is maintained at a uniform head by means of a float 27 that operates an inlet valve 28 in a known manner. Fuel is discharged from the fuel bowl 26 into a venturi section 29 of the carburetor 25 by means of a main fuel discharge nozzle 31. A throttle valve 32 is positioned downstream of the venturi section 29 for controlling the speed of the engine in a known manner. Since the carburetor 25 is conventional in construction, specific details of its construction and operation are not given and are believed to be well within the scope of those skilled in the art.
An air silencer 30, which also may be of any known type, is positioned upstream of the carburetors 25 for silencing the intake air in a suitable manner.
A remote fuel tank 33 is provided for containing the fuel on which the engine 11 operates. In view of the fact that the illustrated embodiment is an outboard motor, the fuel tank 33 may be conveniently positioned within the hull of the associated watercraft. A manually operated pump 34 is provided for drawing fuel out of the fuel tank 33 for delivery to the engine. The pump 34 may be of any known type such as one of the well known bulb type pumps used for this purpose. Manually operated fuel pump 34 delivers fuel through a fuel filter 35 to a main fuel pump 36. The main fuel pump 36 may be of the type driven by the engine such as a diaphragm pump that operates in response to pressure variations within the crankcase chambers 18. Alternatively, the pump 36 may be an electrically driven type or any other known type of pump used for this purpose. The pump 36 delivers fuel to the fuel bowl 26 through the aforedescribed needle valve 28 under the operation of the float 27. The construction of the engine and fuel system thus far described is convention and generally forms no part of the invention.
In addition to supplying fuel to the main fuel system including the main pump 36, the manually operated pump 34 and filter 35 supply fuel to a cold starting and cold enrichment system constructed in accordance with the invention. The cold starting and cold enrichment system includes an inlet conduit 37 that feeds an auxiliary pump 38. The auxiliary pump 38 discharges to a pair of parallel conduits. A starting enrichment valve 39 is positioned in one of these conduits and a cold running enrichment valve 41 is positioned in the other conduit. The parallel conduits in which the valves 39 and 41 are interposed discharge through a common line 42 into a discharge nozzle 43 for each of the manifold intake passages 21. The pump 38 and valves 39 and 41 may be conveniently combined within a single housing, which is shown schematically and which is identified by the reference numeral 44.
Referring now primarily to FIG. 2, the auxiliary pump 38 consists of an outer housing made up of a lower piece 45 and an upper piece 46 between which a diaphragm 47 is clamped. A pumping chamber 48 is defined beneath the diaphragm 47 and a cavity formed by the lower piece 45. A vacuum actuating cavity 49 is positioned above the diaphragm 47 and is defined by a cylindrical wall 51 of the upper piece 46. The actuating cavity 49 communicates with the crankcase chamber 18 by means of a conduit 52 so that variations in pressure in the crankcase chamber 18 will effect changes in pressure in the cavity 49 so as to operate the pump 32 in a manner to be described.
The upper piece 46 defines an inlet chamber 53 to which fuel may flow from the conduit 37 through an inlet port 54. The diaphragm 47 is formed with an inlet check valve portion 55 that will permit fuel to flow from the inlet chamber 53 into the pumping chamber 48 but which prevents reverse flow.
A discharge chamber 56 is also formed by the upper piece 46 and a discharge check valve 57 formed integrally with the diaphragm 47 permits flow from the pumping cavity 48 to the discharge chamber 56. A discharge port 58 communicates the discharge chamber 57 with a delivery conduit 59.
During running of the engine or cranking of it, the pressure in the crankcase chamber 18 will sequentially vary. This pressure variation is transmitted to the cavity 49 so as to alternately cause the diaphragm 47 and specifically its central portion to move between the solid line position as shown in FIG. 2 when the pressure in the crankcase cavity 18 is at a minimum and a distended position as shown in dot-dash line when the pressure in the crankcase cavity 18 is at its maximum. Hence, the volume in the pumping cavity 48 will vary so as to cause fuel to sequentially flow into the cavity 48 through the inlet check valve 55 and be discharged from the cavity 48 through the discharge check valve 57.
The cold starting control valve 39 includes an outer housing 61 that defines an inlet chamber 62. The conduit 59 supplies fuel to the inlet chamber 62 through an inlet port 63. A solenoid winding 64 is positioned within the housing 61 and encircles an armature 65. The armature 65 extends through the inlet cavity 62 and has a portion that cooperates with a seat 66 so as to control the communication of the chamber 62 with the cold starting enrichment conduit 42. A manually operated plunger 67 is also coupled to the armature 65 for actuating the armature downwardly so as to open the valve seat 66 and permit fuel to flow from the chamber 62 to the cold starting enrichment conduit 42. A coil compression spring 68 is positioned beneath the armature 65 so as to normally urge the armature into engagement with the valve seal 66 and prevent this communication.
A suitable control circuit is provided for the solenoid winding 64 so as to energize this winding for a period of time when the starter associated with the engine 11 is actuated. Upon the initiation of the starting cycle, the solenoid winding 64 will be engaged for a period of time so as to draw the armature 65 downwardly and permit cold starting enrichment through opening of the valve seat 66. Alternatively, the cold starting enrichment may be provided manually by the operator depressing the plunger 67 for a desired period of time.
The cold running enrichment valve 41 includes an auxiliary valve assembly, indicated generally by the reference numeral 71, and a temperature responsive valve, indicated generally, by the reference numeral 72. Referring first to the valve 71, it comprises an outer housing assembly consisting of a cylinder portion 73 having a bore 74 in which a valve spool 75 is slidably supported. A branch passage 76 intersects the passage 59 and the bore 74. The spool 75 normally closes the branch passage 76. To the left of the spool 75 there is formed a discharge branch passage 77 that communicates with a passage having a restricted opening 78 formed in the housing 61 of the cold starting enrichment valve 39. The passage in which the restricted opening 78 is formed communicates with the cold starting enrichment conduit 42 and bypasses the cold starting valve consisting of the valve seat 66.
The valve spool 75 is connected to a stem 79 which is, in turn, affixed to a first diaphragm 81 that is contained within the housing of the auxiliary valve 71. The diaphragm 81 defines a fuel chamber 82 that is positioned on the downstream side of the valve spool 75. A coil compression spring 84 is contained within the cavity 82 and acts upon the valve stem 79 so as to urge the diaphragm 81 and valve spool 75 to the left so as to normally close the inlet passage 76.
A second diaphragm 85 is positioned within the housing of the auxiliary control valve 71 and with the diaphragm 81 defines an intermediate vacuum chamber 86. The vacuum chamber 86 receives a signal from a conduit 87 which, in turn, communicates with the thermally responsive valve 72 in a manner to be described.
The diaphragm 85 carries an actuating plunger 88 that extends within the vacuum chamber 86 and which is adapted to engage the diaphragm 81 on occasion, as will be described.
An atmospheric chamber 89 is formed on the left hand side of the second diaphragm 85 and communicates with the atmosphere through an atmospheric port 91.
It should be noted that the construction of the auxiliary control valve 71 is such that the first diaphragm 81 has a smaller effective area exposed to the vacuum chamber 86 than the second diaphragm 85. Hence, when a vacuum signal is present in the chamber 86, the diaphragm 85 will cause a force to be exerted through the plunger 88 on the diaphragm 81 so as to compress the spring 84 and shift the valve spool 75 to the right so that the passages 76 and 77 will communicate with each other. As a result of this, cold running enrichment fuel will be delivered to the conduit 42.
The temperture responsive valve 72 includes an outer housing 92 that is mounted in heat exchanging relationship with an appropriate portion of the engine 11 that is indicative of its temperature such as the cylinder head 18 as shown in FIG. 1. The housing 92 has a signal port 93 that communicates with the vacuum conduit 87 that supplies the vacuum signal to the chamber 86 of the auxiliary control valve 71. In addition, an inlet port 94 is formed in the housing 92 that communicates with a conduit 95 that provides a vacuum signal from the induction manifold passage 21 from a suitable sensing port 96 (FIG. 1).
The ports 93 and 94 communicate with a chamber 97 in which a bimetallic valve disc 98 is positioned. The valve disc 98 is engaged on its underside by means of a coil compression spring 99. The valve disc 98 is a bimetal wafer and is adapted to move between a low temperature position as shown in FIG. 2 to a high temperature position wherein it wharps to a flattened condition so that the spring 99 can urge it into engagement with the ports 93 and 94 and close off their communication. If the temperature at which the valve disc 98 will so wharp can be set at any appropriate level, for example, five degrees centigrade. When the temperature is below five degrees centrigrade, the ports 93 and 94 will communicate with each other through the chamber 97. Above this temperature, the communication is stopped by the wharpage of the disc 98 and the action of the coil spring 99.
OPERATION
The figures of the drawings illustrate the engine as it appears before it is running and assuming that the temperature of the cylinder head as sensed by the temperature responsive valve 72 is below that required to cause the bimetallic valve disc 98 to wharp. That is, the figures illustrate the condition as it appears when an engine is to be cold started.
The operator actuates the manually actuated pump 34 so as to deliver fuel through the fuel filter 35 to the main fuel pump 36. At the same time, fuel will be delivered to the conduit 37 and auxiliary pump 38. The pressurization of the fuel by the manually operated pump 34 will cause fuel to flow past the inlet check valve 55 of the auxiliary pump 38 and past the discharge check valve 57 to the starting valve chamber 62. Once the starting operation is initiated, the solenoid 64 will be actuated for a period of time through the aforedescribed time circuit and the armature 65 will move away from the valve seat 66 so as to permit the pressurized fuel to flow to the conduit 42 for discharge into the induction passages 21 through the nozzles 43. When the engine is cranked, the pump 38 will also be actuated so as to continue to supply pressurized fuel for starting.
Alternatively, manual depression of the plunger 67 will also provide cold starting enrichment as aforedescribed.
Under either cold starting enrichment method, a fuel enrichment in addition to the normal charge provided by the carburetors 25 will be supplied to the crankcase chambers 18 so as to assist cold starting enrichment. Once the engine beings to run, there will be a reduced pressure exerted in the manifold induction passages 21 that is transmitted to the conduit 95 and through the temperature responsive valve 92 to the conduit 87. Hence, a vacuum will be exerted in the chamber 86 of the auxiliary control valve 71. Atmospheric pressure will act in the atmospheric chamber 89 and urge the diaphragm 85 to the right as viewed in FIG. 2. The plunger 88 will contact the diaphragm 86 and also urge it and the valve spool 75 to the right. This will uncover the passage 76 and permit the passages 76 and 77 to communicate with each other so that supplemental cold running enrichment fuel will be delivered through the restricted opening 78 to the cold starting enrichment conduit 42. Hence, further enrichment will be provided and will be continued even when the cold starting enrichment valve 39 moves to its closed position. Hence, there will be good enrichment for cold running and an even speed of the engine can be maintained.
As the engine gradually heats up, the thermally responsive valve member 98 will eventually be heated above the temperature at which it wharps. At this time, the spring 99 will urge the valve member 98 upwardly so as to close the communication between the ports 93 and 94. Hence, the chamber 86 will no longer receive a vacuum signal and the spring 84 will act upon the diaphragm 86 so as to urge it and the valve spool 75 to the left. This will then close the communication between the passages 76 and 77 and the cold running enrichment will be terminated.
Since the auxiliary fuel pump 38 and valves 71 and 39 are positioned within a common casing 44, a relatively simple arrangement may be provided that will permit good cold starting and cold running enrichment. Although in the illustrated embodiment the main and auxiliary fuel pumps 36 and 38 are separate from each other, it should be readily apparent that the invention may be used in conjunction with an arrangement wherein only a single fuel pump is employed. Such a single fuel pump should have two separate discharge passages, one to the carburetor 25 and the other to the cold starting system including the cold starting enrichment valve 39 and the cold running enrichment valve 41. Also, the cold starting and cold running enrichment need not be provided through a nozzle 43 that discharges into the manifold passaes 21, but may be accomplished through a system that discharges directly into the crankcase chambers 18. Alternatively, the cold starting enrichment and cold running enrichment may be discharge directly into the scavenge passages 23. Other changes and modifications from those described may also be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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A cold enrichment device for an internal combustion engine having a pair of parallel flow paths communicating with the engine for delivering cold enrichment fuel. One of the flow paths includes a valve that is responsive to starting of the engine for delivering fuel for a predetermined time period whereas the other flow path includes a temperature responsive valve for providing cold running enrichment fuel.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to systems and methods for the network set-up of wireless devices at the point of sale of the devices.
BACKGROUND OF THE INVENTION
[0002] As network technologies are being adopted in consumer electronics (CE) products such as digital TVs, video recorders, digital still/video cameras, other wireless digital CE devices, etc. to enable these devices to communicate with other like devices in a home network, the network setup process becomes an obstacle for ease of use in these products. This is essentially because network setup is a computer-oriented procedure, which is cumbersome and unfamiliar to most non-technical users.
[0003] For example, even when a home has wireless network installed, each time a user adds a new wireless device, the user must undertake the cumbersome setup process to input network configuration. This typically includes typing in network ID and password, sometimes referred to as a service set identifier (SSID) and wired equivalent piracy (WEP) keys, respectively. Although this may be a common process for a PC-based network, as understood herein the following issues arise when the same process is applied to CE products.
[0004] A user must have knowledge about the nature and location of network configuration information (e.g., SSID and WEP keys) that is required, as well as knowing when and how to input the information. Also, each network product must have an input/output device such as a keypad to type in the necessary information and to display confirmation. Providing such I/O devices, however, is not practical for many CE products. Moreover, because the user interface or setup menu typically varies from product to product, a non-technical user can become further confused.
[0005] Accordingly, with the above in mind users frequently encounter difficulty in connecting new devices to their home networks. As recognized herein, when a user has difficulty completing the setup process, the user typically calls customer support of the manufacturer for assistance. This, however, does not guarantee ease in identifying the cause of the difficulty so that a solution can be quickly provided over the phone, and moreover customer support is costly.
SUMMARY OF THE INVENTION
[0006] The present invention configures a network device such as a wireless network device at the point of sale (POS) for a specific home network to which the device will belong. This may be accomplished by obtaining from the buyer at the POS account information, which is sent to a configuration server that automatically sets up the device for network use without the buyer's further direct involvement. In this way, manufacturers as well as users benefit, since the cost of customer support associated with user-conducted setup is eliminated. Moreover, a sales model is provided by which a network device is automatically configured at the point of sales, thus also providing a benefit to retailers as it is regarded as an additional service and value.
[0007] Accordingly, a method for configuring a network device for a network includes, at a point of sale of the device, receiving a device identification (ID) unique to the device and providing the device ID to an Internet server. The method further includes sending the device ID from the server to a network component in the network, using the device ID as a temporary network ID to establish communication between the component and the device, and sending a main network ID from the component to the device. The main network ID subsequently is used in communication between the device and the network.
[0008] In some implementations the device is a wireless device, the temporary network ID is a service set identifier (SSID), and the main network ID is a SSID. In non-limiting implementations the main network ID is for a main channel and initially is sent to the device on a subchannel using the temporary network ID. If desired, the subchannel can be deactivated after communication is established with the device using the main network ID. The method can also include deriving a password such as a wired equivalent piracy (WEP) key as a function of the device ID.
[0009] In another aspect, a network device associated with a unique device ID executes logic that includes using the device ID as a network ID to obtain a main network ID over a subchannel of a home network. The device sets the device ID to be the main network ID and then subsequently communicates with a main channel of the home network using the main network ID.
[0010] In still another aspect, a system includes means for providing a device ID unique to a network device at a point of sale of the network device. The system also includes means for providing the device ID to a home network, and means for communicating a main network ID to the device over the home network using the device ID as a temporary network ID. Means are provided for subsequently using the main network ID to establish communication between the device and at least one component on the network.
[0011] The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram of a non-limiting system in accordance with present principles; and
[0013] FIG. 2 is a logic chart illustrating non-limiting steps in accordance with present principles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring initially to FIG. 1 , a system is shown, generally designated 100 , which includes one or more points of sales (POS) 101 . A POS 101 can be a retail location or online website at which a user can purchase a digital network device such as a wireless network product (WNP) 102 that may be vended with the below-described device ID stored in it. Without limitation the WNP 102 may be a digital still or video camera, digital music player, wireless digital TV, etc.
[0015] As shown in FIG. 1 , a computerized retail sales terminal 103 may be used to input data at the POS. Sales information (product type, unique device ID, cost, etc.) as well as user data (credit card number from a card 109 via a card reader 110 , name, address, and other registration information) may be input by, e.g., a sales clerk at the terminal 103 . In the case of Internet sales, the terminal 103 may be a user's home PC into which the user inputs the sales and registration information. In any case, the terminal 103 communicates data to a server 104 through a network such as the Internet.
[0016] FIG. 1 shows that a home network 105 , to which the WNP 102 is to belong and/or to be used, communicates with the network using, e.g., a modem 106 . As shown, the modem 106 can be connected to the Internet and also to a wireless access point (WAP) 107 to facilitate wireless connection among devices including the WNP 102 in the home network 105 . In non-limiting embodiments the WAP 107 has a capability to accommodate two wireless channels (main and subchannel), each of which is specified by SSID and WEP key. In one implementation the SSID of the main channel may be designated “N a ”, and the WEP key can be calculated by a specific function F(x), which is commonly implemented in the WNP 102 as well.
[0017] As shown, a personal computer (PC) 108 or other coordinating server-type device may be provided in the home network 105 . The PC 108 preferably has a wireless connection to the WAP 107 via the main channel, and also has access to the server 104 on the Internet through the modem 106 . It is to be understood that without limitation the PC 108 , server 104 , and WNP 102 may have digital processors that execute logic stored on computer-readable media such as disks or solid state media in accordance with the logic of FIG. 2 .
[0018] A user of the home network 105 is assumed to have an account that may be obtained by registration of some network device and/or for some network service. The server 104 stores the user account information. In the following example, the user account is assumed to be associated with the PC 108 and/or an application executed by it.
[0019] With the above in mind, reference is now made to FIG. 2 , which shows a sequence of logic in accordance with present principles. The WNP 102 is vended with an initial temporary device identification designated herein N b , which is unique to each product and which may be in the form of an SSID in, e.g., non-limiting wireless applications.
[0020] At step ( 1 ), at the POS 101 the user's account information (e.g., account name and password that among other things identify the user's home network) are input to the terminal 103 . The account information may be provided by the user directly and input to the terminal 103 manually. Or, the account information may be borne on the user card 109 which can be issued by the manufacture or service provider. The user account information can be recorded on the card 109 on a magnetic strip thereof, or using optical code, IC memory, etc. In this case, the terminal 103 is connected to the card reader 110 to retrieve those data. Alternatively, when the purchase order is placed online, the user may input the account information together with making the purchase.
[0021] At step ( 2 ), the temporary device ID N b is also input through the terminal 103 . Then, at step ( 3 ) the user account information and the temporary device ID N b are both transferred to the server 104 .
[0022] Moving to step ( 4 ), the server 104 accesses its user account database and to retrieve corresponding data for the account identified by the account information received at step ( 3 ), also associating the unique device ID with the corresponding home network. The server 104 adds new data to the account record, specifically that a new device with device ID=N b is in a pending status for network set up. In other words, the server 104 sets the “device registration status” to “pending”, and then waits for the user to access the account.
[0023] This access is shown at step ( 5 ) of FIG. 2 , wherein the user by means of the PC 108 accesses the server with the user account information. In response, at step ( 6 ) the server 104 notifies the PC 108 (or equivalently an application running thereon) that a new device is in the setup pending status, with the server delivering the temporary device ID N b to the PC 108 .
[0024] At step ( 7 ) the PC 108 records the device ID N b to a registered device list, categorizing it as, e.g., “suspended”. The PC 108 also sends the device ID N b to the WAP 107 preferably using the main channel already established with an SSID=N a .
[0025] At step ( 8 ), upon receiving the device ID N b , the WAP 107 sets the SSID of the subchannel mentioned above to be equal to the device ID N b , also calculating the subchannel WEP key to be a function of N b . The function used to calculate the WEP key may be a secret function commonly implemented for or by the WAP 107 and WNP 102 .
[0026] Proceeding to step ( 9 ), the WNP 102 searches for the WAP 107 by scanning for access points in accordance with WAP scanning principles known in the art. This may be invoked by the user from a setup menu, or alternatively it may be started automatically when the power is turned on first time by the user. By scanning, the WNP 102 discovers the subchannel with an SSID=N b . Additionally, at step ( 10 ) the WNP 102 also sets its SSID to be the device ID N b and its WEP key to be the above-discussed function of the device ID N b . As a consequence, the WNP 102 can establish a wireless communication connection with the WAP 107 over the subchannel.
[0027] With the subchannel communication established, at step ( 11 ) the WAP 107 sends the SSID N a of the main channel to the WNP 102 via the subchannel. Now having the main channel SSID, at step ( 12 ) the WNP 102 changes its SSID to be the main channel SSID N a and also sets its WEP key to be a function of the main channel SSID N a , establishing communication with the WAP 107 through the main channel. In this way, security of the main channel SSID and WEP keys of the home network is preserved.
[0028] Completing the logic, at step ( 13 ) the WNP 102 sends a message to the WAP 107 to notify the WAP 107 that communication with the WNP 102 is now over the main channel with SSID=N a . Upon receiving the message, at step ( 14 ) the WAP 107 deactivates the subchannel and preferably erases the SSID of the subchannel. The WAP 107 then notifies the PC 108 that the WNP 102 is now added to the network and available for communication. If desired, at step ( 15 ) the PC 108 can change the status of the WNP 102 in the registered device list from “suspended” to “active”.
[0029] It may now be appreciated that using the logic of FIG. 2 , advantageously the user is requested to do nothing beyond the purchase steps to add a new device to the home network other than to provide user account information at the time of purchase.
[0030] It is to be understood that while in the above example the PC accesses the server to learn of the new device, in other implementations the server can push the new device information to the PC without being asked. It is to be further understood that while a wireless network with SSID is described above in the non-limiting illustrative embodiment, the invention is not limited to wireless networks, but can be applied to other types of networks such as powerline or phoneline communication networks. In these cases, network identification ID is used, corresponding to SSID in the case of wireless, and it depends on each network type and can be transferred in the same way as the SSID described above. It is to be further understood that the WAP 107 may be incorporated into the PC 108 .
[0031] While the particular SYSTEM AND METHOD FOR NETWORK SETUP OF WIRELESS DEVICE AT POINT OF SALE is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims.
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A network device such as a wireless network device is configured using information obtained at the point of sale (POS) for a specific home network to which the device will belong. This may be accomplished by obtaining from the buyer at the POS account information, which is sent to a configuration server that automatically sets up the device for network use without the buyer's further direct involvement.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates, in general, to an improvement to an air induction control device for an internal combustion engine, and more particularly to an air induction control device which modifies the air/fuel mixture in the combustion chamber by controlling the intake vacuum in the engine intake passageway within a desirable range.
2. Description of the Prior Art
During deceleration of an Internal Combustion ("IC") engine the throttle valve in the intake passageway is fully closed despite high engine speed, and accordingly, the intake vacuum downstream of the throttle valve is excessively increased. As a result, several undesirable results may occur. By way of example, engine oil sucked into the combustion chambers of the engine by the action of the increased intake vacuum can cause an increase in the amount of oil burning. Additionally, the fuel lining the intake passage is vaporized, temporarily rendering the fuel/air ratio in the combustion chamber overly rich which can result in stalling and other engine malfunction.
An illustration of another problem associated with deceleration or periods of idle, when the vacuum in the engine is at its maximum, is that the standard carburetors used in internal combustion engines have a venturi whereby the high speed of air drawn into the engine suctions up fuel. When the vacuum in the intake manifold becomes great, the amount of fuel consumed increases, thus decreasing the efficiency of the engine.
Since the earliest internal combustion engines, there has been a search for a method to provide the intake manifold with an optimal mixture of air to fuel, in order to ensure maximum efficiency.
Air induction control valves have heretofore generally been restricted to those intended to prevent extreme vacuum conditions from developing in the combustion chamber during periods of deceleration. Fukuhara, U.S. Pat. No. 4,237,842, discloses such a spring valve that is in communication with the air upstream from the throttle and the air passage downstream through two external tubes. When the intake vacuum exceeds a predetermined level in the downstream valve tube, a valve member is moved against the force of the coil spring toward the stopper and accordingly separates from the valve seat allowing air to enter. Conversely, the valve closes when the intake vacuum in the downstream tube rises above the predetermined level to allow the biasing force of the spring to push the valve member back against the valve seat so as to block communication between the upstream and downstream sides of the valve.
Dorsic, U.S. Pat. No. 4,303,047, shows a method for controlling the vacuum in an engine through a bypass that contains a valve that responds to the differential in pressure between the downstream side of a butterfly valve and the atmosphere. This butterfly valve is downstream of and mechanically connected in a normal position to the carburetor throttle valve.
Morita, U.S. Pat. No. 4,434,778, discloses a valve set in an air passage communicating with the upstream and downstream sides of a throttle valve. When the valve is open the air passes through the valve from the air filter to the air passageway downstream of the throttle valve. A spring in the valve is activated by a diaphragm member which positions the valve body in an open or closed position. The diaphragm consists of two chambers, one of which is in direct communication with the downstream air passage and directly affected by the engine vacuum level, the other of which is in communication with the first chamber through a bellows to which the spring and valve stem are attached.
In early aeronautical IC engines, optional air/fuel mixture was achieved through a manual control of the mixture in which the amount of air is controlled and the variations are made by observation of the temperature variations in the cylinders through the use of appropriate instruments: the temperature indicator in the cylinder heads or an EGT and EET.
In later IC engines, a servo mechanism was added that operated on the basis of engine temperature variations. The servo would close the air intake to the engine to a greater or lesser degree in order to achieve stability through the incorporation of controlled cooling fins. In this way the temperature would be stabilized, and a consistent air intake flow can be maintained.
The devices described above provide some advantages in operation, namely, preventing excessive vacuum formation during declaration. Nevertheless, none of these devices uses a flow restriction element that comprises calibrated openings to effect an increase in fuel efficiency under all operating conditions.
Additionally, none of these devices attempts to polarize oxygen molecules entering the induction control valve to effect more efficient molecular bonding of fuel and air, thus resulting in maximal fuel efficiency in an internal combustion engine.
SUMMARY OF THE INVENTION
According to this invention, an air induction control device is provided for an internal combustion engine, where the engine has an intake passageway, and a throttle valve positioned in the intake passageway. The air induction control device of this invention comprises a means of communication between the air at atmospheric pressure and the air in the downstream passageway from the throttle valve. A valve member is disposed in the communication passageway and is moveable toward the downstream direction, thereby opening the communication passageway in response to a pressure differential reflecting atmospheric pressure greater than the air pressure in the downstream passageway. Means to bias the valve is positioned to apply force to and bias the valve member in the upstream direction, thus closing the communication passageway. The biasing means responds to pressure differential between air at atmospheric pressure and air in the downstream passageway in such a way that the degree of clearance of the valve member from a valve seat varies depending on the pressure differential between the air at atmospheric pressure and the air in the downstream passageway. The valve seat is located upstream from the valve member and is situated so that the valve member rests against the valve seat when the communication passageway is closed. A flow restriction element is positioned downstream from the valve member and comprises a plurality of calibrated openings. The flow restriction element divides the device into a primary chamber and a secondary chamber. The volumetric proportion of the primary chamber: secondary chamber: calibrated openings is within the range 50-70: 25-35:0.8-1.2.
Preferably, the spring is calibrated to a predetermined resistance and the flow restriction element comprises a plate having calibrated openings symmetrically positioned around the flow restriction element perimeter.
It is another object of the invention to provide an air induction control device that acts to maximize fuel efficiency through polarizing air molecules passing through the device in order to optimize molecular bonding of air and fuel prior to and during combustion.
In accordance with the invention, a method of air induction control is provided for an internal combustion engine including an air/fuel intake passageway having a throttle valve. This method comprises providing a communication passageway for communicating between air at atmospheric pressure and air in a downstream passageway from the throttle valve. A valve member is positioned in the communication passageway, which valve member moves toward the downstream direction thereof to open the communication passageway in response to pressure differential reflecting atmospheric pressure greater than pressure in the downstream passageway. Next, the valve member is biased to apply force and to bias the valve member in the upstream direction closing the communication passageway. The biasing means responds to the pressure differential between atmospheric pressure and the air pressure in the downstream passageway. The degree of clearance of the valve member from a valve seat disposed in the communication passageway upstream from the valve member varies depending on the pressure differential between the air in the downstream passageway and atmospheric pressure. Finally, a flow restriction element positioned downstream of the valve member comprising calibrated openings is provided which acts to optimize the air/fuel ratio thereby maximizing engine fuel efficiency.
It is another object of this invention to provide for a method of controlling air induction in order to maximize fuel efficiency through polarizing air molecules that pass through the device in order to optimize molecular bonding of air and fuel.
As pointed out in greater detail below, the air induction control device and method of inducting air of this invention provides important advantages. The air induction control device performs under all operating conditions and acts to maximize fuel efficiency in all internal combustion engines, both of the standard carburetor type and the fuel injection type.
The invention itself, together with further objects and attendant advantages, will best be understood by reference to the following description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a vertical cross sectional view of the preferred embodiment of an air induction device in accordance with the present invention.
FIG. 2 represents an exploded view, cross section, of the present invention.
FIG. 3 represents an exploded view of the valve member and flow restriction element showing the calibrated holes in accordance with the preferred embodiment of this invention.
FIG. 4 represents a bottom view of the flow restriction element of FIG. 3.
FIG. 5 shows an alternative embodiment of an air induction device in accordance with the present invention where the air induction device is attached to the side of the carburetor.
FIG. 6 represents yet another alternative embodiment of the air induction control device in accordance with the present invention.
FIG. 7 represents a carburetor with a built in air induction device in accordance with this invention.
FIG. 8 represents an internal combustion engine wherein a tube connects the intake manifold to the air filter, and an air induction device in accordance with the present invention is positioned along the tube.
FIG. 9 represents an exploded view of an alternative embodiment of an air induction device.
FIG. 10 represents the device in FIG. 9 in assembled form.
FIG. 11 represents an exploded view of an industrial specification of the air induction control device.
FIG. 12 represents a schematic drawing of the air flow around a carburetor engine where no air induction control device has been installed.
FIG. 13 represents a schematic drawing of the air flow in a carbureted engine with an air induction control device installed.
DETAILED DESCRIPTION
Turning now to the drawings, FIG. 1 represents an assembled air induction device 10 in accordance with the preferred embodiment of this invention and FIG. 2 represents a disassembled air induction control device ID. As shown in FIG. 1, valve casing 20 is separable into two halves or sections, an upper section 21 mating with a lower section 22 at a threaded joint 23. A hose or tube 83 (shown in FIG. 8), connects the upper section 21 of the air induction device 10 at a valve inlet 24, which is about 9.5 mm in diameter, to a point upstream 85 (shown in FIGS. 5-8) of a carburetor throttle valve 63 (shown in FIGS. 5 and 7) at which there is air at atmospheric pressure. The communication passageway 38 is closed when a valve member head 25 rests against a valve seat 29 due to the biasing force exerted by a valve biasing means 26, positioned in a spring guide 27 which exerts force against a valve member 28.
The resistance in the biasing means, which pushes the valve member head 25 toward the valve seat 29 and closes it under conditions of equal pressure, is calculated on the basis of the maximum pressure in the intake manifold of standard internal combustion engines used in automobiles and the atmospheric pressure of 1,033.5 grs/cm2 at sea level and 516.75 grs/cm2 at 19,000.00 feet (5757.00 mts) above sea level. This calculation indicates that the preferred resistance is about 257.5 grs/cm.
Turning to FIG. 2, the valve member 28 is situated in a piston like fashion in the spring guide 27 on top of a calibrated spring 26', which spring functions as the valve biasing means. The calibrated spring 26' rests on a flow restriction element 30. The valve member 28 is a compound cylinder, with a smaller diameter cylinder 34 at the bottom of the valve member 28, which smaller cylinder receives the calibrated spring 26', and a larger diameter cylinder 35 that fits into the spring guide 27. The valve member head 25 is shaped in a truncated cone with an edge 37 situated at about a 45° angle to fit flush into the valve seat 29.
The spring guide 27 extends normally from the flow restriction element 30. A ledge 31 is indented into the lower section 22 of the valve casing 20 and supports the flow restriction element 30. The flow restriction element 30 separates the valve into a primary chamber 52 and a secondary chamber 53. In this embodiment, the primary chamber 52 has cylindrical dimensions of about 28 mm in height and about 26 mm in diameter and the secondary chamber 53 has dimensions of about 12 mm in height and about 26 mm in diameter. The lower section 22 comprises a valve outlet 32 which connects the induction control device 10 to a point 84 (shown in FIGS. 5-7) on the downstream passageway of the engine intake passageway, e.g., that part of the engine intake passageway downstream from the throttle valve 63. The valve outlet 32 is connected to the point 84 the downstream passageway by a hose or tube 87 (shown in FIGS. 5-7). The valve outlet has a diameter of about 9.5 mm.
FIG. 3 depicts a perspective view of the valve member 28, the calibrated spring 26', the spring guide 27, and the flow restriction element 30. Openings 41 are spaced symmetrically around the perimeter of the flow restriction element 30. An additional opening 42 is present in the center of the flow restriction element 30 directly below the spring guide 27 and calibrated spring 26'. By way of example, the element 30 in this embodiment is about 30 mm in diameter with of openings 41 of about 2.00 to 3.00 mm in height and about 3.36 mm diameter. The opening 42 in the center of the flow restriction element 30 is about 8.0 mm in diameter. The spring guide 27 has an outside diameter of about 13.0 mm and an inside diameter of about 11.0 mm, and a height of about 20 mm above the flow restriction element. The valve member 28 has a diameter of about 11.0 mm so as to allow the valve member 30 to fit flush into the spring guide 27.
FIG. 4 represents an end view of one embodiment of the flow restriction element 30 with eight symmetrically spaced openings 41 positioned around the perimeter of the flow restriction element 30, and the center opening 42.
Returning to FIG. 1, the upper section 21 and lower section 22 of the valve casing 20 are connected at the threaded joint 23. When the vacuum in the combustion chamber of the engine reaches a specified level it is reflected in the secondary chamber 53. The valve member head 25 is then biased away from the valve seat 29 to a compressed position 25'.
The calibrated spring 26' contained in the spring guide 27 has a tension that is designed to allow a communication passageway 38 to open upon the engine vacuum reaching a specified level. The communication passageway 38 connects the point 84 on the downstream passageway (shown on FIGS. 5-7) with a point upstream at atmospheric pressure 85 (also shown on FIGS. 5-7). The clearance 45 of the biased valve member head 25' to the valve seat 29 is determined by the pressure differential between the atmospheric pressure and pressure in the intake manifold of the engine. Of course, the pressure in the intake manifold of the engine is directly reflected in the secondary chamber 53 of the air induction control device 10.
When the valve member head 25 is compressed (as reflected by numeral 25'), air flow 50 enters the primary chamber 52 where it is homogenized at a constant pressure. Air flow 50 proceeds through the induction control device 10 until the air flow 50 encounters the flow restriction element 30. The flow restriction element 30 comprises eight symmetrical circular openings 41 equally spaced around the perimeter. The air flow, 50 passes the flow restriction element 30 where the air flow becomes polarized 51 enters the secondary chamber 53, and continues past the valve outlet 32, through tube 87 past the point downstream 84 where the air flow reenters the engine intake passageway 61 (shown in FIGS. 5-7) and toward the intake manifold of the engine. (See, for example, FIGS. 5, 6 and 7)
By the action of air flowing through the calibrated openings 41 in the flow restriction element 30, the air flow 50 becomes polarized in a way to optimize the air/fuel mixture thereby maximizing the fuel efficiency of the 52 engine. In this manner, the oxygen molecules are given sufficient electrical excitation to optimize their attraction to the hydrogen contained in the carbon rings of hydrocarbon fuel such as gasoline or the like. In the preferred embodiment, the volumes of the primary chamber 52: secondary chamber 53: combined calibrated openings 41 is in proportion of about 60:30:1.
Variations of the embodiments described above are possible so long as the volumetric proportions of the primary chamber, secondary chamber and calibrated openings remain within the correct proportions, and of course the relative diameters of the inlet and outlet valves are maintained.
For example, in the alternative embodiment of FIG. 5, an air induction control device 60 is mounted to the side of an engine intake passageway 61. Inside the engine intake passageway 61 is the carburetor 62 and the throttle valve 63. The valve intake 24 of the induction control device 60 connects directly to the atmosphere 85 via a tube 83. The valve member head 25 is shown pressed against the valve seat 29 by the spring 26'. The calibrated spring 26' is wrapped around the spring guide 64. Under this variation the spring guide 64 also functions as the valve member 28. The flow restriction element 30 rests on a ledge 65 in the induction control device 60. The air induction outlet 32 is connected to the downstream passageway at point 84 via a tube 87.
Another variation of the present invention is depicted in FIG. 6. In this variation, which the air induction control device 70 functions in much the same way as the air induction control device 60 in FIG. 5.
In another variation depicted in FIG. 7, a carburetor 62 with the engine intake passageway 61 and throttle valve 63 is manufactured with the air induction control device 80 as an integral part thereof, functioning in much the same way as the air induction control device of FIG. 5.
In yet another variation depicted in FIG. 8, the air induction control device 90 is connected to flexible hoses 83, 87. The valve inlet 24 is connected to the hose 83 that leads to the air cleaner housing 81 at 85 and the engine valve cover 82 at 86. The lower section outlet 32 is connected by hose to the intake manifold 82' through hose section 87.
In yet another variation depicted in FIGS. 9 and 10, the upper section 21 of the valve casing 20 is connected to the lower section 22 by a set of screws 86.
By way of further example, FIG. 11 depicts an industrial schematic of an air induction control valve 10 of the type described in FIG. 1.
To better understand the present invention, a comparison of the prior art is shown in FIG. 12 and FIG. 13 respectively. FIG. 12 depicts a schematic drawing of the intake passageway of an internal combustion engine without an air induction control device. Air flow 110 enters the carburetor 62 where it is mixed with fuel from the fuel line 66 on the way to the combustion chamber.
FIG. 13 depicts a schematic drawing of the intake passageway of an internal combustion engine with an air induction control device 10. With the valve closed, air flow enters the carburetor system as in FIG. 12. When the valve member (not shown) opens, air is diverted from the engine intake passageway 111 through the upstream tube 83 of the communication passageway 38 at a point upstream of the carburetor 62 which is at atmospheric pressure 85. The directed air flow 50 then passes through the induction control valve 10. This diverted air flow 50 exits the air induction control device 10 as air flow 51 through the downstream tube where it reenters the downstream passageway.
Other variations can be made without parting from the spirit of the invention and the measurements provided are only exemplary of preferred embodiments of the invention. For example, a wire mesh or screen may replace the calibrated openings of the flow restriction element, which may be made of metal, plastic or resin membrane as long as the appropriate volumetric proportions are maintained. A resin membrane can be especially effective, provided the mesh of the resin membrane is adequate to control the pressure as well, and provide the necessary calibration. Moreover, the volumetric proportion of the primary chamber: secondary chamber: calibrated openings can be within the ratio 50-70:25-35:0.8-1.2, or more preferably of 55-65:27.5-32.5:0.9.1.1. The valve member head may be shaped not only as a truncated cone, but also it may be other shapes, such as hemispherical, triangle, pentagonal and the like. The number and shape of the flow restriction openings may be varied. For example, the number of openings may range from a small number to more than eight, and their shapes vary from circular to elliptical, oblong, arcuate or the like. Further, the valve biasing means can be made of any elastomeric material capable of affording a calibrated biasing force.
In addition, the principles of the present invention can easily be modified by one skilled in the art for use in fuel injection engines.
While not wishing to be bound to any theory of operation, applicant believes that the following discussion illustrates the principles behind the exceptional results reached by this device.
All internal combustion engines operate under either the Otto or Carnot cycles with two or four stroke cycles. Combustion in each cylinder occurs due to the presence of fuel and carburant (air-hydrocarbon) in a certain proportion, the most desirable begin fourteen (14) parts air to each part hydrocarbon. Normally, that proportion is not maintained precisely, but instead the mixture is uneven depending on the conditions present. Sometimes the mixture is at the correct proportion of air and fuel, but variations in atmospheric pressure and air temperature can cause the number of molecules of air per unit of volume at the intake to vary, and consequently, the air/hydrocarbon bond ration deviates from the optimal level.
Due to this change in the air/fuel proportion, the fuel mixture in the cylinders changes, becoming "lean" due to an excess of air is present, but "rich" when there is an excess of fuel. Engine efficiency suffers as a result of either condition. Air/fuel mixture is thus dependent on many factors including atmospheric pressure, outside air temperature, the temperature of the air in the intake manifold, value of the vacuum in the intake manifold, combustion temperature, and molecular bonding of fuel to air prior to and during combustion.
The embodiments described above provide a number of significant advantages. The flow restriction element of this invention acts to treat the air through a polarization of oxygen molecules. This is achieved by forcing the air molecules through the set of calibrated openings. The air, by passing through the flow restriction element and being polarized by friction, facilitates optimal molecular bonding between the gasoline and air molecules prior to entry into the combustion chambers. The flow restriction element, in causing the polarization acts to stabilize the number of bondable molecules by controlling the volume of air passing into the intake manifold of the engine in response to variations of engine temperature, intake manifold vacuum, and atmospheric pressure.
As yet another advantage, the action of the valve in responding to pressure changes in the intake manifold adjusts the amount of air and consequently the proportional mix of hydrocarbons and air. When the valve senses such temperature and pressure changes in the secondary chamber, variations in the quantity of air diverted by the air induction control device from the carburetor are induced. When the air flow through the carburetor is lessened, without the attendant intake vacuum caused by throttling, there is a lessening of fuel flow through the carburetor venturi because of the decreased air velocity in the venturi. The result is decreased suction on the fuel.
Temperature variations will also induce pressure variations. When the temperature changes in the combustion chamber, there is also a change in pressure. A "rich" mixture at a lower temperature becomes a "lean" mixture at high temperature. These temperature variations can influence the displacement of the valve, which correspondingly corrects the mixture through admitting more or less polarized air into the combustion chamber.
For upon engine deceleration, an extreme vacuum builds in the intake manifold of the engine, and the air induction control device opens to equalize the pressure. When the engine is progressively accelerated, the vacuum initially becomes smaller, the air induction control device begins to close and the amount of gasoline drawn in by the venturis increases. When the engine revolutions per minute stabilizes for a given speed, the vacuum increases and the air induction control device opens again. At that time, the degree of opening, e.g., displacement of the valve member, will be a function of the pressure differential. Sudden accelerations close the air induction control device entirely and no air is diverted. When that condition ceases, the valve member is displaced proportional to the difference in pressure ensuring optimal proportion of air to fuel as well as an optimal degree of molecular bonding. Depending on the operating conditions of the engine in which this valve is to be installed, the volume of hydrocarbon (gasoline or liquified gas) utilized is reduced considerably. Testing using the air induction control device of the present invention has shown that the utilized hydrocarbon fuel expended is reduced within the following ranges as compared to engines not using the air induction control device of present invention. The maximum fuel saving, was estimated to be about 58.35% at altitudes between sea level and approximately 1,500.00 meters above sea level. As altitude increases, the fuel savings decline to a lower limit of 22.70% at a maximum altitude considered in the design of 5,750.00 meters (19,000.00 feet) above sea level. The result is a considerable saving of fuel, estimated at 40.50% on the average.
The air induction control device also has the advantage of saving gasoline in all driving conditions and in all engine operating ranges. Also, by operating at a controlled lean mixture, the device helps to clear the spark plugs and the combustion chamber, thereby reducing carbon deposits as well as reducing pollution.
Of course, it should be understood, that a wide range of changes and modifications can be made to the preferred embodiments described above. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it be understood that it is the following claims, including all equivalents, which are intended to define the scope of this invention.
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An air induction control device for an internal combustion engine comprises means defining a communication passageway for communicating between air at atmospheric pressure and the air in the downstream passageway from a throttle valve. A valve member is disposed in the communciation passageway and is moveable toward the downstream direction thereof to open the communication passageway in response to an atmospheric pressure greater than pressure in the downstream passageway. A valve biasing means is disposed to apply force to and bias the valve member in the upstream direction to close the communication passageway in response to the pressure differential between atmospheric pressure and the air pressure in the downstream passageway. A flow restriction element positioned downstream of the valve member comprises calibrated openings defining a primary chamber and secondary chamber, wherein the volumetric proportion of the primary chamber:second chamber:calibrated openings is about 50-70:25-35:0.0-1.2.
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BACKGROUND
[0001] In a variety of well related operations, tools are used to carry out desired tasks at downhole locations. For example, different types of tools are used to drill wellbores, to deploy tubing and other equipment downhole, to perform testing operations, and to conduct servicing operations. During these operations, a tool occasionally becomes stuck in the wellbore or disconnected from its conveyance. If the tool is stuck in the wellbore, the tool can be cut free to enable retrieval of the conveyance and other downhole equipment.
[0002] To retrieve the tool left downhole, a fishing operation is conducted in which a fishing tool is deployed downhole from a surface rig. The fishing tool comprises a latching or attachment end designed to engage the tool, i.e. fish, to be retrieved. However, attachment of the fish can occur deep within the wellbore which makes it difficult to determine whether the fishing tool has contacted and adequately engaged the fish. Many hours of rig time can be wasted in withdrawing the fishing tool to discover the fishing expedition was not successful.
SUMMARY
[0003] In general, the present invention provides a system and method to verify attachment of a fishing tool with a fish. The fishing tool comprises a latching mechanism to latch onto the fish to be retrieved and a detection device to verify connection of the latching mechanism. The detection device provides a signal uphole to verify attachment of the fish.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
[0005] FIG. 1 is a front elevation view of a fishing tool system being deployed into a wellbore, according to an embodiment of the present invention;
[0006] FIG. 2 is a front elevation view similar to that of FIG. 1 but showing the fishing tool engaged with a fish, according to an embodiment of the present invention;
[0007] FIG. 3 is a front elevation view similar to that of FIG. 1 and also showing a communication system for communicating signals uphole, according to an embodiment of the present invention; and
[0008] FIG. 4 is a front elevation view showing an alternate communication system, according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION
[0009] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0010] The present invention relates to a system and methodology for performing a fishing operation. The system and methodology are used to provide an indicator as to when a well tool, i.e. fish, is engaged with the fishing tool. The indicator may be in the form of a signal provided uphole when the fishing tool is engaged with the fish. The signal also can be continually provided uphole while the fish is pulled from the well to inform an operator that the fish remains attached to the fishing tool. The ability to provide this indication to an operator helps avoid withdrawal of the fishing tool without the fish being attached, thus preventing wasted rig time.
[0011] In one embodiment, a fishing tool is deployed downhole into a wellbore via a conveyance, such as a coiled tubing fishing tool conveyance. However, other types of conveyances, including drill string, wireline and other conveyance mechanisms, can be used. The fishing tool usually is deployed downhole through a tubing, such as a casing or a production tubing positioned within the casing. The fishing tool comprises a latching mechanism for engaging and gripping the fish and a cooperating detection device that is able to provide, e.g. transmit, a signal uphole indicating the latching mechanism has engaged or latched onto the fish. A signal can be sent uphole to an operator to indicate full engagement of the fishing tool with the fish, and this signal also can be provided during withdrawal of the fish to indicate continued attachment of the fish to the fishing tool. Depending on the type of detection device used, the signal can be an individual signal, a constant signal, or an intermittent signal.
[0012] Referring generally to in FIG. 1 , one example of a well system 20 is illustrated according to an embodiment of the present invention. In this example, well system 20 comprises a fishing tool 22 that is being delivered downhole into a well via a conveyance 24 , such as a coiled tubing conveyance or other suitable conveyance. The fishing tool 22 is moved downhole towards a well tool 26 , i.e. fish, which is to be retrieved.
[0013] The fishing tool 22 is moved downwardly along a wellbore 28 and often down through a tubing 30 , such as a well casing. In other applications, tubing 30 may comprise production tubing or other tubing positioned in wellbore 28 , often within a surrounding casing. Fishing tool 22 is appropriately sized for movement through the tubing as necessary for a given application. As illustrated in FIG. 1 , wellbore 28 extends down from surface equipment 32 positioned at a surface location 34 . Surface equipment 32 may comprise a rig for deploying fishing tool 22 and conveyance 24 .
[0014] In the embodiment illustrated, fishing tool 22 comprises a latching mechanism 36 designed for attachment with fish 26 when moved into engagement with fish 26 , as illustrated in FIG. 2 . The design of latching mechanism 36 can vary according to the application and according to the type of well tool/fish to be retrieved within wellbore 28 . For example, latching mechanism 36 can be designed to engage the fish 26 internally or externally. Additionally, latching mechanism 36 may have various configurations and components that allow fishing tool 22 to be latched onto specific types of well tools.
[0015] Fishing tool 22 further comprises a detection device 38 positioned to detect when fishing tool 22 has latched onto fish 26 and to provide an appropriate signal uphole indicating the attachment. By way of example, detection device 38 may comprise a switch 40 , such as a contact switch, appropriately positioned so that it is automatically switched upon full engagement of fishing tool 22 with fish 26 . The detection device 38 is then able to output a signal uphole indicating fishing tool 22 has been latched onto fish 26 . By way of example, the detection device 38 may be a powered device able to output the signal, or the detection device 38 can simply be used to complete a circuit that extends uphole to the surface location 34 .
[0016] In the embodiment illustrated in FIG. 3 , for example, fishing tool 22 is a “smart” tool coupled with a surface display system 42 via a communication line 44 . Surface display system 42 may be part of an overall control system utilized in conducting the fishing operation. According to one example, communication line 44 is a hardwired line designed to carry signals from detection device 38 to display system 42 . For example, communication line 44 may comprise an electrical line for carrying an electrical signal uphole from detection device 38 . Alternatively, communication line 44 may comprise an optical fiber or optical communication line able to carry optical signals uphole from detection device 38 . The hardwired communication line 44 can be routed along conveyance 24 . If conveyance 24 comprises a coiled tubing conveyance, the communication line 44 can be secured along the coiled tubing or routed within a wall of the coiled tubing. In other applications, communication line 44 may comprise a wireless communication line.
[0017] Regardless of the specific type of communication line 44 , detection device 38 may be a constant signal device able to output or convey a constant signal to display system 42 while fishing tool 22 is attached to fish 26 . By way of example, detection device 38 may comprise contact switch 40 that is switched upon full engagement of the fishing tool 22 with the fish 26 to enable transmission of a constant signal during the attachment. Thus, an operator is provided with an indication that the fish 26 remains attached during the entire retrieval process as the fish is withdrawn from wellbore 28 .
[0018] In alternate embodiments, the detection device 38 may be of a design that enables output of the signal only upon initial engagement of fishing tool 22 with fish 26 . Other designs enable the detection device 38 to provide periodic or intermittent signals uphole indicating retention of the fish 26 . This latter approach can be useful when the fishing tool 22 is not a smart tool and does not have an electrical line or fiber-optic cable extending to the surface.
[0019] As illustrated in FIG. 4 , for example, detection device 38 may comprise a pressure device able to output an individual or multiple pressure pulses that do not require a hardwired communication line extending between the fishing tool 22 and the surface. The pressure pulses are delivered uphole along an interior of conveyance 24 , as indicated by arrows 46 , or along an annulus surrounding conveyance 24 , as indicated by arrows 48 . By way of example, this embodiment of detection device 38 may comprise a valve 50 that actuates to provide a pressure response upon engagement of the fishing tool 22 with the fish 26 . The valve 50 may be a pressure inducing or pressure indicating valve actuated mechanically upon engagement of the fishing tool 22 with the fish 26 , or the valve 50 can be actuated by another source of energy. For example, valve 50 can comprise a solenoid actuated valve or otherwise actuated valve that is activated upon attachment of the fish 26 .
[0020] The system and methodology can be used to provide an operator with better information during a fishing operation. Knowledge of the status of the well tool fished from a downhole location enables more consistent and efficient fishing operations. It should be noted that the specific size, configuration and components of the fishing tool 22 can vary according to the environment and according to the type of tool that is to be fished from the wellbore. Furthermore, the configuration of the detection device also can vary according to the desired signal output, available communication lines, environment, and other factors that affect the overall operation.
[0021] Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims.
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A technique provides a system and method to verify attachment of a fishing tool with a downhole well tool. The fishing tool comprises a latching mechanism that latches onto the well tool to be retrieved. The fishing tool also comprises a detection device to verify connection of the latching mechanism. The detection device provides a signal uphole to verify attachment to the well tool.
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BACKGROUND OF THE INVENTION
The introduction of the electron microscope made it necessary for the users thereof to dry the specimens that were going to be viewed through such a microscope. If such a specimen is not dried, the beam of electrons becomes difficult to focus; i.e., the electron beam is subjected to a moisture-contaminated "vacuum."
Originally specimens were simply air dried by exposing the specimen to the ambient air or to vacuum conditions, thus permitting the water in the specimen to evaporate. Such techniques were not entirely satisfactory since the surface tension of the water would cause a specimen to tear or be compressed during this form of drying procedure. Accordingly, a specimen so dried would wither and its three-dimensional characteristics would be distorted, thereby giving rise to a less than complete evaluation of a specimen held under an electron microscope.
At least one answer to overcoming the problem of having the specimens tear and become compressed was the introduction of the technique of critical point drying. The advantages of critical point drying were set out by T. F. Anderson in a paper entitled, "Techniques for the Preservation of Three-Dimensional Structure in Preparing Specimens for the Electron Microscope," published in the Transactions of the New York Academy of Science, Series II, 13, 130 (1951). In accordance with the critical point drying technique, the specimen containing water is first exposed (immersed) in a bath of ethanol. Thereafter the specimen is immersed in a bath of amyl acetate followed by being immersed in a bath of liquid CO 2 . The water is miscible with the ethanol; the ethanol is miscible with amyl acetate; and the amyl acetate is miscible with the liquid CO 2 . Accordingly, by diffusion the water is displaced by the ethanol, the ethanol is displaced by the amyl acetate, and the amyl acetate is displaced by the liquid CO 2 . The liquid CO 2 is then changed to a gaseous state above the critical point so that all surface tension forces are eliminated during vaporization. By using this technique the specimen is dried, but it retains its original three-dimensional form.
The procedure described above is suitable for pieces of animal and plant tissue of reasonable size. However, no good method exists for containing such small particle materials as microorganisms or fibers. By small particle materials is meant those having diameters of from 1 to 1,000 microns. Bacteria, yeasts, and mold spores are often not larger than a few microns and are not easily contained during the critical point drying process without greatly prolonging the duration of the drying process.
The exchange of liquid during the displacement steps takes place from inside the biological cell to the surrounding medium. Such an exchange takes place by diffusion and the distances involved in the exchange are in the order of a few microns and the traveling times of the solvent molecules are in the order of 0.01 to 1 sec. The diffusion rate is directly related to the concentration gradient between the inside and outside of the cell membrane according to the equation Q = - A D P (ΔC/Δx) t where Q = solute crossing a surface area A, D = diffusion coefficient, P = the permeability factor of the membrane, (ΔC/Δx) = concentration gradient, and t = time. It has been determined that if the concentration gradient can be maintained at a high level by the flow of liquid through the sample container, the displacement time is greatly reduced from an ordinary critical point drying procedure where the rate of liquid exchange is determined by the slow process of diffusion. It has been determined that the concentration gradient can be held at a high level by agitation but in the technique employed heretofore, agitation has not been effected easily because small particle specimens to be dried have to be confined. The present device effects the high level of concentration gradient by continuous replenishment of the fluid coming in contact with the specimen.
It is known that microorganisms can be filtered from a fluid stream by passing the stream into a holder containing a filter disposed across the stream flow, thus collecting the microorganisms on the upstream surface of the filter. For example see U.S. Pat. No. 2,672,431.
DETAILED DESCRIPTION OF THE INVENTION
The present device provides a specimen capsule which includes a threaded base which has aperture means therein to allow fluid to pass therethrough and which is further formed to have a seat to hold a pair of filters. In use, the device holds a small specimen between said pair of filters. There is further included a rubberlike seal and a retainer ring means to hold the filters on the base and a threaded cap, with an aperture therein, which is threadably fitted over the base to cause the retaining ring to come into abutment with the filters and hold them firm against said base seat. In addition the present device provides a capsule holder wherein a plurality of specimen capsules can be simultaneously located to effect critical point drying of a plurality of specimens at the same time without danger of cross-contamination.
The objects and features of the present invention will be better understood from the following description taken in conjunction with the drawings in which:
FIG. 1 is an elevation view of the specimen capsule;
FIG. 2 is a sectionalized view of the specimen capsule along the lines 2--2 of FIG. 1;
FIG. 3 is an elevation view of the specimen capsule holder;
FIG. 4 is a sectionalized view of the capsule holder along lines 4--4 of FIG. 3; and
FIG. 5 is a sectionalized view of the capsule holder as in FIG. 4 holding a plurality of specimen capsules and spacers.
In FIG. 2 the specimen capsule is depicted as having a base 11 which is threaded and has an aperture 13 therein. The base 11 is formed to provide a ledge 15 onto which sits a support grid 17. The support grid can be fabricated from any rigid material, such as nylon or metal, which is characterized by adequate strength and is inert to the fluids employed. In the preferred embodiment the support grid is the "Swinnex" support grid manufactured by Millipore Corporation of Bedford, Mass. As is apparent from FIG. 2, the support grid has a plurality of apertures 18 therein which allow the surrounding fluid or the fluid coming in contact with the specimen to pass therethrough. When the support grid 17 is located in the base 11, resting on ledge 15, its lower surface 19 is flush with the seat 21. It should be understood that when the capsule is being loaded with the specimen, the base is turned over from the position shown in FIG. 2 and hence the surface 19 would be the upper surface.
As can be seen in FIG. 2, filters 23 and 25 are disposed to rest on the seat 21 and the support grid 17. The specimen which is going to be dried (which generally is in the order of 10 microns or less in diameter) is held between the filters 23 and 25. The filters in the preferred embodiment are fritted silver filters. Such filters are fabricated from silver balls jointed together to create voids therebetween in the order of 0.2-1.2 microns. Silver fritted filters are used in order to provide an electrically conducting mount to enable the electrons to be conducted away, as required in scanning electron microscopy. When a specimen has been dried, it remains on the filter and is coated with a conductive metal to a thickness below 400 angstroms. If a nonmetallic filter were used and coated with only 400 angstroms of metal, it would be more apt to deteriorate under an electron bombardment; hence, the silver fritted filters are used.
Further in FIG. 2 there is depicted a rubber seal 29 which is fitted over the filters 23 and 25. On top of the rubber seal 29 is located a retainer ring 31. Thereafter a cap 33 is threaded onto the base 11. The cap 33 has an aperture 35 formed therein. As the cap 33 is threaded down the retainer ring 31 presses down against the rubber seal 29 which in turn pushes the filters 23 and 25 against the seat 21. Cap 33 and retainer ring 31 may also be combined into a single unit. In response to threading the cap 33 and the base 11 together into the capsules, all of the members such as the support grid 17, the filters 23 and 25, the rubber seal 29, and the retainer ring 31 are locked in place. The specimen capsule may also be used for larger specimens, in the order of 1 mm., by placing rubber seal 29 between filters 23 and 25. There are two notches 36 and 37 cut into the base 11 to accommodate a spanner chuck which can be employed to effect the foregoing assembly of the specimen capsule. Thereafter the specimen capsule is flipped over to assume the position shown in FIG. 2 and it is in this position that it is placed into the capsule holder FIGS. 3, 4, and 5.
FIG. 3 shows the capsule holder body 41 with the cylinder cap 57 and O-ring 61 in place.
In FIG. 4 the capsule holder body 41 is shown having a capsule chamber 43 therein, which has a threaded section 47 in the top portion and a threaded aperture 45 in the bottom portion.
FIG. 5 shows the same sectionalized view of the specimen holder as shown in FIG. 4 with a plurality of specimen capsules (39a-39d) loaded in capsule chamber 43.
In the base of capsule chamber 43 there is located a "Teflon" spacer 49a. The lowermost capsule 39a is disposed on the "Teflon" spacer 49a. On the top of the lowermost capsule 39a there is disposed a "Teflon" spacer 49b to separate the capsules 39a and 39b. In a like manner "Teflon" spacer 49c separates capsules 39b and 39c, and spacer 49d separates capsules 39c and 39d. In addition there is a "Teflon" spacer 49e located between the uppermost capsule 39d and cylinder cap 57. Each "Teflon" spacer has a central opening to permit the fluid which comes in contact with the specimen to pass therethrough to the next higher capsule and prevents the fluid from bypassing the capsules on the outside.
When the capsules and the spacers have been stacked as shown in FIG. 5, the cylinder cap 57 is threaded into threaded section 47 to tightly clamp all of the members (capsules and spacers) as shown. Now it should be understood that while four capsulses are shown in FIG. 5 there could be more or less depending upon the size of the capsule holder. It should also be understood that other materials besides "Teflon" can be used for fabricating the spacers, the prerequisite being that the material be firm and noncorrosive.
Into the threaded aperture 45 there is threaded a tubular pipe or end piece which serves to connect a centrifugal or peristaltic pump, or any other means of obtaining pressurized liquid, to the holder. This arrangement permits any sequence of liquids to be pumped through the holder and through the capsules. The pump maintains a pressure differential of between 2 lb. to 10 lb. across the holder. The cylinder cap 57 is formed to have a threaded aperture 59 therein as well as two notches 62 and 63 which accept a spanner tool for tightening the cap 57 into capsule holder body 41 and groove 60 running across cap 57 through threaded aperture 59 for the purpose of allowing gases or vapors to escape. A pipe system of any number of varieties can be connected to aperture 59 to conduct the contact fluid away. An O-ring 61 is located somewhere on the outside of holder 41.
In operation the contact fluids (ethanol/amyl acetate) are pumped through the pipe located in threaded aperture 45 and thereafter through the first spacer 49a. The spacers are locked in tightly so that there is no leakage around the capsules into the space between the end of the capsules and the inside wall of capsule chamber 43. The contact fluid enters the aperture 35 (FIG. 2) of the capsule, passes through the centers of the retaining ring 31 and the rubber seal 29. The contact fluid goes through the filters 25 and 23 and on through the apertures 18 in the support grid 17. In the last step of replacing amyl acetate with liquid CO 2 , the pipes are unthreaded, and the capsule holder is placed in the pressure vessel of an existing commercial or self-made critical point drying apparatus. The O-ring 61 prevents the liquid CO 2 from flowing by the holder and forces it through the capsules. This may also be accomplished by using a flat gasket either below or above the holder in the pressure vessel.
As the contact fluid passes through the filters 25 and 23, it does not pass through the specimen held between said filters. The contact fluid merely comes in contact with the specimen and takes a path of less impedance around the specimen and on through an open filter. Because there is only a small differential of pressure across the holder and because the filters per se provide an impedance to the flow of the contact fluid through the holder, the contact fluid experiences a relatively gentle flow around the specimen. This gentle flow around the specimen enables the contact fluid to be continually in a changing state so that (ΔC/Δx), the concentration gradient, is held at a relatively high level, thereby reducing the time necessary to effect a drying by the critical drying technique. It has been found by actual performance that time to effect the drying of a specimen (or specimens if a plurality is done simultaneously) is reduced to 25% of the time critical point drying efforts took heretofore.
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The present device and technique enables a small specimen to be subject to a continuous maximum concentration gradient by continually replenishing the fluid coming in contact with the specimen. Accordingly, the diffusion rate from the specimen to the fluid in contact is maintained at a high level, and the fluid-exchange steps are completed quickly. Further, the device is designed to hold a plurality of specimens so that a number of specimens can be "dried" simultaneously and quickly.
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